Instruction Manual IM , Rev 1.2 November 2007 OPM Opacity/Dust Density Monitor.

Transcription

1 Instruction Manual OPM 4000 Opacity/Dust Density Monitor

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3 HIGHLIGHTS OF CHANGES Page General Page 1-1 Page 1-1 thru 1-4 Summary Effective August 31, 2006 Rev 1.0 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. Added information under Component Checklist. 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 Page 1-8 thru 1-9 Page 2-1 Page 2-2 Page 2-3 Page 2-4 Page 2-5 thru 2-6 Page 2-7 Page 2-8 Page 2-9 Page 2-10 Page 2-11 Page 2-12 Page 2-13 thru 2-14 Page 2-15 thru 2-16 Page 2-17 Added Figure 1-2, Transceiver Assembly with Weather Cover. Updated Tables 1-1 and 1-2 to represent current conditions. Added the bulleted list under Overview. Added Clearance and Sample Area headings along with descriptive text. Added Figure 2-1, Installation Clearances and Weather Cover Dimensions. Added information and procedural steps under Regulatory Process Considerations, along with Figure 2-2, Transmitter Location. Organized information under Installation of Stack Flanges into procedural steps. Converted important installation reminders from body text into the five Notes. Added Figure 2-3, Mounting the Stack Flanges. Added Figure 2-4, Stack Flange Installation. 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. Updated Figure 2-6, Air Plenum to better illustrate its assembly. Added Attach Blower heading and step 1. Added Note regarding the installation procedures for the transceiver and retro reflector. Added Mounting the Control Unit procedural steps. Relocated Figure 2-8, Control Unit from the end of the section. Added Figure 2-9, Panel Cutout for Control Unit, and Figure 2-10 Control Unit Dimensions. Added procedural steps under System Wiring Installation. 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 Page 3-1 Revised Figure 2-14, Service Module Switch Location. Updated procedural steps under Beam Alignment Procedure. Revised Figure Moved Air Flow Switch information to Section 8, Troubleshooting. Added the Caution and information under Overview.

4 HIGHLIGHTS OF CHANGES (CONTINUED) Page Effective August 31, 2006 Rev 1.0 (Continued) Summary Page 3-2 Page 3-3 Page 4-1 Page 4-2 Page 4-4 Page 5-1 Page 5-2 Page 5-3 Page 6-1 Page 6-1 thru 6-3 Page 6-2 Page 6-3 Page 6-3 Page 6-4 Page 7-1 Page 7-1 thru 7-2 Added Stack Exit Correlation Computation information and Figure 3-1, Lx and Lt Stack Dimensions. Reformatted body text into bulleted lists and procedural steps. Added Overview and bulleted list. Reformatted body text under Alarm Set Point Adjustments and Alarm Time Delay Adjustment into procedural steps. 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. Added Overview and bulleted list. Changed the Procedure heading to Installation, and renumbered the procedural steps. Added Figure 5-2, Zero Jig Installation. 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. Renumbered procedural steps under Clear Stack Zero and Span Calibration. Updated Figure 5-2, Zero Calibration to better illustrate PT-1 and PT-3 locations. Renumbered procedural steps under Zero Reflector Adjustment. Relocated Span Filter Mark procedural steps from the end of the section to follow the Zero Reflector Adjustment procedural steps. 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. Added Overview information. 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 Page 8-1 thru 8-2 Page 8-2 Page 9-1 Added Caution. Revised Troubleshooting table to include references. Added Air Flow Switch heading and body text. Removed information regarding Level III spare parts. Page Summary Effective January, 2007 Rev 1.1 Cover Page 1-4 Page 1-7 Page 1-9 Added picture of control unit to the cover photo. Added picture of control unit to Figure 1-2, Transceiver Assembly with Weather Cover. Revised the TTL Bulls-Eye on Figure 1-3, Component Relationships. 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.

5 HIGHLIGHTS OF CHANGES (CONTINUED) Page Effective January, 2007 Rev 1.1 (Continued) Summary Page 2-20 Page 4-3 Revised the Beam Alignment Procedure. Replaced Figure 2-15, Alignment of the Transceiver. 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 Page 9-1 thru 9-2 Page A-2 thru A-24 Page B-1 Back Cover Revised step 3 under Zero Cal Value and Span Cal Value. Revised Section 9, and added three new spare parts. Added note 11 to the safety data section. Added new language translations. Updated the return of materials address. Updated the address blocks. Page Summary Effective November, 2007 Rev 1.2 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.

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

8 OPM 4000 Instruction Manual SECTION 4 Operation SECTION 5 Zero Jig and Neutral Density Filters SECTION 6 Zero and Span Calibration SECTION 7 Maintenance SECTION 8 Troubleshooting SECTION 9 Spare Parts APPENDIX A Safety Data Overview Control Unit Operations Front Panel LEDs Fault Messages Manual Controls Alarm Set Point Adjustments Alarm Time Delay Adjustment ma Outputs Recorder or Other Device Calibration Auto Cal Timer Adjustment Remote Calibration Cycle Initiate Remote Calibration Cycle Acknowledgment Service Module Switches Overview Using the Zero Jig Installation Coarse Adjustments Filter Correction Filter Certification Overview Clear on Stack Zero and Span Calibration Zero Reflector Adjustment Span Filter Mark Record the Zero/Span Values in the Quick Menu Zero Cal Value Span Cal Value Off Stack Zero Calibration Overview Preventive Maintenance Schedule Control Unit Preventive Maintenance Weather cover/blower preventive maintenance Corrective Maintenance Lamp Replacement Transceiver Fuse Replacement Service Module Fuse Replacement Circuit Board Replacements Troubleshooting Air Flow Switch Spare Parts Safety Instructions A A-24 TOC-2

9 Instruction Manual OPM 4000 APPENDIX B Returning Equipment to the Factory APPENDIX C ModBus Communications Returning Material B-1 Modbus Communications C-1 TOC-3

10 OPM 4000 Instruction Manual TOC-4

11 Instruction Manual OPM 4000 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.

12 OPM 4000 Instruction Manual PREFACE DEFINITIONS The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the OPM 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. The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication. 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. NOTE Highlights an essential operating procedure, condition, or statement. SYMBOLS : EARTH (GROUND) TERMINAL : PROTECTIVE CONDUCTOR TERMINAL : RISK OF ELECTRICAL SHOCK : WARNING: REFER TO INSTRUCTION BULLETIN 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. ii

13 Instruction Manual OPM 4000 Section 1 Description and Specifications Component Checklist page 1-1 System Overview page 1-1 Specifications page 1-8 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 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.

14 OUT SP PV REM LOC OPM 4000 Instruction Manual Figure 1-1. Typical System Package (Sheet 1 of 2) 1 Instruction Manual IM Rev. 1.0 May OPM 4000 Opacity/Dust Density Monitor Analytical MESSAGE DIS ACK 3 AUTO MAN Model: Serial: Operate Zero Span Normal Test Opacity T % External Meter (ma) 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 10. Transceiver with Air Plenum attached 11. Terminal Board 8 Model Serial Note: The optional weather covers are not shown in the typical system package

15 Instruction Manual OPM 4000 Figure 1-1. Typical System Package (Sheet 2 of 2) Model: Serial: Terminal Board 2. Mounting Plate 3. Air Blower 4. Air Filter 5. Air Hose with Clamps 6. Retro Reflector with Air Plenum attached Notes: 1. Plug air blower into an external AC power source. 2. The optional weather covers are not shown in the typical system package

16 OPM 4000 Instruction Manual Figure 1-2. Transceiver Assembly with Weather Cover Weather Cover Service Module Terminal Board Transceiver Mounting Plate Duplexer Control Unit Filter Air Blower 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. 1-4

17 Instruction Manual 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. 1-5

18 OPM 4000 Instruction Manual Normal Mode of Operation Internal Calibration System, Zero Mode Internal Calibration System, Span Mode 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. 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. 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. 1-6

19 Instruction Manual OPM 4000 Figure 1-3. Component Relationships Transceiver With Auto Zero Span Capability TTL Bulls-Eye Projection Lens Retro Reflector Aperture P Main Lamp RD Span Filter MD Aperture V Zero Reflector Span Filter out: Span Filter in: Zero Reflector out: Zero Reflector in:

