Emerson OPM4001 User manual

I N S T R U C T I O N M A N U A L R E V 4 . 2
OPM4001 Opacity/Dust Density Enhanced
Controller Installation and Operation
Manual

I N S T R U C T I O N M A N U A L R E V 4 . 2
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CONTENTS
TECHNICAL SUPPORT HOTLINE ............................................................................................................................................4
SECTION 1 SYSTEM DESCRIPTION ........................................................................................................................................5
Transmissometer /retro reflector.................................................................................................................................5
RCU.............................................................................................................................................................................7
Optional Air Purge Weather Cover System ...................................................................................................................7
Alignment system........................................................................................................................................................7
Cabling .......................................................................................................................................................................7
SYSTEM SPECIFICATIONS ........................................................................................................................................................8
SECTION 2 INSTALLATION CONSIDERATIONS.....................................................................................................................10
Before start up ..........................................................................................................................................................10
Environment ............................................................................................................................................................. 10
MOUNTING THE AIR PLENUM AND WEATHER COVERS................................................................................................................... 11
Transceiver and retro reflector assembly ................................................................................................................... 12
Beam alignment procedure .......................................................................................................................................13
Air flow switch .......................................................................................................................................................... 14
Control unit...............................................................................................................................................................14
SECTION 3 BEFORE START UP ............................................................................................................................................15
STACK EXIT CORRELATION COMPUTATION .................................................................................................................................15
SECTION 4 CONTROL UNIT PAGE DESCRIPTION..................................................................................................................16
CONTROL UNIT SCREENS.......................................................................................................................................................16
General page layout..................................................................................................................................................16
Control unit Glossary of terms ...................................................................................................................................17
Company information page .......................................................................................................................................18
Home Page ...............................................................................................................................................................18
Clean screen..............................................................................................................................................................18
Calibration Page........................................................................................................................................................19
Fault Page................................................................................................................................................................. 19

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Settings Page ............................................................................................................................................................ 20
Operator Setup .........................................................................................................................................................21
Tech Setup and Backup/Restore ................................................................................................................................ 21
Set Local Time and Date ............................................................................................................................................ 24
Change Passwords ....................................................................................................................................................26
Diagnostics Page.......................................................................................................................................................27
Alarm Page ............................................................................................................................................................... 28
Display Page ............................................................................................................................................................. 29
About Page ............................................................................................................................................................... 30
SECTION 5 MODBUS AND ANALOG OUTPUTS....................................................................................................................31
MODBUS ADDRESS INFORMATION .......................................................................................................................................... 31
RS/485 COMMUNICATIONS AND CONNECTION .........................................................................................................................33
ALARM RELAY DESCRIPTIONS .................................................................................................................................................34
ANALOG OUTPUT CONNECTIONS............................................................................................................................................35
Output Channels #1, 2, 3 and 4.................................................................................................................................. 36
4-20MA ..........................................................................................................................................................................36
SERVICE MODULE ............................................................................................................................................................... 37
SECTION 6 CLEAR PATH ADJUSTMENTS ............................................................................................................................. 38
Clear on stack zero and span calibration.................................................................................................................... 38
Zero reflector adjustment..........................................................................................................................................39
Span filter value ........................................................................................................................................................40
Record the zero/span values......................................................................................................................................40
Off stack zero calibration...........................................................................................................................................40
SECTION 7 MICRO-TURN AUDIT KIT...................................................................................................................................41
USING THE ON LINE ZERO REFLECTOR (OPTION) ..........................................................................................................................41
FILTER CORRECTION FORMULA ............................................................................................................................................... 42
SECTION 8 PREVENTIVE/CORRECTIVE MAINTENANCE .......................................................................................................43
Preventive/corrective maintenance schedule .............................................................................................................43
Trouble Shooting....................................................................................................................................................... 46
Trouble shooting -continued......................................................................................................................................47

