Oxymitter 4000 Oxygen Transmitter

Oxymitter 4000 Oxygen Transmitter

Instruction Manual IM-106-340, Rev 4.0 February 2006 Oxymitter 4000 Oxygen Transmitter http://www.raihome.com Instruction Manual IM-106-340, Rev 4...

3MB Sizes 1 Downloads 19 Views

Recommend Documents

transmisor de oxigeno oxymitter 4000 - Emerson
fábrica, la(s) pieza(s) defectuosa(s), despuès de que el comprador se lo ... comprador en caso de fallo de cumplimient

Oxygen Transmitter E2618-O2 - Evikon MCI
Calibration. Oxygen O2. Sensing method long-life electrochemical cell. Sampling method diffusion. Detection range. 0...2

Transmitter
13.10.2017 - der NATO AIR BASE Geilenkirchen werden 35 .... die sich an über 60 Stationen, verteilt auf ganz Köln und

10000 $8000 $4000 $4000
all in license fee. Song Plugger Fee 20% = $2,000.00. $8,000 remaining. $4,000. $4,000. Publishing. Master recording. Ad

Transmitter - Vde.com
18.01.2017 - Auf sie wartet keiner im Bullenkloster. Ein paar Kilometer weiter, im Grü- nen und in gesunder Luft, liegt

ozone - Oxygen Healing Therapies
Oxygen/ozone therapy has a long history of research and clinical application with humans. The German chem- by Philip Mol

DRIVE 4000
CYCLO DRIVE 4000. Bei der Vorbereitung dieses Kataloges haben wir uns bemüht, ihn so übersichtlich zu gestalten, daß

SATRON VT Pressure Transmitter
Jan 1, 2014 - ±2 % of max. span, VT4 - VT5. Mounting position effect. (VT3 - VT7). Zero error < 0.32 kPa, which can be

Universal Visor Transmitter - SmartHomeUSA.com
Q: Door opener does not react after pressing the button on the transmitter? ... DO NOT let children use the garage door

Belt Pack Transmitter - Lectrosonics.com
Fill in for your records: ..... As the battery voltage drops, the lamp will grow dim and finally go out. ... battery. In

Instruction Manual IM-106-340, Rev 4.0 February 2006

Oxymitter 4000 Oxygen Transmitter

http://www.raihome.com

Instruction Manual IM-106-340, Rev 4.0 February 2006

Oxymitter 4000

Table of Contents Essential Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

SECTION i Introduction

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv What You Need To Know. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Can You Use the Quick Start Guide? . . . . . . . . . . . . . . . . . . . . . . . . . .vii Quick Start Guide for Oxymitter 4000 Systems . . . . . . . . . . . . . . . . . . viii Quick Reference Guide Manual Calibration Instructions . . . . . . . . . . . . ix HART Communicator Fast Key Sequences . . . . . . . . . . . . . . . . . . . . . . x

SECTION 1 Description and Specifications

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Handling the Oxymitter 4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 IMPS 4000 (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 SPS 4001B (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Model 751 Remote Powered Loop LCD Display . . . . . . . . . . . . . . . . 1-13 Probe Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Diffusion Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

SECTION 2 Installation

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Selecting Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Remote Electronics Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Electrical Installation (with Integral Electronics) . . . . . . . . . . . . . . . . .2-10 Electrical Installation (with Remote Electronics) . . . . . . . . . . . . . . . . 2-13 Install Interconnecting Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 IMPS 4000 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 SPS 4001B Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

SECTION 3 Configuration of Oxymitter 4000 with Membrane Keypad

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Terminal Block Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Oxymitter 4000 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Logic I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Recommended Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

TOC-1

Instruction Manual

Oxymitter 4000

IM-106-340, Rev 4.0 February 2006

SECTION 4 Configuration of Oxymitter 4000 with LOI

Verify installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Terminal Block Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Oxymitter 4000 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Logic I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Recommended Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

SECTION 5 Startup and Operation of Oxymitter 4000 with Membrane Keypad

Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

SECTION 6 Startup and Operation of Oxymitter 4000 with LOI

Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Start Up Oxymitter 4000 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Navigating the Local Operator Interface . . . . . . . . . . . . . . . . . . . . . . . 6-3 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 LOI Key Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 LOI Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Oxymitter 4000 Setup at the LOI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 LOI Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Oxymitter 4000 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Remote Powered Loop LCD Display (Optional) . . . . . . . . . . . . . . . . 6-10