20 OPM 4000 Instruction Manual 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 D 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, T 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 seconds High Opacity Alarm Reset Automatic Open Transistor Collector Four selectable Outputs 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 0.2 to 3.0 (Lx / 2*Lt) 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. Configuration Speed: ,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 1-8

21 Instruction Manual OPM 4000 OPM 4000 Specifications Light Source Aging Automatic Compensation 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 Table 1-2. Product Matrix OPM 4000 OPACITY DUST DENSITY MONITOR - ORDERING INFORMATION Select complete model number from the Product Matrix 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 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 OPM Example 1-9

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23 Instruction Manual OPM 4000 Section 2 Installation Overview page 2-1 Installation Considerations page 2-2 Mechanical Installation page 2-5 System Wiring Installation page 2-15 Beam Alignment Procedure page 2-19 Before installing this equipment, read the Safety instructions for the wiring and installation of this apparatus in Appendix A. Failure to follow safety instructions could result in serious injury or death. Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death. Before making any electrical connections, make sure the AC power supply is first switched off. Failure to do so could cause personal injury or even death. Make sure that the voltage and frequency of the AC supply match the designations on the analyzer component tags. NOTE If installed path length is not within 10% of the factory set path length, return the unit to the factory so the path length can be reset. OVERVIEW This section describes: Considerations prior to installation. Mechanical installation procedures, including the applicable drawings and pictures to assist in the process. Wiring schematics for the OPM 4000 system. The beam alignment procedure.

24 OPM 4000 Instruction Manual INSTALLATION CONSIDERATIONS Choose an Installation Site Accessibility Clearance Environment The primary considerations for choosing a site for the OPM 4000 are accessibility, ambient environmental conditions, and locating the unit to obtain a representative sample of the process. The following general guidelines should be considered. Locate the instrument where it will provide safe access for periodic maintenance and inspection. A platform or walkway is required for access to the sensors and weather covers. The optimum condition is to have the mounting flanges and weather covers approximately 5 feet (1,5 m) above the floor. A minimum of 12 in. (305 mm) from the bottom of the weather cover to the floor is required in order to remove the air filters. Installation clearances for the transceiver, retro reflector and optional weather covers are shown in Figure 2-1. Locate the stack-mounted units in an area with ambient temperatures between -4 o to +131 o F (-20 ο to 55 o C). (Consult the factory for other temperature ranges.) Areas that are clean and dry are desirable. Avoid areas with condensation. Maintenance intervals are directly related to the installation environment. Intervals can vary from 2 to 3 months in fairly clean environments, to twice a month in dirty environments. Lens cleaning is a function of the ambient conditions and cleanliness of the purge air. Choose a location that will minimize excessive vibration or shock. Locate the control unit in an easily accessible area with temperatures between 32 o to 122 o F (0 o to 50 o C). To permit the operator to read and/or change controls, the unit should not be mounted higher than five feet from floor level. Sample Area Stack Exit To achieve a representative sample, the accepted practice is to have the measurement path of the instrument directly in the center of the stack. An area should be chosen where the gases are not stratified in the stack or duct. When installed near a bend, install the transceiver in the plane defined by the bend; refer to "Regulatory/Process Considerations". Avoid locations where large amounts of condensed water is present. The transceiver should be located a minimum of two stack diameters from the stack exit. Ideally the transciever should be installed eight to ten stack diameters from the stack exit. 2-2

25 Instruction Manual OPM 4000 Figure 2-1. Installation Clearances and Weather Cover Dimensions R in. (311 mm) in. (156 mm) R 7.5 in. (191 mm) 6 to 8 in. (152 to 203 mm) (156 mm) 6 to 8 in. (152 to 203 mm) VERTICAL AXIS TOP VIEW * SIDE VIEW ** Cover In Upright Position Leave 3 in. (76 mm) clearance from flange face for swinging in. (533 mm) (2) Covers Stack or Breeching Wall OD RETRO Minimum Swing Clearance 34 in. (863 mm) From Flange Center TRANSCEIVER GAS FLOW 30.5 (775 mm) (3) Covers 60 in. (1524 mm) Optional Weather Cover Optional Weather Cover PLATFORM PLATFORM *Note 1: The top view represents the transceiver and retro reflector assemblies with their swing clearances. Optional weather covers are not shown. **Note 2: The side view represents the installation and swing clearance dimensions for the optional weather covers

26 OPM 4000 Instruction Manual Regulatory/Process Considerations The EPA has established the following guidelines for choosing an opacity/dust density monitor installation site: 1. Locate the transmitter across a section of a duct or stack that will provide a particulate matter flow through the path of the transmitter beam representative of the duct or stack flow. 2. Ensure the transmitter location is down-stream from all particulate control equipment. 3. Locate the transmitter as far from bends and obstructions as practical. 4. If a transmitter is to be located less than 4 duct diameters downstream from a bend, install the transmitter in the plane defined by the bend, as shown in Figure Ideally, locate the transmitter eight to ten stack diameters upstream from the stack exit and three to five diameters downstream from any bends, junctions, or other constrictions in the stack or duct. For best results, mount the transceiver and retro reflector modules so the light beam is exactly perpendicular to the stack or duct and the beam goes through the center. Do not install the transmitter downstream of a wet scrubber. The water droplets introduced to the gas stream by such equipment will interfere with the opacity readings. For an accurate measurement under these conditions, choose a location upstream from a wet scrubber or a location downstream from the scrubber where the water droplets are vaporized by the reheating of the gas. Figure 2-2. Transmitter Location Less than 4 duct diameters Note: The transceiver and retro reflector are shown with the optional weather covers installed

27 Instruction Manual OPM 4000 MECHANICAL INSTALLATION Installation of Stack Flanges NOTE The beam of the instrument must be kept in a horizontal plane; the transceiver cannot be rotated more than ±10 o from vertical. The weather covers must be installed vertically level. Mounting on stack diameters under 6 feet NOTE Flanges should be mounted approximately 5 feet (1,5 m) up from the deck of the platforms, roof or walk way. 1. Form two mounting holes in the stack at locations specified in "Installation Considerations". Holes must be on the same horizontal and vertical axes. A liquid level can be used to ensure that modules are installed on the same horizontal plane. 2. Insert a piece of 2-1/2 in. (64 mm) pipe through the mounting holes. Make sure pipe is protruding far enough to allow installation of the 3 in. pipe flange assemblies over each end (Figure 2-3, Stacks Under 6 Feet Across). NOTE The customer is required to supply and install two 3 in. IPS flanges at eye level directly across from each other. 3. The flanges must be aligned so that the total deviation of the light source flange relative to a common centerline does not exceed ±1 o and the retro reflector flange does not exceed ±3 o. Any deviation within these limits can be countered during the installation and alignment of the light source and retro reflector with the system's alignment adjustments. 4. Weld the pipe flanges to the mounting nipples, as shown in Figure Install the pipe flange assemblies into the stack/duct wall. The flange should be 6 to 8 in. (152 to 203 mm) from the stack or insulation (Figure 2-4). Mounting on stack diameters over 6 feet 1. Form two mounting holes in the stack at locations specified in "Installation Considerations". Holes must be on the same horizontal and vertical axes. A liquid level can be used to ensure that modules are installed on the same horizontal plane. 2. Locate one 3-1/2 in. (89 mm) diameter hole (large enough to accept the 3 in. mounting nipple) and the other hole approximately 1/2 in. (13 mm) diameter, directly across from each other. 2-5

28 OPM 4000 Instruction Manual NOTE An alignment tool can be purchased from the factory to ensure accurate alignment. 3. Attach the alignment tool to the pipe flange assembly and insert the assembly into the 3-1/2 in. (89 mm) hole in the stack wall. 4. Align the assembly with the 1/2 in. (13 mm) diameter hole on the opposite side by viewing through the alignment tool (Figure 2-3, Stacks Over 6 Feet Across). 5. The flanges must be aligned so that the total deviation of the light source flange relative to a common centerline does not exceed ±1 o and the retro reflector flange does not exceed ±3 o. Any deviation within these limits can be countered during the installation and alignment of the light source and retro reflector with the system's alignment adjustments. 6. Weld the pipe flange to the mounting nipple (Figure 2-4). Care must be exercised when welding to maintain alignment. 7. Install the pipe flange assembly into the stack/duct wall. The flange should be 6 to 8 in. (152 to 203 mm) from the stack or insulation (Figure 2-4). NOTE The 1/2 in. (13 mm) diameter hole should now be enlarged to approximately 3-1/2 in. (89 mm) to accept the other flange/pipe assembly. 8. Proceed in the same manner for installation on the opposite side. Install the other pipe flange assembly with the alignment tool attached, and secure to the stack/duct wall (Figure 2-4). Maintain concentric alignment with the pipe flange assembly previously installed on the opposite wall. 2-6