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SECTION 9 SPARE PARTS.................................................................................................................................................... 48
SECTION 10 DRAWINGS.....................................................................................................................................................50
OPM6127 1OF3–CONTROL UNIT TO SENSOR WIRING/DUAL BLOWER...................................................................................51
OPM6127 2OF3–CONTROL UNIT TO SENSOR WIRING /SINGLE BLOWER ................................................................................52
OPM6127 3OF3–CONTROL UNIT TO SENSOR WIRING /NO BLOWER ..................................................................................... 53
RS485: Pin out........................................................................................................................................................... 54
SECTON 11 ALARM MATRIX...............................................................................................................................................55

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TECHNICAL SUPPORT HOTLINE
For assistance with problems, please call the Customer Support Center (CSC).
Phone: [phone]
In addition to CSC, you may also contact Field Watch. Field Watch coordinates Emerson Process Management’s field
service throughout the U.S. and abroad.
Phone: [phone]-RMST (1-800-654-7768)
Emerson Process Management may also be reached via the Internet through e-mail and World Wide Web:
E-mail: [e-mail]
World Wide Web: www.raihome.com
Warnings and Safety Guidelines for user safety and equipment protection.
This manual is intended to aid trained and competent personnel in the installation of this equipment. Only a technician or
engineer trained in the local and national electrical standards should perform tasks associated with the electrical wiring of
this device.
WARNINGS
UNDER NO CIRCUMSTANCES WILL EMERSON PROCESS MANAGEMENT BE LIABLE OR RESPONSIBLE FOR
ANY CONSEQUENTIAL DAMAGE THAT MAY ARISE AS A RESULT OF INSTALLATION OR USE OF THIS
EQUIPMENT.
ALL EXAMPLES AND DIAGRAMS SHOWN IN THE MANUAL ARE INTENDED TO AID UNDERSTANDING. THEY
DO NOT GUARANTEE OPERATION.
EMERSON PROCESS MANAGEMENT ACCEPTS NO RESPONSIBILITY FOR ACTUAL USE OF THIS PRODUCT
BASED ON THESE EXAMPLES.
DUE TO THE GREAT VARIETY OF POSSIBLE APPLICATIONS FOR THIS EQUIPMENT, THE USER MUST ASSESS
THE SUITABILITY OF THIS PRODUCT FOR SPECIFIC APPLICATIONS.
MAKE SURE TO HAVE SAFETY PROCEDURES IN PLACE TO STOP ANY CONNECT3ED EQUIPMENT IN A SAFE
MANNER IF THE CONTROLLER SHOULD MALFUNCTION OR BECOME DAMAGED FOR ANY REASON.
DO NOT REPLACE ELECTRICAL PARTS OR TRY TO REPAIR THIS PRODUCT IN ANY WAY.
ONLY QUALIFIED FACTORY TRAINED SERVICE PERSONNEL TRAINED IN ITS OPERATION SHOULD OPEN THE
DEVICE’S HOUSING OR CARRY OUT REPAIRS.
THE MANUFACTURER IS NOT RESPONSIBLE FOR PROBLEMS RESULTING FROM IMPROPER OR
IRRESPONSIBLE USE OF THIS DEVICE.
You may cause an electric shock, fire or damage the equipment if you ignore any of these safety precautions.

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SECTION 1 SYSTEM DES CRIPTION
TRANSMISSOMETER /RETRO REFLECTOR
The OPM4001 is a precision, double-pass, dual beam Transmissometer that consists of a transceiver (transmitter/receiver) mounted
on one side of a stack or duct and a passive reflector mounted on the opposite side. The light source, photo detectors, and all
measurement/reference optics used in opacity measurement are housed in the transceiver.
NORMAL MODE OF OPERATION
The Dual beam measurement system has a stack mounted Transmissometer sensor system consists of an optical transceiver
mounted on one side of the stack and a retro reflector mounted on the other. To avoid errors due to ambient light, the wide band
lamp (See Drawing) is electronically modulated and projects a collimated beam of light, which is split into a reference beam, and a
measurement beam by an optical Beam splitter. The reference beam is directed to the reference detector, RD. The measurement
beam is projected across the stack to a Retro
reflector that returns the beam back across the
stack to a beam splitter and directs the
measurement beam to the measurement
detector, MD. A portion of the returning light is
also sent to the TTL (Thru the Lens) bulls-eye
target viewed through a window provided at the
rear of the Transmissometer. The bulls-eye is
used to correct changes in alignment and is
unique in that no moving parts are used!
The ratio of the measurement and reference
detectors is used to provide Transmittance 2 (T
2) signal. Because the same light source is used
for both detectors, and a Measurement /
Reference ratio is used throughout for the
calculations, the monitor is insensitive to
variations in light intensity. Since all
measurements are made on a ratio basis, all
resulting computations are independent of the absolute intensity of the light source or contamination of the optics associated with
the collection and focusing of the energy from the lamp. The (T 2) signal is converted to a current format and sent to the control unit
for processing. At the control unit the signal is processed to read 0-100% Opacity, provide alarms and outputs.