SECTION 7 HART/AMS

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 HART Communicator Signal Line Connections. . . . . . . . . . . . . . . . . . 7-2 HART Communicator PC Connections . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Off-Line and On-Line Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Logic I/O Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 HART/AMS Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 HART Communicator O2 Cal Method . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Defining a Timed Calibration via HART . . . . . . . . . . . . . . . . . . . . . . . . 7-9 D/A Trim Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

SECTION 8 Troubleshooting

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Identifying And Correcting Alarm Indications. . . . . . . . . . . . . . . . . . . . 8-5 Calibration Passes, but Still Reads Incorrectly . . . . . . . . . . . . . . . . . 8-22

SECTION 9 Maintenance and Service

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Calibration with Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Semi-Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Manual Calibration with Membrane Keypad. . . . . . . . . . . . . . . . . . 9-3 Calibration with LOI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Oxymitter 4000 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Removal and Replacement of Probe . . . . . . . . . . . . . . . . . . . . . . . 9-7

TOC-2

Instruction Manual IM-106-340, Rev 4.0 February 2006

Oxymitter 4000

SECTION 10 Replacement Parts

Probe Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Electronics Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6

SECTION 11 Optional Accessories

HART Handheld 375 Communicator . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Asset Management Solutions (AMS) . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 By-Pass Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 IMPS 4000 Intelligent Multiprobe Test gas Sequencer . . . . . . . . . . . 11-3 SPS 4001B Single Probe Autocalibration Sequencer . . . . . . . . . . . . 11-4 O2 Calibration Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Catalyst Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Oxy Balance Display and Averaging System . . . . . . . . . . . . . . . . . . . 11-6

APPENDIX A Safety Data

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . A-15

APPENDIX B Return of Material

Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

TOC-3

Instruction Manual

Oxymitter 4000

TOC-4

IM-106-340, Rev 4.0 February 2006

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Oxymitter Oxygen Transmitters READ THIS PAGE BEFORE PROCEEDING!

ESSENTIAL INSTRUCTIONS

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 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 Rosemount Analytical 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 Rosemount Analytical. 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.

If a Model 275/375 Universal HART® Communicator is used with this unit, the software within the Model 275/375 may require modification. If a software modification is required, please contact your local Rosemount Analytical Service Group or National Response Center at 1-800-433-6076 or 1-888-433-6829.

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section i

Oxymitter 4000

Introduction Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iv Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iv Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iv What You Need To Know . . . . . . . . . . . . . . . . . . . . . . . . . . page v Can You Use the Quick Start Guide? . . . . . . . . . . . . . . . . page vii Quick Start Guide for Oxymitter 4000 Systems . . . . . . . . page viii Quick Reference Guide Manual Calibration Instructions page ix HART Communicator Fast Key Sequences . . . . . . . . . . . page x

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 PREFACE

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Oxymitter 4000 Oxygen Transmitter. 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.

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 CONDUCT OR TERMINAL : RISK OF ELECTRICAL SHOCK : WARNING: REFER TO INSTRUCTION MANUAL

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.

iv

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

WHAT YOU NEED TO KNOW

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.

BEFORE INSTALLING AND WIRING A ROSEMOUNT ANALYTICAL OXYMITTER 4000 OXYGEN TRANSMITTER 1. What type of installation does your system require? Use the following drawings, Figure 1 and Figure 2, to identify which type of installation is required for your Oxymitter 4000 system. Figure 1. Installation Options Oxymitter 4000 with Integral Electronics

OXYMITTER 4000

Line Voltage 4-20 mA Cal. Gas Instr. Air (Ref. Air)

OXYMITTER 4000 WITH SPS 4001B Line Voltage 4-20 mA SPS 4001B

Line Voltage Cal. Gas 1 Cal. Gas 2 Instr. Air (Ref. Air)

LOGIC I/O Cal. Gas Ref. Air

OXYMITTER 4000 WITH REMOTE IMPS 4000 OPTION Line Voltage 4-20 mA

LOGIC I/O Cal. Gas Ref. Air

Line Voltage Cal. Gas 1 Cal. Gas 2 Instr. Air (Ref. Air)

37260001

IMPS 4000

v

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 2. Installation Options Oxymitter 4000 with Remote Electronics

OXYMITTER 4000

Line Voltage 4-20 mA Cal. Gas Instr. Air (Ref. Air)

OXYMITTER 4000 WITH REMOTE ELECTRONICS AND SPS 4001B Line Voltage 4-20 mA Logic I/O Calibration Gas Reference Air Cal. Gas 2 Cal. Gas 1 Instr. Air

SPS 4001B

OXYMITTER 4000 WITH REMOTE ELECTRONICS AND IMPS Line Voltage 4-20 mA Logic I/O

Reference Air Cal. Gas 2 Cal. Gas 1 Instr. Air

vi

IMPS 4000

37260049

Calibration Gas

Instruction Manual IM-106-340, Rev. 4.0 February 2006

CAN YOU USE THE QUICK START GUIDE?