29 Instruction Manual OPM 4000 Figure 2-3. Mounting the Stack Flanges STACKS UNDER 6 FEET ACROSS 6 in. - 8 in. ( mm) 3 in. Sch 40 Mounting Nipple VERTICAL AXIS 2-1/2 in. (64 mm) Pipe Size to Span as needed (for alignment) GAS FLOW Stack or Breeching Wall OD STACKS OVER 6 FEET ACROSS Alignment Tool ½ in. (13 mm) Alignment Hole NOTE If installed path length is not within 10% of the factory set path length, return the unit to the factory so the path length can be reset. 2-7

30 OPM 4000 Instruction Manual Figure 2-4. Stack Flange Installation VERTICAL AXIS PIPE FLANGE 7.5 in. (191 mm) Stud Anchors 6 in. (152 mm) Bolt Circlle Field Weld Pipe Flange to Mounting Nipple Outside Wall Surface Field Weld Mounting Nipple to Pipe Flange and Metal Stack/ Duct Wall Outside Wall Surface 6 to 8 in mm) Clearance 3 in. SCH 40 Mounting Nipple 6 to 8 in mm) Clearance MASONRY STACK WALL INSTALLATION METAL WALL STACK OR DUCT INSTALLATION 2-8

31 Instruction Manual OPM 4000 Mounting the Air Plenum and Weather Covers Control unit, transceiver and retro reflector serial numbers must match in order to ensure acurate measurements. After the installation site has been selected and the platform requirements have been met, the mounting flanges should be installed and aligned as described in "Installation of Stack Flanges". Flanges should be installed with the mounting faces on the vertical plane. NOTE 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 with less of a chance of damage while attaching the air plenums and optional weather covers. Figure 2-5. Transceiver and Retro Reflector Hinge Pins Hinge Pin 1. Verify that the control unit, transceiver and retro reflector serial numbers match. 2. If an air plenum is attached to either the transceiver or retro reflector, un-clip both hold-down latches, swing open and lift up and off the hinge pins (Figure 2-5). Place the transceiver and retro reflector in a safe place. 3. If the OPM 4000 is equipped with weather covers remove the two weather cover hood hinge pins located on the upper right and left hand corner of the hood. NOTE The air plenum and weather cover are attached to the customer supplied 3 in. pipe flange by four 2-1/2 in. long 5/8-11 bolts. 2-9

32 OPM 4000 Instruction Manual 4. Working from the 3 in. pipe flange, assemble in the following order (Figure 2-6): a. gasket b. mounting plate c. gasket d. mating flange and air plenum 5. Place a flat washer onto each of the four 5/8-11 bolts. 6. Once aligned, place the 5/8-11 bolt and flat washer through the top hole of the middle plate so it is flush against the mating flange. 7. Place a split lock washer over the end of the bolt and secure with a nut. Repeat for the remaining three mounting bolts. Attach Blowers Connect an air blower to the air blower port on the transceiver using the air hoses and clamps. Connect the other air blower to the air blower port on the retro reflector using the air hoses and clamps. See Figure 2-6 for the air blower port location. Figure 2-6. Air Plenum Mounting Plate 3 Pipe Flange Mating Flange Middle Plate Mounting Nipple 5/8-11 Bolt (4) Latch Gasket Air Blower Port Gasket Mating Flange and Air Plenum

33 Instruction Manual OPM 4000 Mounting the Transceiver and Retro Reflector NOTE The installation procedures below are for both the transceiver and the retro reflector. Installation dimensions and clearances are shown in Figure Attach the transceiver and retro reflector to the air plenum assembly by placing them on the hinge pins (Figure 2-7). 2. Close transceiver and retro reflector and secure in place with the two hold-down latches. Figure 2-7. Upper and Lower Hinge Pins Upper Hinge Pin Lower Hinge Pin 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. 3. Power up the air-purge blowers to prevent stack particulate from accumulating in the nipple and air-purge housing. 2-11

34 OPM 4000 Instruction Manual Mounting the Control Unit NOTE Mount the control unit (Figure 2-8) at eye level for best viewing of the display. Figure 2-8. Control Unit Make a 3.13 x 7.5 in. (80 x 191 mm) cut-out in the control panel where the control unit will be mounted (Figure 2-9). 2. Check that gasket seals are snug against each side of the flange, as shown in Figure Slide the controller into the cut-out. 4. From the rear of the control unit, insert the panel mounting hardware in the slots provided on the top and bottom of the control unit (Figure 2-10). 5. Secure the control unit by tightening the screws with the 1/8 in. hex socket wrench until the control unit is securely held in place (Figure 2-10). 2-12

35 Instruction Manual OPM 4000 Figure 2-9. Panel Cutout for Control Unit 1.75 in. (45 mm) minimum spacing to mount next unit above or below in. (16 mm) minimum spacing CUTOUT 7.5 in. (191 mm) 3.13 in. (80 mm)

36 OPM 4000 Instruction Manual Figure Control Unit Dimensions in. (95 mm) Flange Gasket 8.00 in. (203 mm) 1.13 in. (29 mm) 1/8 in. Hex Socket Gasket 0.50 in. (13 mm) max. 1/2 in. & 3/4 in. Conduit K.O in. (197 mm) Mounting Hardware 0.75 in. (19 mm) 3/4 in. Conduit KO 0.5 in. (13 mm) Removable Rear Cover 7.38 in (188 mm) Field Wiring Terminal Blocks Located behind this cover 1.13 in. (29 mm) 3.0 in. (76 mm) 2-14

37 Instruction Manual OPM 4000 SYSTEM WIRING INSTALLATION Disconnect and lock out all power before wiring the system. The following procedures outline the necessary wring connections for the OPM 4000 system. Terminal identifications for the control unit are shown in Figure Wiring diagrams are shown in Figure 2-12 and the pin designations are shown in Figure The recommended cable connecting the transceiver to the control room unit is Belden PN 8778, six individually shielded twisted pair, 22 AWG, PVC jacketed, 80ºC. Maximum connecting cable length is 1000 feet (305 m) for 22 AWG wire, and 3000 ft (914 m) for 18 AWG wire. Control Unit 1. Connect terminal 17 on the control unit to terminal 17 on TB Connect terminal 18 on the control unit to terminal 16 on TB Connect shield covering the wires from terminals 17 and 18 of the control unit to terminal 15 on TB Connect terminal 11 on the control unit to terminal 14 on TB Connect terminal 12 on the control unit to terminal 13 on TB Connect terminal 6 on the control unit to terminal 12 on TB Connect terminal 5 on the control unit to terminal 11 on TB Connect shield covering the wires from terminals 6 and 5 of the control unit to terminal 10 on TB Connect terminal 9 on the control unit to terminals 9 and 8 on TB Connect terminal 5L on the control unit to terminal 7 on TB Connect terminal 6L on the control unit to terminal 6 on TB Connect shield covering the wires from terminals 5L and 6L of the control unit to terminal 8 on TB Connect terminal 7L on the control unit to terminal 5 on TB Connect terminal 9 on the control unit to terminal 3 on TB Connect shield covering the wires from terminals 7L and 9 of the control unit to terminal 2 on TB 1. Air Flow Switches 1. Connect terminals 5 and 4 on TB 1 to the transceiver air flow switch. 2. Connect shield covering the wires from terminals 5 and 4 on TB 1 to terminal 2 on TB Connect terminals 1 and 2 on terminal board 2 (TB 2) to the retro reflector air flow switch. 4. Connect shield covering the wires from terminals 1 and 2 on TB 2 to terminal 3 on TB

