Emerson Rosemount Analytical OPM 4000 User manual

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Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
Opacity/Dust Density Monitor

HIGHLIGHTS OF CHANGES
Effective August 31, 2006 Rev 1.0
Page Summary
General Revised and removed the figures from Section 8, Drawings, and relocated them to their
applicable sections. Changed all references of the Micro-turn 200 to read as the Zero Jig.
Page 1-1 Added information under Component Checklist.
Page 1-1 thru 1-4 Added General information under System Overview.
Page1-2 thru 1-3 Added Figure 1-1, Typical System Package (Sheet 1 and 2).
Page 1-4 Added Figure 1-2, Transceiver Assembly with Weather Cover.
Page 1-8 thru 1-9 Updated Tables 1-1 and 1-2 to represent current conditions.
Page 2-1 Added the bulleted list under Overview.
Page 2-2 Added Clearance and Sample Area headings along with descriptive text.
Page 2-3 Added Figure 2-1, Installation Clearances and Weather Cover Dimensions.
Page 2-4 Added information and procedural steps under Regulatory Process Considerations, along
with Figure 2-2, Transmitter Location.
Page 2-5 thru 2-6 Organized information under Installation of Stack Flanges into procedural steps.
Converted important installation reminders from body text into the five Notes.
Page 2-7 Added Figure 2-3, Mounting the Stack Flanges.
Page 2-8 Added Figure 2-4, Stack Flange Installation.
Page 2-9 Updated Figure 2-5, Transceiver and Retro Reflector Hinge Pins to better illustrate the
hinge pin. Revised and streamlined information for Mounting the Air Plenum and Weather
Covers.
Page 2-10 Updated Figure 2-6, Air Plenum to better illustrate its assembly. Added Attach Blower
heading and step 1.
Page 2-11 Added Note regarding the installation procedures for the transceiver and retro reflector.
Page 2-12 Added Mounting the Control Unit procedural steps. Relocated Figure 2-8, Control Unit
from the end of the section.
Page 2-13 thru 2-14 Added Figure 2-9, Panel Cutout for Control Unit, and Figure 2-10 Control Unit Dimensions.
Page 2-15 thru 2-16 Added procedural steps under System Wiring Installation.
Page 2-17 Added Figure 2-11, Control Unit Terminal Identification.
Page 2-18 thru 2-19 Added Figure 2-12, Typical System Wiring (Sheets 1 and 2).
Page 2-20 Revised Figure 2-14, Service Module Switch Location. Updated procedural steps under
Beam Alignment Procedure. Revised Figure 2-15. Moved Air Flow Switch information to
Section 8, Troubleshooting.
Page 3-1 Added the Caution and information under Overview.

HIGHLIGHTS OF CHANGES (CONTINUED)
Effective August 31, 2006 Rev 1.0 (Continued)
Effective January, 2007 Rev 1.1
Page Summary
Page 3-2 Added Stack Exit Correlation Computation information and Figure 3-1, Lx and Lt Stack
Dimensions.
Page 3-3 Reformatted body text into bulleted lists and procedural steps.
Page 4-1 Added Overview and bulleted list.
Page 4-2 Reformatted body text under Alarm Set Point Adjustments and Alarm Time Delay
Adjustment into procedural steps.
Page 4-4 Reformatted body text under Auto Cal Timer Adjustment into procedural steps.
Reformatted first paragraph under Service Module into a bulleted list. Added the second
paragraph, along with the normal operation conditions.
Page 5-1 Added Overview and bulleted list.
Page 5-2 Changed the Procedure heading to Installation, and renumbered the procedural steps.
Page 5-3 Added Figure 5-2, Zero Jig Installation.
Page 6-1 Added Overview information. Reformatted the first paragraph under Clear Stack Zero and
Span Calibration into a bulleted list and note regarding the normal levels of day light.
Page 6-1 thru 6-3 Renumbered procedural steps under Clear Stack Zero and Span Calibration.
Page 6-2 Updated Figure 5-2, Zero Calibration to better illustrate PT-1 and PT-3 locations.
Page 6-3 Renumbered procedural steps under Zero Reflector Adjustment.
Page 6-3 Relocated Span Filter Mark procedural steps from the end of the section to follow the Zero
Reflector Adjustment procedural steps.
Page 6-4 Reformatted Record the Zero/Span Values in the Quick Menu into procedural steps.
Reformatted the first paragraph under Off Stack Zero Calibration into a bulleted list and
renumbered the procedural steps.
Page 7-1 Added Overview information.
Page 7-1 thru 7-2 Revised Preventive Maintenance Schedule.
Page 7-4 thru 7-10 Added Corrective Maintenance information along with Figures 7-1 thru 7-6.
Page 8-1 Added Caution.
Page 8-1 thru 8-2 Revised Troubleshooting table to include references.
Page 8-2 Added Air Flow Switch heading and body text.
Page 9-1 Removed information regarding Level III spare parts.
Page Summary
Cover Added picture of control unit to the cover photo.
Page 1-4 Added picture of control unit to Figure 1-2, Transceiver Assembly with Weather Cover.
Page 1-7 Revised the TTL Bulls-Eye on Figure 1-3, Component Relationships.
Page 1-9 Revised the Product Matrix to read OPM4000 instead of OPM3000.
Page 2-10 Added information on how to attach a single or dual blowers. Added callouts to Figure 2-6,
Air Plenum.