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INTERNAL CALIBRATION SYSTEM, ZERO MODE
Zero and span calibration checks can be initiated manually, automatically or by a PLC or computer. During the zero calibration mode
a calibrated zero reflector is placed in front of the transceiver optical package testing all optical surfaces and electronic components
to assure zero point has not changed.
INTERNAL CALIBRATION SYSTEM, SPAN MODE
In the span mode a Span filter of known Neutral Density is placed in the measurement path and produces a specific upscale reading
in accordance with the latest E.P.A. requirements. The zero and span cycle provides a continuous check of all the optical
components and surfaces, the main lamp, the detector, interconnecting wiring, control unit and computation analysis.

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RCU
The RCU provides instrument control functions, opacity readings, alarms, analog outputs,
communications, system information and more. The color 5x7” viewing screen can be seen in
low light levels and bright. The RCU is rated NEMA 4X/IP65 when panel mounted. Battery backup
for all memory is typically 7 years.
The control unit should be mounted in a control room environment i.e., clean, temperature with
max/min of +0oto +50 o C (+32 o to + 122 o F). The OPM4001 ENHANCED control unit provides
instrument control functions, opacity readings, alarm and fault indicators, analog outputs, and
diagnostics with contact closures.
OPTIONAL AIR PURGE W EATHER COVER SYSTEM
The transceiver and reflector may be mounted in weather covers. The weather covers are fairly
compact to allow movement around them even on a three-foot walkway or platform. They protect
the stack-mounted components from dirt, moisture; stack temperatures within the specified ambient
temperatures limits, and errant air currents around the stack.
The air purge system constantly circulates air past the optical window. The air flow is directed
through the hose to an air plenum on the stack side of the optical window. The air flow in the air
plenum area results in reduced pressure and increased velocity. This venturi effect tends to
continually draw the air around the optical window into the purge air stream, thereby keeping the
lens clean for long periods.
ALIGNMENT SYSTEM
The OPM4001 ENHANCED includes a built-in through-the-lens alignment system. The alignment target can be viewed through a
window on the transceiver. Adjustments to changes in alignment are provided by a 3-point alignment system, which is integral to
the air plenum.
CABLING
The standard cabling used between the stack-mounted units and the control unit is at a minimum 6-pair, #20 AWG, twisted,
shielded. Separation distances approximately 1000FT, more pairs or larger gage than 20 AWG is also acceptable.

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SYSTEM SPECIFICATIONS
REMOTE CONTROL UNIT:
Enclosure
Panel mounted IP65/NEMA4X Dimensions: 197X146.6X68.5mm (7.75" X 5.77"
X2.7").
Approvals
CE and UL Listed
Digital Display
LED backlight, Instant and Average Opacity -5 to 99% Opacity
Ambient Temperature Range
0 to +50oC (+32 to + 122oF)
Power Requirements
Power 20.4 to 28.8VDC < 10% ripple, 20va
Alarm Time Delay & set point
Field programmable.
Alarm Reset
Manual or Automatic
Analog Outputs (4)
Four 12-bit Analog outputs 4-20mA, Field selectable range -5.0 to 100%.
Ch1 and Ch2 Individually field selectable for Instant % opacity, or 6 minute
average with z/s checks or without checks for process control.
Exit Correlation (Lx / Lt)
0.3~1.0 OPLR
Calibration check options
Selectable internal timed or computer initiates or push button on demand.
Communication
Remote access, RS485 MODBUS networking.
Battery Backup
7 years typical