Oxymitter 4000 Use this Quick Start Guide if... 1. Your system requires an Oxymitter 4000 with or without the SPS 4001B OPTION. Installation options for the Oxymitter 4000 are shown in Figure 1. 2. Your system does NOT require an IMPS 4000 OPTION installation. 3. Your system does NOT use a Remote Electronics as shown in Figure 2. 4. You are familiar with the installation requirements for the Oxymitter 4000 Oxygen Transmitter. You are familiar with the installation requirements for the Oxymitter 4000 Oxygen Transmitter with a SPS 4001B. If you cannot use the Quick Start Guide, turn to Section 2: Installation, in this Instruction Manual.

vii

Instruction Manual

Oxymitter 4000 QUICK START GUIDE FOR OXYMITTER 4000 SYSTEMS

IM-106-340, Rev. 4.0 February 2006

Before using the Quick Start Guide, please read "WHAT YOU NEED TO KNOW BEFORE INSTALLING AND WIRING A ROSEMOUNT ANALYTICAL OXYMITTER 4000 OXYGEN TRANSMITTER" on the preceding page. 1. Install the Oxymitter 4000 in an appropriate location on the stack or duct. Refer to "Selecting Location" in Section 2: Installation, for information on selecting a location for the Oxymitter 4000. 2. If using an SPS 4001B, connect the calibration gasses to the appropriate fittings on the SPS 4001B manifold. 3. Connect reference air to the Oxymitter 4000 or SPS 4001B, as applicable. 4. If using an SPS 4001B, make the wiring connections as shown in the SPS 4001B Single Probe Autocalibration Sequencer Instruction Manual. 5. If NOT using an SPS 4001B, make the following wire connections as shown in Figure 3: line voltage, 4-20 mA, and logic I/O. 6. Verify the Oxymitter 4000 switch configuration is as desired. Refer to "Oxymitter 4000 Configuration", "SW1 Setting", and "SW2 Setting" all in Section 3: Configuration of Oxymitter 4000 with Membrane Keypad, or "Oxymitter 4000 Configuration", "SW1 Setting", and "SW2 Setting" all in Section 4: Configuration of Oxymitter 4000 with LOI. 7. Apply power to the Oxymitter 4000; the cell heater will turn on. Allow approximately one half hour for the cell to heat to operating temperature. Once the ramp cycle has completed and the Oxymitter 4000 is at normal operation, proceed with step 8 or 9. 8. If using an SPS 4001B, initiate a semi-automatic calibration. 9. If NOT using an SPS 4001B, perform a manual calibration. Refer to "Calibration with Keypad" or "Calibration with LOI" both in Section 9: Maintenance and Service, in this instruction manual. NOTE If your system has a membrane keypad you can refer to the Quick Start Guide on the following pages.

viii

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 3. Oxymitter 4000 without SPS 4001B Wiring Diagram Terminal Block

AC Line Voltage Port

AC Terminal Cover

Line Voltage (85 to 264 VAC)

AC

L1

AC

N Ground Lugs

+ Logic I/O

+

4-20 mA Signal

4-20

Left Side of Oxymitter 4000

QUICK REFERENCE GUIDE MANUAL CALIBRATION INSTRUCTIONS

Signal Port

29770003

-

Performing a Manual Calibration with a Membrane Keypad 1. Place the control loop in manual. 2. Press the CAL key. The CAL LED will light solid. 3. Apply the first calibration gas. 4. Press the CAL key. When the unit has taken the readings using the first calibration gas, the CAL LED will flash continuously. 5. Remove the first calibration gas and apply the second calibration gas. 6. Push the CAL key. The CAL LED will light solid. When the unit has taken the readings using the second calibration gas, the CAL LED will flash a two-pattern flash or a three-pattern flash. A two-pattern flash equals a valid calibration, three-pattern flash equals an invalid calibration. 7. Remove the second calibration gas and cap off the calibration gas port. 8. Press the CAL key. The CAL LED will be lit solid as the unit purges. When the purge is complete, the CAL LED will turn off. 9. If the calibration was valid, the DIAGNOSTIC ALARMS LEDs indicate normal operation. If the new calibration values are not within the parameters, the DIAGNOSTIC ALARMS LEDs will indicate an alarm. 10. Place the control loop in automatic.