38 OPM 4000 Instruction Manual Terminal Board 1 (TB 1) to Terminal Board 2 (TB 2) 1. Connect terminals 3 and 4 on TB 1 to terminals 1 and 2 on TB Connect shield covering the wires from terminals 3 and 4 on TB 1 to terminal 1 on TB Connect shield covering the wires from terminals 1 and 2 on TB 2 to terminal 3 on TB 2. Figure Control Unit Terminal Identification 120 Vac tie points 24 Vdc inputs Activate by connecting to term. 9 (DOUT -) N L L DIN 1 DIN 2 DIN 3 DIN 4 DIN 5 1 Isolated 2 RS Vdc ma 7 Sinking ma ohms (50 ma max) Vdc or 4-20 ma (JP2 jumpers connect 250 ohm resistors) JP2 5 1L 2L 3L 4L 5L 6L 7L 8L 1U 2U 3U 4U 5U 6U 7U 8U N L NC C NO NC C NO + - COM DOUT + DOUT 1 DOUT 2 DOUT 3 DOUT 4 DOUT V AOUT 1 + AOUT 1 - AOUT 2 + AOUT V + 24 V AIN 1 + AIN 1 - AIN 2 + AIN 2 - AIN 3 + AIN 3 - AIN 4 + AIN 4 - AIN 5 + AIN V + 24 V 120 Vac 22 VA 50/60Hz Rout 1 (120Vac) (8A max) Rout AIN 250 ohm resistor jumpers ROUT 1-1 (C) ROUT 1-1 (NO) ROUT 1-2 (C) ROUT 1-2 (NO) (Optional J Board) 1U Power Neutral 2U Power High 4U & 5U Dry contact, closed during Cal. Check 7U & 8U Dry Contact, closed during Hi Opacity check 4L Remote alarm silence 5L Maintenance contact from service module 6L Lost power contact from service module 7L Air flow switches from transceiver and retro 8L Remote cal initiate (Momentarily gnd. to initiate) (Terminal 9 =gnd.) 4 +24Vdc (DOUT +) 5 Open collector transistor for span solenoid 6 Open collector transistor for zero solenoid 7 Open collector transistor for High Opacity alarm 8 Open collector transistor for Fault alarm 9 Common (DOUT -) 11 & ma output (Instantaneous Opacity) to recording device and service module 13 & ma output (Average Opacity) (Optional J Board) 40 Rout1-1(C) 41 Rout1-1(NC) 41 Rout1-2(C) 42 Rout1-2(NC) Descr: Descr:

39 Instruction Manual OPM 4000 Figure Typical System Wiring CONTROL UNIT T-squared from Transmissometer (+) 4-20 ma T-squared from Transmissometer (-) 4-20 ma Inst. Opacity to Service Module (+) 4-20 ma Inst. Opacity to Service Module (+) 4-20 ma Zero solenoid control to Service Module Zero solenoid control to Service Module 6 5 Control signal reference 9 Maintenance contacts from Service Module Power Status contacts from Service Module 5L 6L Air flow contacts Control signal reference 7L 9 Note: OPM 4000 Control Unit (for Terminal ID detail refer to Control Unit Terminal Identification Drawing) (+) 4-20 ma Average Opacity (-) 4-20 ma Average Opacity Line 11 Neutral TRANSCEIVER WEATHER COVER Red Black Yellow Black Blue Black Green Black White Black TB 1 TRANS. AIR FLOW SW Note: P1 and P2 are illustrated in Figure ma Outputs AC Power 115 Volts 50/60 Hz AC Power 115 Volts 50/60Hz BLOWER A A Duplexer B C J G H F D E B C D E F G H J P1 P2 Transceiver Service Module RETRO REFLECTOR WEATHER COVER TB BLOWER RETRO REFLECTOR AIR FLOW SW AC Power 115 Volts 50/60Hz I I 2-17

40 OPM 4000 Instruction Manual Duplexer and AC power Supply 1. Connect the line wire (terminal 11 of the control unit) to an AC power source. 2. Connect the neutral wire (terminal 12 of the control unit) to an AC power source. 3. The transceiver blower is factory wired to the duplexer. 4. Plug the retro reflector blower into an AC power source. 5. Plug the service module into the duplexer. 6. Plug the duplexer into an AC power source. Figure P1 and P2 Pin Designations TRANSCEIVER WEATHER COVER BLOWER A B C I J G H F D E P1 A B C D E F G H I J P2 Transceiver Service Module A B I H G H G I A B C J F F J C D E E D P1 Connector (Female connector viewed from socket end) P2 Connector (Male connector viewed from pin end)

41 Instruction Manual OPM 4000 BEAM ALIGNMENT PROCEDURE NOTE Alignment can not be done unless the power is applied to the stack mounted service module. The control unit does not have to be connected or powered to perform an alignment. For optimal alignment accuracy the stack should be at normal operating temperature. Alignment should be completed before instrument calibration. Service module switches (Figure 2-14) should be in the normal operating positions given below. Operate/Zero - Operate Operate/Span - Operate Normal/Test - Normal Opacity/T 2 - Opacity Figure Service Module Switch Location OPERATE ZERO NORMAL TEST SPAN EXTERNAL METER (ma) OPACITY T % 00.3 Model: Serial:

42 OPM 4000 Instruction Manual 1. Turn on the power to all air purge systems and the service module. 2. Adjust the 3 adjusting bolts on the middle plate so it is level and parallel to the mating flange. The adjusting bolts have nylon locking inserts to prevent loosening by vibration. 3. Look through the viewing port located on the rear of the transceiver to determine monitor alignment. 4. Adjust the 3 adjusting bolts to align the beam image in the center of the cross hair (bulls-eye) as shown in Figure Figure Alignment of the Transceiver. Adjusting Bolts Beam image in the center of the cross hair

43 Instruction Manual OPM 4000 Section 3 Startup and Calibration Overview page 3-1 Before Startup page 3-1 Edit Keys page 3-3 Quick Menu page 3-3 Displaying the Factory Set OPLR page 3-3 Zero/Span Calibration Check page 3-4 OVERVIEW This section describes the necessary adjustments and precautions to be enacted before the startup of the OPM 4000 system. Read the entire manual to familiarize yourself with the instrument before attempting startup. BEFORE STARTUP Startup Service You must complete the following before startup is attempted. 1. Measure and record flange-to-flange distance for use in future off line calibration procedures. 2. 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 in this section. After system operation has been verified, connect and test external connections. 3. The air purge and weather cover system, transceiver, retro reflector, and service module must be installed and power applied. 4. Control unit must be installed and wired to the service module and customers equipment as applicable. 5. All wiring and mechanical installations must be complete. All wiring must be checked and power applied to both the control unit and the stack service module. 6. Beam alignment procedure has been completed. Emerson Process Management is available to assist you; call our Customer Support Center (CSC) at for details and to schedule startup.

44 OPM 4000 Instruction Manual Stack Exit Correlation Computation NOTE The stack exit correlation is especially important to verify. If possible, all dimensions should be verified by actual measurements. Lx/Lt is the ratio of the inside diameter at the top of the stack to the inside diameter of the stack where the instrument is located (Figure 3-1). If the ratio is greater than 1.0, the exit opacity will be greater than the opacity at the instrument location. The OPM 4000 uses this correction factor to calculate the stack exit opacity. It is not practical to have an Lx/Lt factor much greater than 2.0 because the error of the instrument increases as Lx/Lt becomes greater. Lx = inside stack diameter at stack exit. Lt = inside stack diameter at the transmitter location. Lf = flange to flange distance between the transceiver and retro reflector unit. 1. Measure and record Lx and Lt and compute the Optical Path Length Ratio (OPLR). 2. Check that the calculated value and the OPLR found in the Factory OPLR, are within ±2%, refer to "Zero/Span Calibration Check". Example: A stack with a 120 in. (3048 mm) stack exit ID and a 120 in. (3048 mm) pathlength. OPLR = Lx 2*Lt OPLR = 120 2*120 = Enter the exit diameter (Lx) and measured diameter (Lt) in the control unit. Refer to Section 4: Operation, for info on using the control unit. Figure 3-1. Lx and Lt Stack Dimensions Lx Stack TRANSCEIVER RETRO REFLECTOR Lt Lf Note: Transceiver and retro reflector are shown without the optional weather covers

