http://www.raihome.com
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
Opacity/Dust Density Monitor
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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.
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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
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
http://www.raihome.com
OPM 4000 Opacity/Dust Density Monitor
ESSENTIAL
INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management designs, manufactures and tests its products
to meet many national and international standards. Because these
instruments are sophisticated technical products, you MUST properly install,
use and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to
and
integrated into your safety program when installing, using, and maintaining
Emerson’s Rosemount Analytical products. Failure to follow the proper
instructions may cause any one of the following situations to occur: Loss of
life; personal injury; property damage; damage to this instrument and
warranty invalidation.
• Read all instructions
prior to installing, operating and servicing the
product.
• If you do not understand any of the instructions, contact your
Emerson Process Management representative for clarification.
• Follow all warnings, cautions and instructions
marked on and
supplied with the product.
• Inform and educate your personnel in the proper installation,
operation and maintenance of the product.
• Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes. Connect all products to the proper electrical and
pressure sources.
• To ensure proper performance, use qualified personnel
to install,
operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson Process Management.
Unauthorized parts and procedures can affect the product's
performance, place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire,
electrical hazards or improper operation.
• Ensure that all equipment doors are closed and protective covers
are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.
The information contained in this document is subject to change without
notice.
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
ii
PREFACE The purpose of this manual is to provide information concerning the
components, functions, installation and maintenance of the OPM 4000.
Some sections may describe equipment not used in your configuration. The
user should become thoroughly familiar with the operation of this module
before operating it. Read this instruction manual completely.
DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS and NOTES found
throughout this publication.
NOTE
Highlights an essential operating procedure, condition, or statement.
SYMBOLS
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a
manual illustration number. It is not a part number, and is not related to the
illustration in any technical manner.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETI
N
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
iii
TECHNICAL SUPPORT
HOTLINE:
For assistance with technical problems, please call the Customer Support
Center (CSC). The CSC is staffed 24 hours a day, 7 days a week.
Phone: 1-800-433-6076 1-440-914-1261
In addition to the CSC, you may also contact Field Watch. Field Watch
coordinates Emerson Process Management’s field service throughout the
U.S. and abroad.
Phone: 1-800-654-RSMT (1-800-654-7768)
Emerson Process Management may also be reached via the Internet through
e-mail and the World Wide Web:
e-mail: [email protected]
World Wide Web: www.raihome.com
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
iv
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
http://www.raihome.com
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-7
COMPONENT
CHECKLIST
A typical Rosemount Analytical OPM 4000 Opacity/Dust Density Monitor
should contain the items shown in Figure 1-1. Sheet 1 shows the assembly on
the transceiver side, and sheet 2 shows the assembly on the retro reflector
side. Items on the mounting panel are factory installed and come as shown.
Figure 1-2 shows the transceiver assembly with the optional stainless steel
weather cover.
Due to the availability of optional accessories, the system package will vary.
Use the product matrix, in Table 1-2, to compare your order number against
your unit. The first part of the matrix defines the model. The last part defines
the various options and features of the OPM 4000. Ensure the features and
options specified by your order number are on or included with the unit.
SYSTEM OVERVIEW
General The OPM 4000 Opacity/Dust Density Monitor provides continuous, low
maintenance, precision measurement of opacity and optical density in
industrial applications. It is a cost-effective instrument that serves as an aid in
operating pollution and/or process control equipment.
Opacity refers to the amount of light being scattered or absorbed by particles
in the light beam path. An opacity or dust density transmitter (also called a
transmissometer) measures the particulate level of stack emissions. One of
the most common reasons for measuring opacity is to comply with
Environmental Protection Agency (EPA) or other national requirements.
Federal regulations for new emission sources and many state regulations for
both new and existing sources specify maximum limits for stack emission
opacity.
A transmissometer can be used in a variety of applications. Those
applications include monitoring the efficiency of emission control systems,
detecting broken bags in baghouses, and determining the time rapping cycles
for electrostatic precipitators. Another application is to gauge the
effectiveness of injecting flue gas conditioning agents used to improve
electrostatic precipitator performance.