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TRANSCEIVER/ REFLECTOR:
Enclosure/Power Requirements
NEMA 4X. Power 120 or 240VAC +/- 10%, 50/60Hz. 65va for
transceiver, 65va for Service module.
Path Length
2 to 50 feet (0.6 to 4.6 15.2 meters)
Optical System
Double Pass with Wide band source, Electronic Modulation. USDEP
40 CFR 60 appendix B, PS-1 and ASTM D 6216 specifications.
Ambient Light Immunity
Wide band source, Electronic Modulation. USDEP 40 CFR 60
appendix B, PS-1 and ASTM D 6216 specifications.
Reflector
Type 1 (plastic) reflector assembly, long path Glass.
Alignment Verification
Built-in through-the-lens system standard
SOURCE Aging Compensation
Automatic
SOURCE Expected Life
70,000 hours (Field proven for > 8 years)
Ambient Temperature Limits
-40 to +130oF (-40 to +54oC)
Process Gas
Up to 750oF (400 o C) higher available contact the factory.
Mounting Flanges
3 inch IPS, 150# flange (other sizes available)
DESIGN AND PERFORMANCE:
Peak and Mean Spectral Response
Photopic; 515 to 585 nm, less than 10% of peak response outside
the desired 400 to 700 nm region. USDEP 40 CFR 60 appendix B,
PS-1 and ASTM D 6216 specifications.
Angle of View
<4.0 o from optical axis
Angle of Projection
< 4.0 o from optical axis
Calibration Error
< +2% of full scale
Response time
< 10 second
Zero Drift
< 1% (24 hours)
Calibration Drift
< 1% (24 hours)
Operational Period
6 Months

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SECTION 2 INSTALLATION CONSIDERATIONS
BEFORE START UP
You must complete the following before start up is attempted.
Measure and record flange -to-flange distance to verify it is the same as final check out sheet.
If you are using a recorder, DAS, etc., DO NOT CONNECT THEM NOW. Outputs and inputs from other sources should be left off until
system has been completely checked according to the following instructions. After system operation has been verified connect and
test external connections.
Read the instructions first to familiarize yourself with the instrument before attempting start up.
The air purge and Weather cover system, Transceiver, Retro reflector, Service module must be installed and power applied.
Control unit must be installed and wired to the service module and customers equipment as applicable.
All wiring and mechanical installations must be complete per drawings provided in this manual. All wiring must be checked and
power applied to both the control unit and the stack maintenance module.
Beam Alignment procedure has been completed.
ENVIRONMENT
Locate the control unit in an easily accessible area with temperatures between +32oto 122oF. To permit the operator to read
and/or change controls, the unit should not be mounted higher than five feet from floor level.

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MOUNTING THE AIR PLENUM AND WEATHER COVERS
WARNING! CONTROL UNIT, TRANSCEIVER & RETRO SERIAL NUMBERS MUST
MATCH.
After the installation site has been selected and the platform requirements have been met, the mounting flanges should be installed
and aligned as described on Drawings OPM6130 and 6131. Flanges should be installed with the mounting faces on the vertical plane.
1) Before installing the Transceiver, Retro reflector or any type of
weather cover remove the air plenum from both the Transceiver
and retro reflector. Removal will make the installation easier and
less chance of damage while mechanical attachment of the air
plenums and optional weather covers when provided.
2) If the transceiver and retro reflector have been shipped from the
factory with the air plenum attached, un-clip both hold down
latches, swing open and lift up & off the hinge pins. Place the
Transceiver and retro in a safe place.
3) The air plenum is attached to the customer supplied 3" pipe flange
by four 2 1/2" long 5/8-11 bolts. Working from the 3" flange the
correct assembly is: gasket then air plenum.
4) If you have weather covers remove the two (2)-weather cover hood hinge pins located on the upper right and left
hand corner of the hood. The air plenum and weather cover are attached to the 3" pipe flange by four (4) 2 1/2"
long 5/8-11 bolts. Working from the 3" flange the correct assembly is; gasket, weather cover mounting plate,
gasket, mating flange & air plenum. Place the 5/8-11 bolt through the top hole of the middle plate. Place a flat
washer between the middle plate and mating flange and pass the bolt through. Slip a split lock washer over the
bolt and secure with a nut.
Repeat for the remaining
three mounting bolts.
5) Any wiring or air hoses can be
connected now.