HIGHLIGHTS OF CHANGES (CONTINUED)
Effective January, 2007 Rev 1.1 (Continued)
Effective November, 2007 Rev 1.2
Effective October, 2008 Rev 1.3
Page Summary
Page 2-20 Revised the Beam Alignment Procedure. Replaced Figure 2-15, Alignment of the
Transceiver.
Page 4-3 Revised steps 3 and 5 under Alarm Set Point Adjustments, Alarm Time Delay
Adjustments, and Auto Cal Timer Adjustments.
Page 5-3 Revised the logo on the zero jig in Figure 5-2.
Page 6-4 Revised step 3 under Zero Cal Value and Span Cal Value.
Page 9-1 thru 9-2 Revised Section 9, and added three new spare parts.
Page A-2 thru A-24 Added note 11 to the safety data section. Added new language translations.
Page B-1 Updated the return of materials address.
Back Cover Updated the address blocks.
Page Summary
Page 2-1 Added note regarding installed path length.
Page 2-2 Clarified transceiver distance from stack exit.
Page 2-7 Added note regarding installed path length.
Page 2-15 Added information on recommended transceiver to control room cable.
Page 7-3 Deleted two year maintenance recommendations.
Appendix C Added Appendix C.
Page Summary
Throughout Updated revision level and date.
TOC Updated Table of Contents.
D-1 through D-10 Added Appendix D, OPM 2000 Retrofit Instruction
I-1, I-2 Updated Index of terms.
Back cover Revised e-mail addresses and copywrite date.

Instruction Manual
IM-105-4000, Rev 1.3
October 2008
TOC-1
OPM 4000
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1
Description and
Specifications
Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OPM 4000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Normal Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Internal Calibration System, Zero Mode . . . . . . . . . . . . . . . . . . . . . 1-6
Internal Calibration System, Span Mode . . . . . . . . . . . . . . . . . . . . 1-6
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
SECTION 2
Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Choose an Installation Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Stack Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Regulatory/Process Considerations . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installation of Stack Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Mounting the Air Plenum and Weather Covers . . . . . . . . . . . . . . . 2-9
Attach Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Mounting the Transceiver and Retro Reflector. . . . . . . . . . . . . . . 2-11
Mounting the
Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
System Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Beam Alignment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
SECTION 3
Startup and Calibration
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Before Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Startup Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Stack Exit Correlation Computation . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Verifying Instrument Operation and Configuration . . . . . . . . . . . . . 3-3
Edit Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Quick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Displaying the Factory Set OPLR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Zero/Span Calibration Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
TOC-2
SECTION 4
Operation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control Unit Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Front Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Alarm Set Point Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Alarm Time Delay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-20 mA Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Recorder or Other Device Calibration . . . . . . . . . . . . . . . . . . . . . . 4-3
Auto Cal Timer Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Remote Calibration Cycle Initiate . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Remote Calibration Cycle Acknowledgment . . . . . . . . . . . . . . . . . 4-4
Service Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
SECTION 5
Zero Jig and Neutral
Density Filters
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Using the Zero Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Coarse Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Filter Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Filter Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
SECTION 6
Zero and Span
Calibration
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Clear on Stack
Zero and Span Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Zero Reflector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Span Filter Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Record the Zero/Span Values in the Quick Menu . . . . . . . . . . . . . . . . 6-4
Zero Cal Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Span Cal Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Off Stack Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
SECTION 7
Maintenance
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Control Unit Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Weather cover/blower preventive maintenance. . . . . . . . . . . . . . . . . . 7-3
Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Transceiver Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Service Module Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Circuit Board Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
SECTION 8
Troubleshooting
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Air Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
SECTION 9
Spare Parts
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Instruction Manual
IM-105-4000, Rev 1.3
October 2008
TOC-3
OPM 4000
APPENDIX A
Safety Data
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
APPENDIX B
Returning Equipment to
the Factory
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C
ModBus
Communications
Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
APPENDIX D
OPM 2000 Retrofit
Instructions
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Overview of the Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Removal of Existing Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Remove Transceiver Side Components. . . . . . . . . . . . . . . . . . . . .D-2
Remove Retro Reflector Side Components . . . . . . . . . . . . . . . . . .D-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Install Retro Reflector Side Components . . . . . . . . . . . . . . . . . . . .D-3
Install Transceiver Side Components. . . . . . . . . . . . . . . . . . . . . . .D-7
Install Stack Service Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
Beam Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
Startup and Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
Retrofit Kit
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9

Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
TOC-4