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
1-2
Figure 1-1. Typical System Package (Sheet 1 of 2)
38450040
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OPM 4000
Opacity/Dust Density
Monitor
Instruction Manual
IM-105-4000 Rev
. 1.0
May 2006
Model:
Serial:
Operate
Zero
Span
Normal
Test
External
Meter (mA)
Opacity
T
2
0-100%
Model
Serial
1
2
3
4
5
6
7
8
9
10
11
1. Zero Jig
2. Instruction Manual
3. Mounting Plate
4. Control Unit
5. Service Module
6. Air Blower
7. Air Filter
8. Air Hose with Clamps
9. Duplexer
Note: The optional weather
covers are not shown in
the typical system package.
10. Transceiver with
Air Plenum attached
11. Terminal Board
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
1-3
OPM 4000
Figure 1-1. Typical System Package (Sheet 2 of 2)
38440041
Model:
Serial:
Notes: 1. Plug air blower into an external AC power source.
2. The optional weather covers are not shown in the
typical system package.
1
2
1. Terminal Board
2. Mounting Plate
3.
4.
5.
6.
Air Blower
Air Filter
Air Hose with Clamps
Retro Reflector with Air Plenum attached
3
4
5
6
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
1-4
Figure 1-2. Transceiver
Assembly with Weather Cover
Opacity data can also serve as a rough indicator of combustion efficiency.
Extreme changes in opacity may indicate inefficient combustion or boiler
problems. Because the transmitter gives accurate, immediate response data,
corrective actions can be taken as soon as problems occur. This data serves
not only the compliance requirement of pollution regulation standards but also
as a means to achieve improved efficiency and operating profit.
Originally, a trained smoke reader determined the particulate level of stack
emissions solely by observation. The opacity of the plume was judged in
reference to a standard Ringelmann scale of 0 to 5. These determinations
tended to be influenced by several sources of error such as sky haze, sun
position, and the subjective determination of the observer. These sources of
error, especially at lower opacity levels, can produce highly variable readings
even when performed by a trained observer.
38450039
Weather
Cover
Mounting
Plate
Duplexer
Terminal
Board
Transceiver
Air Blower
Filter
Service
Module
Control
Unit
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
1-5
OPM 4000
OPM 4000 System
Features
Transmissometer/Retro Reflector
The OPM 4000 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.
The function of the reflector is to return the measurement beam to the
detector in the transceiver, creating a double pass across the process stream.
The standard reflector is used for measurement path lengths up to 15 feet
(4,6 m). For longer path lengths, maximum 60 feet (18,3 m), reflectors, optical
parts and electronics will vary.
Control Unit
Mounted in a control room environment, the OPM 4000 control unit provides
instrument control functions, opacity readings, alarms and fault indicators,
analog outputs, and diagnostics with contact closures.
Service Module
The service module is used to pass signals to and from the transceiver and
control unit, display opacity via digital meter, initiate maintenance zero and
span cycles and insertion of external current meter in the transceiver to
control unit 4-20 mA loop.
Optional Air Purge Weather 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
temperature limits, and errant air currents around the stack.
The air purge system constantly circulates air past the optical window. The
airflow is directed through the hose to an air plenum on the stack side of the
optical window. The airflow 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 OPM 4000 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 cable. More pairs or
larger than 20 AWG is acceptable.
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
1-6
Normal Mode of
Operation
The dual beam measurement system has a stack mounted transmissometer
sensor system that consists of an optical transceiver mounted on one side of
the stack and a retro reflector mounted on the other (Figure 1-3). To avoid
errors due to ambient light, the lamp 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 a
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, and provide alarms and outputs.
Figure 1-3. Component
Relationships
RD MD
Aperture P
Main Lamp
TTL Bulls-Eye
Projection Lens
Retro Reflector
Aperture V
Zero Reflector
Span Filter
Span Filter out:
Span Filter in:
Zero Reflector out:
Zero Reflector in:
Transceiver With Auto Zero Span Capability
38450001
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
1-7
OPM 4000
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 up scale reading in accordance
with the latest EPA 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.
SPECIFICATIONS Specifications for the OPM 4000 system are listed in Table 1-1.
Table 1-1. OPM 4000
Specifications
OPM 4000 Specifications
Design and performance Meets or exceeds PS-1 revised and ASTM D6216-98
Peak and Mean Spectral
Response
Photopic; 515 to 585 nm, less than 10% of peak response
outside 400 to 700 nm
Relative Spectral Response <10%
Angle of View <4.0
o
from optical axis
Angle of Projection <4.0
o
from optical axis
Calibration Error/Accuracy ±1% of full scale
Remote control unit
Numeric Digital Display 5/8 in.