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TRANSCEIVER AND RETRO REFLECTOR ASSEMBLY
6) Attach the Transceiver and Retro reflector to the
air plenum assembly by placing them on the hinge
pins.
7) Close transceiver & retro and secure in place with
the two hold down latches.
8) The air-purge blowers should be powered up at
this time to prevent stack particulate from
accumulating in the nipple and air-purge housing.
Caution: If installed location has a positive pressure the air-purge system must be used continuously during installation to prevent
process gases from contaminating optical surfaces or over heating instrument electronics. If the system is shut off for more than
momentary interruptions, the instrument may be damaged. Failure to provide continuous air-purge may void the warranty.
All wiring from the control unit to the transceiver should be completed at this time.
NOTE: THE AIR PLENUM ASSEMBLY FOR BOTH TRANSCEIVER AND RETRO MUST BE INSTALLED AS BELOW, I.E. THE PINS ON
THE LEFT SIDE POINTING UP!

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BEAM ALIGNMENT PROCE DURE
Note: Alignment cannot be done unless the power is applied to the stack mounted service module. The control unit does not have to
be connected or powered. For alignment accuracy, the stack should be at normal temperature.
MAINTENANCE MODULE SWITCHES SHOULD BE IN THE NORMAL OPERATING POSITIONS:
Zero/Operate - Operate
Span/Operate - Operate
Normal/Test - Normal
Opacity/T2- Opacity
9) If not already on, turn on the power to all air purge systems and service
module.
10) Align the Reflector mating flange so it is plumb and parallel to the 3" 150#
mounting flange. Use the 3 adjusting nuts on the air purge plenum flange until this is
accomplished. The adjusting nuts have nylon locking inserts to prevent loosing by vibration.
11) Move to the Transceiver, and determine monitor alignment by looking
through the viewing port located on the rear of the transceiver and observing whether the beam image is in the
center of the cross hair (bulls-eye).

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AIR FLOW SWITCH
If you have an airflow alarm when the system is powered check the airflow switch. With the blower running and the source under
normal conditions disconnect the leads of the switch and place an ohmmeter across them. The switch should be closed, less than 2
ohms, if flow is enough to overcome stack pressure and blower inlet is clear. Cover the air cleaner inlet and verify the switch opens.
Replace the leads the test is complete.
CONTROL UNIT
Mount the control unit at eye level for best viewing of the display.
Cut out for panel mounting is shown in the drawing section. Insert the control unit through the cut out hole. Insert the panel
mounting hardware in the slots provided on each side of the control unit from the rear. Tighten the screws until the control unit is
securely held in place.
Wire the control unit per drawing section and Energized power.
NOTE: CONTROLLER REQUIRES 24VDC.
5.7" 256-Color Touch panel, QVGA TFT display (or CSTN), 197X146.6X68.5mm (7.75" X 5.77" X2.7")
Display ‘touchable’ images, text and graphs according to real-time conditions and historical values
‘Touch’ properties can be assigned to all text and graphic on-screen elements
Data entry/modification via keypad
LCD illuminated screen
Virtual keyboard
Info mode: view/modify I/O status, integer values, and system data via the
panel