45 Instruction Manual OPM 4000 Verifying Instrument Operation and Configuration EDIT KEYS Before calibrating: Beam alignment procedure must be completed as outlined in Section 2: Installation. Apply power to both the control unit and the sensors for a minimum of 30 minutes before any adjustments are attempted. Observe the front panel LEDs and confirm the red operate and the green RUN LEDs are on. Press the ACK button to confirm NO ALM'S message is displayed. Press the DIS button until OPACITY % is displayed. All data entry, editing and diagnostics are accomplished with four EDIT keys behind the hinged cover (Figure 3-2). QUICK MENU 1. Open the hinged cover and press the EDIT (ESC) button [the red EDIT (ESC) LED will light]. The message display will read QUICK MENU. 2. Press the ENTER key then the EDIT key to scroll through the listing shown below. Alarm Set Point Alarm Time Delay Auto Cal Cycle Time Zero Cal Value Span Cal Value OPLR Read Only In % opacity In seconds In hours In % opacity In % opacity XX.XX DISPLAYING THE FACTORY SET OPLR 1. Open the hinged cover and press the EDIT (ESC) button [the red EDIT (ESC) LED will light]. The message display will read QUICK MENU. 2. Press the ENTER key then the EDIT key or hold and scroll down until the display reads "OPLR Read Only". 3. Press the ENTER key; the OPLR is displayed. The OPLR is a read only block and cannot change the OPLR setting. It is intended for a convenient place to view the OPLR. The OPLR is factory set and cannot be changed in the field. If an OPLR change is required, contact the factory for return authorization number and shipping instructions. 3-3

46 OPM 4000 Instruction Manual Figure 3-2. OPLR Display MESSAGE Edit Value Light Scroll Menu Light ACK DIS Moves Message Cursor ALARM RUN OPERATE ZERO CAL. AUTO MAN SPAN HIGH OPACITY REM LOC I A D EDIT EDIT ENTER (ESC) EDIT EDIT Keys Hinged Cover ZERO/SPAN CALIBRATION CHECK The zero calibration has been set at the factory by placing the instrument on an optical bench and using the flange-to-flange dimensions recorded in the customer s order. This zero value is critical as it can offset smoke measurement if not correctly set. The measurement reflector contains an aperture that is chosen during the factory calibration and is fixed. The transceiver is aligned with the beam centered on the retro reflector and the electronics is adjusted to produce a zero opacity value. The zero jig is then adjusted to provide a low value (typically 1-2%). This value and the span filter up scale value are recorded and entered in the Quick Menu under "Zero Cal Value" and "Span Cal Value". When the system enters a manual or auto cal check cycle, the current zero and span values are checked against the stored values. If either the zero or span current value exceeds the stored value by ±2% opacity, the fault system will energize. To verify the zero/span calibration check, follow the procedure below. 1. Push the CAL. AUTO/MAN key to initiate a manual calibration cycle. The Alarm LED will light and the left/right bargraph will blink. This is normal since a manual calibration is considered a fault condition. 2. Press the ACK key. The ALARM LED and bargraphs will stop blinking. The message display will read MANUAL CAL ALARM. 3. Push the DIS key to return to display opacity. 4. Push the ACK key (after the calibration cycle is complete) to clear any alarms. If no alarms are present, the system is working properly. 3-4

47 Instruction Manual OPM 4000 Section 4 Operation Overview page 4-1 Control Unit Operations page 4-1 Service Module page 4-4 OVERVIEW CONTROL UNIT OPERATIONS Front Panel LEDs Fault Messages This section describes: Operation of the OPM 4000 through the control unit. How to make alarm adjustments. Various terminal locations. How to operate the service module. The control unit front panel is shown in Figure 4-1 and described below. The following LED indicators are located on the control unit. ALARM - Red LED is blinking when a fault is detected. Performing a manual calibration will cause an alarm condition. RUN - Green LED is on during normal operation and blinking if system is in S/M mode. The primary use of S/M mode is to prevent 4-20 ma outputs from changing while modifying blockware. OPERATE - Red LED is on during normal operation. CAL. AUTO/MAN - Red LED is on during calibration check mode. ZERO - Red LED is on when zero calibration cycle is in progress, off during span or normal operation. SPAN - Red LED is on when span calibration cycle is in progress, off during zero or normal operation. HIGH OPACITY - Red LED is on if opacity exceeds set point for more than the time delay (typically 30 seconds). REM/LOC - Not used. The following mesages are displayed during a fault condition. Air purge low - Airflow to the transceiver and/or retro reflector is not sufficient. No Stack Power - Indicates loss of service module power or other related power or component failure from the service module. T Lost/low - Transceiver 4-20 ma current loop output is out of specification or missing.

48 OPM 4000 Instruction Manual Figure 4-1. OPLR Display MESSAGE Edit Value Light Scroll Menu Light ACK DIS Moves Message Cursor ALARM RUN OPERATE ZERO CAL. AUTO MAN SPAN HIGH OPACITY REM LOC I A D EDIT EDIT ENTER (ESC) EDIT EDIT Keys Hinged Cover Maintenance Mode - Indicates a maintenance mode switch on the service module is in a maintenance position and the system is not displaying or outputting the opacity reading. Window Dust - Dirt has accumulated on the transceiver lens and/or the zero mirror in excess of the > 5% limit and must be cleaned. Zero Cal Fail - During calibration check the zero reading has exceeded the > 2% opacity set point. Span Cal Fail - During calibration check the span reading has exceeded the > 2% opacity set point. Manual Calibration - A manual calibration check has been started from the control unit front panel. Manual Controls ACK - Acknowledges fault alarms and displays the fault message. DIS - Changes displayed value each time it is pressed. The display rotates between opacity %, average opacity, dust/zero shift, and hours to next calibration. CAL. AUTO/MAN - initiates a maintenance cal cycle and resets calibration cycle timer clock. 4-2

49 Instruction Manual OPM 4000 Alarm Set Point Adjustments Alarm Time Delay Adjustment 1. Open the hinged cover and press the EDIT (ESC) button [the red Edit (ESC) LED will light]. The message display will read QUICK MENU. 2. Press the ENTER key then the EDIT key 1 time until the Display reads ALARM SET POINT. 3. Press the ENTER key; the Edit Value Light will flash. 4. Press and hold the EDIT or EDIT key until the desired set point in % opacity is displayed, i.e is 20.00% opacity. 5. Press ENTER then press the EDIT key 4 times to return to normal operation. 1. Open the hinged cover and press the EDIT (ESC) button [the red Edit (ESC) LED will light]. The message display will read QUICK MENU. 2. Press the ENTER key then the EDIT key 2 times until the Display reads ALARM TIME DELAY. 3. Press the ENTER key; the Edit Value Light will flash. 4. Press and hold the EDIT or EDIT key until the desired time in seconds is displayed, i.e. 15 is 15 seconds delay. 5. Press ENTER then press the EDIT key 4 times to return to normal operation ma Outputs The OPM 4000 is equipped with two 4-20 ma outputs. The ranges are set during final test to the information supplied by the customer. Maximum current loop resistance is 800 ohms. AOUT1 (instantaneous opacity, zero/span when in check mode) is connected at terminals 11 and 12 and supplies the opacity signal to a recorder or DAS and to the service module for display at the sensor location. AOUT2 (average opacity, zero/span when in check mode) is connected at terminals 13 and 14. Recorder or Other Device Calibration Auto Cal Timer Adjustment Remote Calibration Cycle Initiate On the control unit front panel press the CAL. AUTO/MAN key for a maintenance zero and span cycle. Both outputs will correspond to the opacity display value. 1. Open the hinged cover and press the EDIT (ESC) button [the red Edit (ESC) LED will light]. The message display will read QUICK MENU. 2. Press the ENTER key then the EDIT key 3 times or scroll down until the Display reads AUTOCAL CYCL TMR. 3. Press the ENTER key; the Edit Value Light will flash. 4. Press and hold the EDIT or EDIT key until the desired set point in hours is displayed, i.e equals 24 hour intervals. 5. Press ENTER then press the EDIT key 4 times to return to normal operation. To have an external device cause the OPM 4000 to begin calibration cycle, connect an N.O. dry contact to terminal 8L and 9. A momentary closure will initiate a 3-minute zero and a 3-minute span check cycle. Total time of calibration check is 6 minutes. 4-3