(15,9 mm) 4-digit LED
Selectable for instantaneous opacity, average opacity,
optional mg/m
3
Display Resolution 0.1% Opacity
Alphanumeric 8 character
LED (0.2 in.) Fault Display
Air purge low, No Stack Power, T2 4-20 Lost/low,
Maintenance Mode, Window Dust, Zero Cal Fail, Span Cal
Fail, Manual Cal.
Bargraph Left/Right: 51 segments LED 5.1 in. (129,5 mm) for
instant/average opacity. 20 segment LED 2.1 in. (53,3 mm)
for window dust and drift in % opacity.
Operator Indicating LED’s Run, Alarm, Operate, Cal in progress
High Opacity Set Point 0-100% of full scale
High Opacity Delay Adjustable 0-300 seconds
High Opacity Alarm Reset Automatic
Open Transistor Collector
Outputs
Four selectable
Dry Contacts Two selectable (option: two additional)
Instantaneous Opacity and
Average Outputs
4-20 mA grounded reference, 800 ohms max. (two
additional optional)
OPLR/Exit Correlation
(Lx / 2*Lt)
0.2 to 3.0
Cal Cycle Initiate Local, remote and timed adjustable 1 to 24 hours
Enclosure NEMA 13, IP65, Height: 7.38 in. (187,5 mm) x Width: 3.00
in. (76,2 mm) x Depth: 7.75 in. (196,9 mm), Weight 6 lbs
(2,24 kg)
Ambient Temperature Range 32
o
to 122
o
F (0
o
to 50
o
C)
Ambient Temperature Limits -4
o
to+130
o
F (-20
o
to +54
o
C) (Cold weather option
available.)
Process Gas Up to 750
o
F (400
o
C), standard (higher available-contact
factory)
Power Requirements 120 VAC (±15%), 50/60 Hz, 22VA
Network Protocol: Modbus (ASCII or RTU mode), type RS-485,
optically isolated, RS-232 with telephone modular handset
connector.
Instruction Manual
IM-105-4000, Rev 1.3
October 2008
OPM 4000
1-8
Table 1-2. Product Matrix
OPM 4000 OPACITY DUST DENSITY MONITOR - ORDERING INFORMATION
Select complete model number from the Product Matrix
Configuration Speed: 1200-38,400 baud, type RS-232, and RS-485
Transceiver Service module
Display 5/8 inch (15,9 mm), 4-digit LED, selectable for % opacity
and % transmittance
Local Zero/Span Manual on demand
Test Jacks Transceiver to remote control current loop
Diagnostics Loss of power, current loop open, maintenance mode
Transceiver/Reflector
Enclosure NEMA 4 watertight enclosure
Path Length 3 to 40 feet (0,9 to 12 m) standard, longer available
Optical System Double pass
Light Source Aging
Compensation
Automatic
Light Source Life > 5 years
Alignment Verification Passive built-in through-the-lens system
Mounting Flanges 3 in. IPS, 150 lbs (56 kg) pipe flange
Ambient Light Immunity Solid-state electronic light modulation
Design and Performance
Peak and Mean Spectral
Response
Photopic; 515 to 585 nm, less than 10% of peak response
outside 400 to 700 nm.
Relative Spectral Response <10%
Angle of View <4.0
o
from optical axis
Angle of Projection <4.0
o
from optical axis
Calibration Error/Accuracy ±1% of full scale
Response Time <10 seconds
Zero Drift <0.5%
Calibration Drift <0.5%
Operational Period In excess of PS-1 required 336 hrs
Zero/Span Calibration Manual or automatic with zero mirror and neutral density
filter
OPM 4000 Specifications
OPM4000 Opacity/Dust Density Monitor
Code Intelligent Electronics
01 Basic Unit – Digital Display, (2) 4-20 mA Outputs, RS 232/485, Modbus
Code Transceiver and Path Length
11 3-15’ Path Length
12 >15-21’ Path Length
13 >21-40’ Path Length
14 >40’ Path Length
Code Weather Cover and Blowers
00 None
01 Weather Covers and Blowers
02 Weather Covers Only
Code Zero Jig Type
01 Zero Jig and Neutral Density Filters
02 Zero Jig Only
OPM4000 01 12 02 01 Example
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