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Lt
Lx
OPLR *2 
SECTION 3 BEFORE START UP
You must complete the following before start up is attempted.
Check that all parts have the identical serial numbers.
Measure and record flange -to-flange distance to verify it is the same as final check out sheet.
If you are using a recorder, DAS, etc., DO NOT CONNECT THEM NOW. Outputs and inputs from
other sources should be left off until system has been completely checked according to the following instructions.
After system operation has been verified connect and test external connections.
Read the instructions first to familiarize yourself with the instrument before attempting start up.
The air purge and Weather cover system, Transceiver, Retro reflector, Service module must be installed and
power applied.
Control unit must be installed and wired to the service module and customers equipment as applicable.
All wiring and mechanical installations must be complete per drawings provided in this manual. All wiring must be
checked and power applied to both the control unit and the stack maintenance module.
Beam Alignment procedure has been completed.
STACK EXIT CORRELATION COMPUTATION
The stack exit correlation is especially important to verify. If possible all dimensions should be verified by actual measurements.
Measure and record inside stack dimensions at the measuring point and at the stack exit, and compute the Optical Path Length Ratio
(O.P.L.R.). Verify that the calculated and the value of O.P.L.R. found in the About page are within +/- 2%.
Lx = Stack exit inner diameter, Lt = Inner diameter of the effluent path
Example: A stack with a 120" stack exit I.D. and a 120" path length
50.0
120*2120 OPLR

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SECTION 4 CONTROL UNIT PAGE DESCRIPTION
CONTROL UNIT SCREENS
GENERAL PAGE LAYOUT

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CONTROL UNIT GLOSSARY OF TERMS
OUTPUT TYPE SETUP –“Output type” refers to the 4-20mA outputs.
Instant opacity, z/s outputted during cal cycle.
Average, 6 minute opacity average z/s outputted during cal cycle.
Last - instant opacity, last value is held during cal cycle.
Note: Last should be used if you are using the output for process control signal.
ALARM AUTO/MANUAL SETUP –Press return/enter button to enter. Choose between 1-auto or 2- manual.
Auto means when the high opacity alarm has been activated and when the level of smoke drops below the alarm point the
alarm contacts 02 & 04 and icon will reset automatically.
Manual reset means when the high opacity alarm has been activated, pushing the return/enter button 04 contact will de-
energize but 02 will remain energized. When the level of smoke drops below the alarm point the return/enter button is
pushed and both 02 &04 will be de-energised.
OUTPUT SCALING SETUP –Press return/enter button to enter.
Set Ch 1 or 2 to desired opacity range i.e, for 4ma to represent minimum opacity and 20mA to represent maximum
opacity. The 20mA value of 99.9 is used to represent 100%.
Note; For CFR 40, PS-1 the set 4mA to -5% To get negative values press +/- once for negative then button 5 then +/-
again for the decimal placement. i.e, Ch.1 4 mA: -5.0 % 20mA: 99.9%
MODBUS I.D. SETUP –Press return/enter button to enter and input the node number (1 to 32) desired press Press
return/enter button to to set then ESC to exit.

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COMPANY INFORMATION PAGE
When power is first applied the company info page is
displayed. Wait a few seconds and the Home page will
appear. Or touch “LOGO and it will immediately go to
the Home page.
HOME PAGE
Touch the icon to go to the sections.
Calibration
Fault
Alarms
Settings
Displays
Diagnostics
About
CLEAN SCREEN
To clean the screen press the clean screen icon on the home page, green blank page will come in to view with a countdown clock
starting at 10 seconds. Use appropriate cleaner and cloth to clean this screen. When done it will automatically return to the home
screen.

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CALIBRATION PAGE
Touch the Cal Icon on the home page. Initiate a Z/S
check by pressing the Green Manual Cal Initiate button
(It will turn Yellow). The zero is 3 minutes and span is 3
minutes long for calibration cycle of 6 minutes. The
Right column will show In Zero and at about 30 seconds will update the
Green Pass or the Red Fail icon. The values are entered at set up in the
tech screen under “Zero cal value, Span Cal Value". If these values are
within +/- 2% Opacity the green Pass will be shown, If it is not it will
show Red Fail and trigger the fault system. Fail will remain in memory
until after the values are corrected and another cal is initiated.
The current opacity and window dust is displayed below for your
convenience. The system will automatically return to monitoring the
process at the 6 minute point from cal start. You will know this because
the Manual Cal Initiate icon will return to Green. It is not necessary to
stay in this screen after initiation and recommended to return to the
screen normally displayed.
FAULT PAGE
Acknowledge Fault button: when in fault pressing the Ack button
will temporarily open the fault contact 14.
After time limit (set in tech screen 4: default 1 minute) if any
fault is showing the relay will close, energize. If all faults are
cleared the relay will auto reset to open, de-energize.