50 OPM 4000 Instruction Manual Remote Calibration Cycle Acknowledgment SERVICE MODULE Dry contacts on terminal 4U (common) and 5U (NC) acknowledge when the calibration is in progress. This contact remains closed until calibration is completed, i.e. both zero and span. The service module is used to: Pass signals to and from the transceiver and control unit. Display opacity via digital display. Initiate maintenance zero and span cycles. Insert an external current meter in the transceiver to control unit 4-20 ma loop. The service module has a digital display for reading opacity from the control unit and Transmittance 2 (T 2 ) from the transceiver. It also has connections for attaching a meter for troubleshooting or calibration when necessary. Other switches are provided for initiating zero and span modes during service or maintenance. If any switch causes the system to read data, other than stack opacity, the control unit fault alarm system will be energized notifying the operator. A fault output signal (open transistor collector) is also energized for use with other alarms or DAS systems, which need to know opacity readings are not representative of the actual stack opacity and a fault condition exists. Only two conditions are considered normal operation: 1. Reading opacity 2. Computer or internal clock initiated calibration check cycle Switches OPACITY / T 2 This switch selects the display of the stack digital meter. In the opacity mode the digital displays % opacity from the control unit. In the T 2 mode it is the signal out of the transceiver in % Transmittance 2. OPERATE / ZERO This switch controls the zero mirror solenoid. In the operate position the mirror is not in the measuring path and is considered normal operation. When the mirror solenoid is energized, the mirror is placed in the measurement path and is considered a maintenance condition, i.e. signal is not representative of the stack smoke. The control unit will indicate a fault. Energize and observe the digital meter to test the system response to zero % opacity. Energize in conjunction with the span filter to observe the up scale span % opacity calibration point. OPERATE / SPAN This switch controls the span filter solenoid. In the operate position the span filter is not in the measuring path and is considered normal operation. When the span filter solenoid is energized, the span filter is placed in the measurement path and is considered a maintenance condition, i.e., signal is not representative of the stack smoke. The control unit will indicate a Fault. Energize in conjunction with the zero mirror to observe the up scale span calibration point. 4-4

51 Instruction Manual OPM 4000 NORMAL / TEST This switch controls the EXTERNAL ma METER connections. In the normal mode the terminals are shorted. In the test mode the terminals are open and the current loop from the transceiver is interrupted allowing the use of an external current meter to be placed in series with the transceiver current output. When this is in the test mode position it is considered a maintenance condition and fault condition. If no current meter is in the test jacks, the loop current the control unit will indicate will be full scale and the control unit will indicate a fault. 4-5

52 OPM 4000 Instruction Manual 4-6

53 Instruction Manual OPM 4000 Section 5 Zero Jig and Neutral Density Filters Overview page 5-1 Using the Zero Jig page 5-1 OVERVIEW USING THE ZERO JIG Figure 5-1. Zero Jig This section describes: The purpose and functions of the zero jig. How to calculate the filter values using the OPLR. How to make adjustments on the iris. The zero jig (Figure 5-1), or Micro-turn 200, on-line test and audit system contains a test reflector, three neutral density filters, filter certification certificates and a carrying case. The zero jig on-line test and audit system may be used for: Opacity audit Linearity checks and adjustments System accuracy verification Service on-line or off-stack Mounting Screw Fine Adjustment (Large Knob) Reflector Plate

54 OPM 4000 Instruction Manual Installation The zero jig (Figure 5-2) on-line test reflector is inserted over the transceiver lens. The filters provided are marked in single-pass opacity; this is the same as double-pass with a correlation factor (OPLR) of Hold the zero jig in a position to see the reflector. Turn the fine adjustment (large knob) so the iris begins to open, exposing more of the reflector. This direction will cause the monitor to lower opacity. To raise opacity, turn in the opposite direction so the iris begins to close. 2. Loosen clamps on the transceiver and swing it open. 3. Clean the lens using alcohol and a clean lint free paper that will leave no film on the lens. 4. Place the zero jig on the two alignment pins (Figure 5-2) with the reflector facing toward the transceiver (away from the stack). 5. Secure the device to the transceiver by tightening the mounting screw. 6. Using the fine adjustment (large knob) start by raising the opacity level above zero then slowly turn the knob in the opposite direction to just reach zero. If you cannot reach zero, or you cannot come above zero, see "Coarse Adjustments". 7. Place the neutral density slides in the slot provided on the top of the device just behind the mounting screw. The system should read the same value written on the label within ±2%. 5-2

55 Instruction Manual OPM 4000 Figure 5-2. Zero Jig Installation Mounting Screw Alignment Pin Alignment Pin Fine Adjustment (Large Knob)

56 OPM 4000 Instruction Manual Coarse Adjustments Opacity Below Zero If the opacity reading is below zero and you can not reach zero after you have turned the adjustment knob as far as it will go into the zero jig housing, perform the following procedure: Do not force the knob. Stop at the first sign of binding. 1. Hold the zero jig in your hand so you can see the iris and retro reflector. Turn the fine adjustment knob so that the iris is closed as far as it will go. 2. Loosen the coarse adjustment set screw. 3. Turn the fine adjustment knob in the opposite direction as far as it will go. 4. Tighten the coarse adjustment set screw. Be sure not to tighten more than 1/16 of a turn to prevent damage to the iris ring. 5. After the setscrew is tight again try to reach zero. Repeat if necessary. Opacity Above Zero If the opacity reading is above zero and you can not bring it up after you have turned the adjustment knob as far as it will go into the zero jig housing, perform the following procedure: Do not force the knob. Stop at the first sign of binding. 1. Hold the zero jig in your hand so you can see the iris and retro reflector. Turn the adjustment knob so that the iris is open as far as it will go. 2. Loosen the coarse adjustment set screw. 3. Turn the fine adjustment knob in the opposite direction as far as it will go. 4. Tighten the coarse adjustment set screw. Be sure not to tighten more than 1/16 of a turn to prevent damage to the iris ring. 5. After the setscrew is tight, again try to reach zero. Repeat if necessary. 6. After performing all of the above steps, if you can not reach zero, or zero is unstable, contact the factory for assistance. Filter Correction If you have an OPLR (correlation factor) other than 0.5, your neatral density slides will read differently. To calculate what the slide will read with another OPLR use the following formula: 1 M2 0.5 Op1 1 *100 = OP2 100 Where: OP1 = Standard filter value in % M2 = OPLR for your instrument 5-4

57 Instruction Manual OPM 4000 OP2 = Standard filter value at your OPLR in % Example: Standard filter value is 23.1%. Find what it will read at OPLR of *100 = 54.5% 100 Filter re-calibration is available from Emerson Process Management. If not regulated by EPA regulations in your state to a more frequent schedule, we suggest you re-calibrate once a year, at a minimum. If you have filters from other manufacturers we can calibrate them as well (call for pricing). Filters are tested per USA Code of Federal Regulations 40CFR60 Appx. B, Performance Specification 1, Section Attenuation Calibration. Filter Certification QA/QC testing by Emerson Process Management of the filters at an interval of not more than 6 months is recommended. Filter certification, replacement, or additional neutral density filters are available from Emerson Process Management. Emerson s Rosemount Analytical neutral density filters for the zero jig are calibrated on a Perkin-Elmer Lambda Series 6 / PECSS Spectrophotometer per Federal Environmental Protection Agency specifications. These specifications are contained in the Code of Federal Regulations 40 CFR 60, Appendix B, Performance Specification 1, Attenuator Calibration. The filters are scanned over the visible region from 380 to 780 nanometers in one nanometer step and the resulting transmittances of the filter are weighted to the Source C Human Eye Response by multiplying each value by its associated response factor. The corrected values of transmittance are converted to % opacity and the value is recorded on the filter and associated chart. 5-5

58 OPM 4000 Instruction Manual 5-6

59 Instruction Manual OPM 4000 Section 6 Zero and Span Calibration Clear on Stack Zero and Span Calibration page 6-1 Zero Reflector Adjustment page 6-3 Span Filter Mark page 6-4 Record the Zero/Span Values in the Quick Menu page 6-4 OVERVIEW CLEAR ON STACK ZERO AND SPAN CALIBRATION This section describes how to install, adjust, and record the zero reflector and span values. Conditions prior to calibration. Do not attempt these adjustments in inclement weather. A clear stack condition must exist to perform this calibration. Power must have been on for no less than 30 minutes. NOTE After the cover is removed from the transceiver, normal levels of day light in the area will not effect the calibration. To complete this procedure the zero jig on-line test kit, with a high filter of at least 0.8 OD, is required. 1. Swing both the retro reflector and transceiver open and clean the protective windows (Figure 6-1). Return both to the closed position. 2. Verify alignment; the beam must be centered on the TTL target. Refer to the "Beam Alignment Procedure" in Section 2: Installation. 3. On the transceiver, remove the screw below the target viewing window and pull the housing straight back until it clears the optical plate. 4. On the service module make sure the NORMAL/TEST switch is in the NORMAL position. NOTE All adjustments are on the R/M signal processor board (Figure 6-2). 5. Adjust the zero potentiometer (PT-1 Zero) clockwise until the opacity reading is greater than 15%. 6. Slowly turn the zero potentiometer counterclockwise until the opacity reads 0-1%. 7. Install the zero jig on-line test reflector on the transceiver and attach the device to the transceiver with the mounting screw.

60 OPM 4000 Instruction Manual Figure 6-1. Zero Reflector Protective Window Zero Reflector Figure 6-2. Zero Calibration R/M Signal Processor Board PT-1 Zero PT-3 Span

61 Instruction Manual OPM With the fine adjustment (large knob), adjust the zero jig until the opacity reading is 0-1%. Lock the fine adjustment. 9. Place high opacity filter (for best results at least an 0.8 OD) in the slot provided in the zero jig. 10. Adjust the span potentiometer (PT-3 Span) until the opacity value on the service module opacity display is equal to the filter s correlated value. See Section 5: Zero Jig and Neutral Density Filters, for filter correlation formulas. 11. Remove the filter and adjust the zero potentiometer PT-1 Zero for 0-1% opacity. 12. Repeat steps 9 through 11 until the displayed opacity values are within 0.5% opacity. 13. Remove the zero jig on-line test reflector and replace the transceiver cover and secure the transceiver in place. You must complete Zero Reflector Adjustment procedure next. ZERO REFLECTOR ADJUSTMENT Once the clear on stack zero and span calibration has been performed, the zero reflector needs to be adjusted according to the following procedure. 1. Find and record the zero offset value found in the QUICK MENU under Zero Cal Value, see "Zero/Span Calibration Check" in Section 3: Startup and Calibration, for procedures to access the quick menu. 2. Place the OPACITY/T 2 switch on the service module in the OPACITY position to observe the correlated opacity on the digital display. 3. Swing open the transceiver. 4. Place the ZERO switch on the service module in the ZERO position. This will raise the zero reflector into place. After 30 seconds observe and record the zero value. 5. Return the mirror to the normal resting position by returning the ZERO switch to the OPERATE position. 6. Insert a 1/16 in. Allen wrench into the adjustment set screw located on the top of the zero reflector (Figure 6-1). Turn the set screw clockwise 1/8 turn. 7. Remove the Allen wrench and place the ZERO switch in the ZERO position. After 15 seconds make sure the reading is moving toward the desired value. (If value is moving away from the desired value, repeat step 6 and turn set screw counterclockwise). 8. Repeat steps 5 through 7, each time making small 1/8-turn increments until the desired value is reached. 9. Cycle 2 to 3 times more and wait 15 to 20 seconds between cycles to ensure repeatability. 10. Record the final value; enter it into the Zero Cal Value in the QUICK MENU. 11. Swing transceiver into operate position and secure in place. 6-3

62 OPM 4000 Instruction Manual SPAN FILTER MARK The span filter mark must be performed in order to enter the span value into the control unit. 1. With the ZERO switch in the ZERO position, place the SPAN switch in the SPAN position. (Span is not adjustable, final value is a function of filter value, transceiver calibration, and OPLR). 2. Record the final value; enter it into the Span Cal Value in the QUICK MENU. 3. Return both ZERO and SPAN switches to the OPERATE position. 4. Place the NORMAL/TEST switch to the NORMAL position. 5. Place the OPACITY/T 2 to the OPACITY position. RECORD THE ZERO/SPAN VALUES IN THE QUICK MENU Zero Cal Value Span Cal Value OFF STACK ZERO CALIBRATION In order to enter the zero cal value into the control unit, the clear on stack zero and span calibration must already be performed. 1. At the control unit, open the hinged cover and press the EDIT (ESC) button [the red Edit (ESC) LED will light]. The message display will read QUICK MENU. 2. Press the ENTER key, then the EDIT key 4 times or hold and scroll down until the display reads ZERO CAL VALUE. 3. Press the ENTER key; the Edit Value Light will flash. 4. Press and hold the EDIT or EDIT key until the zero value recorded in "Clear on Stack Zero and Span Calibration" is displayed. 5. Press ENTER then press the EDIT key 3 times to return to normal operation. In order to enter the span cal value into the control unit, the clear on stack zero and span calibration must already be performed. 1. Press the EDIT (ESC) button [the red Edit (ESC) LED will light]. The message display will read QUICK MENU. 2. Press the ENTER key then the EDIT key 5 times or hold and scroll down until the display reads SPAN CAL VALUE. 3. Press the ENTER key; the Edit Value Light will flash. 4. Press and hold the EDIT or EDIT key until the span value recorded in "Clear on Stack Zero and Span Calibration" is displayed. 5. Press ENTER then press the EDIT key 3 times to return to normal operation. This completes the calibration. This procedure may be used if: Clear stack condition is not possible and the zero appears to be incorrect. The flange-to-flange distance on site is different than the original factory setup. 6-4

63 Instruction Manual OPM Remove the transceiver and retro reflector from the hinge pins. 2. Remove the service module and install the system on test stands at the correct flange-to-flange distance plus 11 in. (279,4 mm). The additional 11 in. (279,4 mm) compensates for air plenum spacing, as the air plenums are not used for the off stack zero calibration. If test stands are not available, an alternate method is to use 3 in. pipe flanges with air plenums installed. Contact the factory for air plenum availability. Set the spacing between the 3 in. flanges exactly the same as the flange-to-flange measurement. 3. Clean the transceiver and retro reflector windows. 4. Connect the control unit with the control to service module test cable kit and apply power to the system. 5. The retro reflector must be level. 6. Follow instruction for "Clear on Stack Zero and Span Calibration". 6-5

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65 Instruction Manual OPM 4000 Section 7 Maintenance Overview page 7-1 Preventive Maintenance Schedule page 7-1 Control Unit Preventive Maintenance page 7-3 Install all protective equipment covers and safety ground leads after equipment repair or service. Failure to install covers and ground leads could result in serious injury or death. OVERVIEW PREVENTIVE MAINTENANCE SCHEDULE This section describes the routine maintenance of the Rosemount Analytical OPM 4000 Opacity/Dust Density Monitor. The amount of maintenance required depends on the environment to which the instrument is subjected. A unit that is subjected to extremely dusty conditions, vibration, and movement will require considerably more maintenance than a unit that is rigidly mounted in a clean, dust-free atmosphere. Item to Check Frequency Procedure Zero/Span Daily Check that readings are within specification (±2%). Refer to Section 6: Zero and Span Calibration. Fault conditions Daily Check for fault conditions; refer to "Fault Messages" in Section 4: Operation. Projection lens Monthly or as required Clean with cloth and lens cleaning fluid. Beam alignment Monthly or as required Check alignment; refer to "Beam Alignment Procedure" in Section 2: Installation. Transceiver and retro reflector windows Monthly or as required Clean with cloth and lens cleaning fluid. To access, refer to "Mounting the Transceiver and Retro Reflector" in Section 2: Installation. Zero reflector Monthly or as required Clean with optical cloth and lens cleaning fluid. Refer to Section 5: Zero Jig and Neutral Density Filters for additional help. All daily and monthly checks 3 months COM Audit 3 months Perform COM Audit per EPA regulation 40 CRF, 60 App. B, PS-1. Air blower 3 months Check for excessive noise. Air filters 3 months Replace.

66 OPM 4000 Instruction Manual Novemebr 2007 Item to Check Frequency Procedure Air flow switch 3 months Ensure that air flow switch is operating properly. Refer to "Air Flow Switch" in Section 8: Troubleshooting. Air hoses and clamps 3 months Check for tightness and wear; replace as necessary. Electrical connections 3 months Make sure electrical connections are wired correctly and secure. Refer to "System Wiring Installation" in Section 2: Installation. Mounting hardware 3 months Check bolts for tightness. Weather cover 3 months Clean as required. To access or remove, refer to "Mounting the Air Plenum and Weather Covers" in Section 2: Installation. Weather cover gaskets 3 months Check for leakage. Cables and connectors 6 months Check, clean, replace as required. Flange 6 months Push build-up into stack to clear flange. To access flanges, refer to "Installation of Stack Flanges" in Section 2: Installation. All quarterly checks Yearly Air plenum Yearly Remove transceiver and retro reflector to clean air plenum. Refer to "Mounting the Air Plenum and Weather Covers" in Section 2: Installation. Clear stack or off stack zero Yearly For instructions, refer to Section 6: Zero and Span Calibration. Hoses and gaskets Yearly Replace if necessary. Inner optics Yearly Clean if necessary. System operations Yearly Check all system operations. Refer to Section 4: Operation. Transceiver and retro reflector 3-5 years (site dependent) Return to the factory for internal alignment and cleaning. To access or remove, refer to "Mounting the Transceiver and Retro Reflector" in Section 2: Installation. Additional preventive maintenance Yearly Corrective and preventive maintenance schedules should be adjusted according to site specific conditions to ensure the maximum availability of accurate measurement data. Routine checks should be implemented to: Observe and correct the operation of the air-purge system giving particular attention to keeping the optical path within the mounting flanges clear of dirt build-up. Observe and correct the operation of peripheral accessory equipment such as recorders, computers, etc. Observe and correct the stack zero measurement whenever a clear stack condition exists. Care should be exercised to ensure that both transmittance and opacity measurements are at their prescribed values. Verify that instrument operating manuals are available and that maintenance logs are properly maintained and reviewed. Replace any worn hoses and gaskets. 7-2

67 Instruction Manual OPM 4000 CONTROL UNIT PREVENTIVE MAINTENANCE WEATHER COVER/BLOWER PREVENTIVE MAINTENANCE Preventive maintenance consists of cleaning the instrument regularly and inspecting it occasionally for broken or damaged parts. Regular maintenance will improve the reliability of your instrument and prevent break downs. Cleaning - Accumulations of dirt and dust on components act as an insulating blanket preventing efficient heat dissipation. Dust on circuit boards and wires can cause arcing and short circuits resulting in damage to components or even instrument failure. Clean your instrument with clean high-pressure air before this happens. The control unit chassis provides protection from dust and dirt and should be in place during normal operation of the instrument. Exterior - Dust the chassis with a soft cloth. Dust the front panel with a soft paintbrush. Dirt clinging to the surface can be removed with a soft cloth dampened with a mild detergent and water solution. Avoid using abrasive cleaners, as they will scratch the housing and front panel. Interior - Dust in the interior of the control unit should be removed before it builds up enough to cause arcing and short circuits during periods of high humidity. Dust is best removed from the interior by the type of canned air used for computer cleaning. Dirt clinging to the surfaces can be removed with a soft paintbrush. Visual Inspection - Inspect the interior occasionally for broken connections, improperly seated semiconductors, damaged or improperly installed circuit boards, heat damaged components, etc. If heat damaged components are found, care must be taken to find the cause of the excessive heat and measures must be taken to prevent recurrence of the damage. Semiconductor Checks - Periodic checks of the semiconductor devices in this instrument are not recommended. The best check of semiconductor performance is actual operation of the instrument. Periodically - Check and inspect all hoses and wire connections inside the weather covers. 7-3

68 OPM 4000 Instruction Manual Novemebr 2007 CORRECTIVE MAINTENANCE Disconnect all power before installing or replacing components. Failure to disconnect power may result in electrical shock and/or damage to the equipment. NOTE Make sure to carefully record the wiring connections and locations before disconnecting. This will aid in the installation of the unit. Lamp Replacement Figure 7-1. Lamp/Bulb Removal 1. Remove the transceiver cover by removing the screw below the target viewing window and pulling the housing straight back until it clears the optical plate. 2. Remove the lamp wire connector from the J2 socket on the R/M signal processor board. 3. Remove the two socket head cap screws (Figure 7-1) using an Allen wrench. Remove the lamp holding fixture 4. Turn the set screws to loosen the clamp for lamp removal. 5. Remove the lamp assembly consisting of the lamp, wires and connector. 6. Install new lamp assembly in the lamp holding fixture and tighten set screws. 7. Install lamp holding fixture and secure with the two socket head cap screws. Connect J2. 8. Calibrate the OPM 4000 per Section 3: Startup and Calibration. 9. Install cover. Socket Head Cap Screw Lamp Holding Fixture Socket Head Cap Screw Set Screws Lamp

69 Instruction Manual OPM 4000 Figure 7-2. Transceiver Fuse Transceiver Fuse (F1) Transceiver Fuse Replacement Service Module Fuse Replacement 1. Remove the transceiver cover by removing the screw below the target viewing window and pulling the housing straight back until it clears the optical plate. 2. Pull fuse (F1) from the clamp (Figure 7-2). 3. Firmly press new fuse into the clamp on the power/modulator board. 4. Install cover. 1. Press down on the service module fuse, and turn counterclockwise for removal (Figure 7-3). 2. When installing new service module fuse, align notches, press down and turn clockwise. Figure 7-3. Service Module Fuse Fuse Service Module NORMAL OPERATE ZERO SPAN EXTERNAL METER (ma)

70 OPM 4000 Instruction Manual Novemebr 2007 Circuit Board Replacements The R/M Signal processor board and the Power/modulator board are located directly across from each other inside the transceiver housing, see Figure 7-4. The CPU board and the backup memory module are located inside of the control unit, see Figure 7-6. R/M Signal Processor Board Replacement Procedures 1. Remove the transceiver cover by removing the screw below the target viewing window and pulling the housing straight back. 2. Tag and remove all wiring connected to the signal processor board. 3. Remove the four nuts (Figure 7-4) holding the signal processor board. 4. Install new signal processor board. Install wiring removed in step Calibrate OPM 4000 per Section 3: Startup and Calibration. 6. Install cover. Power/Modulator Board Replacement Procedures 1. Remove the transceiver cover by removing the screw below the target viewing window and pulling the housing straight back. 2. Tag and remove all wiring connected to the power/modulator board. 3. Remove the four socket head cap screws (Figure 7-5) with an allen wrench to remove the power/modulator board. 4. Install new power/modulator board. Install wiring removed in step Calibrate OPM 4000 per Section 3: Startup and Calibration. 6. Install cover. Figure 7-4. Circuit Board Locations R/M Signal Processor Board Nut Nut Power/Modulator Board Nut

71 Instruction Manual OPM 4000 Figure 7-5. Power/Modulator Board Replacement Iris Assembly Socket Head Cap Screws Socket Head Cap Screws Rotary Solenoid Zero Arm Central Processing Unit (CPU) Board Replacement Procedures 1. Remove screw on top of the control unit (Figure 7-6). 2. Open control unit front panel to access CPU board. 3. Tag and remove all wiring from the CPU board. 4. Remove CPU board by pulling out of control unit. 5. Install CPU board and reconnect wires removed in step Install front panel and secure with screw. 7. Calibrate OPM 4000 per Section 3: Startup and Calibration. 7-7

72 OPM 4000 Instruction Manual Novemebr 2007 Backup Memory Module 1. Remove screw on top of the control unit (Figure 7-6). 2. Open control unit front panel to access the backup memory module. 3. Press on sides of chip and pull back to remove. 4. Install the backup memory module. 5. Install front panel and secure with screw. 6. Calibrate OPM 4000 per Section 3: Startup and Calibration. Figure 7-6. CPU Board and Backup Memory Module Screw CPU Board Front Panel Backup Memory Module