ix

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Perform Calibration 2

3

1

O2 Upper Range Value

1

3

Trim Analog Output 2

3

4

1

1

Analog Output Lower Range Value 3

Toggle Analog Output Tracking 2

2

2

View O2 Value

2

1

1

View Analog Output 1

2

2

1

1 38330001

HART COMMUNICATOR FAST KEY SEQUENCES

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) Rosemount Analytical 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

x

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 1

Oxymitter 4000

Description and Specifications Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1 IMPS 4000 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-12 SPS 4001B (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-12 Model 751 Remote Powered Loop LCD Display . . . . . . . page 1-13 Probe Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-13 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-16

COMPONENT CHECKLIST

A typical Rosemount Analytical Oxymitter 4000 Oxygen Transmitter should contain the items shown in Figure 1-1. Record the part number, serial number, and order number for each component of your system in the table located on the first page of this manual. Also, use the product matrix in Table 1-1 at the end of this section 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 Oxymitter 4000. Ensure the features and options specified by your order number are on or included with the unit.

SYSTEM OVERVIEW Scope

http://www.processanalytic.com

This Instruction Manual is designed to supply details needed to install, start up, operate, and maintain the Oxymitter 4000. Signal conditioning electronics outputs a 4-20 mA signal representing an O2 value and provides a membrane keypad or fully functional Local Operator Interface (optional) for setup, calibration, and diagnostics. This same information, plus additional details, can be accessed with the HART Model 275/375 handheld communicator or Asset Management Solutions (AMS) software.

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 1-1. Typical System Package

1

Instr IM-1 uctio n Dece06-340CManual mber Rev. 2005 4.2

OX YM ITT

HA ZA OX RDOU ER YG EN S AR4000 TRAN EA SM ITT ER

8

2 An al

yt

ic

al

An aly tic al

7

3

4 MAN 4275A00 English

Communicator

HART

o

5

6

1. 2. 3. 4. 5. 6. 7. 8.

1-2

Instruction Manual IMPS 4000 Intelligent Multiprobe Test Gas Sequencer (Optional) Oxymitter 4000 with Integral Electronics SPS 4001B Single Probe Autocalibration Sequencer (Optional) (Shown with reference air option) HART® 275/375 Communicator Package (Optional) Adapter Plate with Mounting Hardware and Gasket Remote Electronics (Optional) Reference Air Set (used if SPS 4001B without reference air option or IMPS 4000 supplied)

37260002

An aly tic al

Instruction Manual IM-106-340, Rev. 4.0 February 2006

System Description

Oxymitter 4000 The Oxymitter 4000 is designed to measure the net concentration of oxygen in an industrial combustion processes process; i.e., the oxygen remaining after all fuels have been oxidized. The probe is permanently positioned within an exhaust duct or stack and performs its task without the use of a sampling system. The equipment measures oxygen percentage by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output voltage of the cell is given by the following Nernst equation: EMF = KT log10(P1/P2) + C Where: 1. P2 is the partial pressure of the oxygen in the measured gas on one side of the cell. 2. P1 is the partial pressure of the oxygen in the reference air on the opposite side of the cell. 3. T is the absolute temperature. 4. C is the cell constant. 5. K is an arithmetic constant. NOTE For best results, use clean, dry, instrument air (20.95% oxygen) as the reference air. When the cell is at operating temperature and there are unequal oxygen concentrations across the cell, oxygen ions will travel from the high oxygen partial pressure side to the low oxygen partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade. The output is proportional to the inverse logarithm of the oxygen concentration. Therefore, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the Oxymitter 4000 to provide exceptional sensitivity at low oxygen concentrations. The Oxymitter 4000 measures net oxygen concentration in the presence of all the products of combustion, including water vapor. Therefore, it may be considered an analysis on a "wet" basis. In comparison with older methods, such as the portable apparatus, which provides an analysis on a "dry" gas basis, the "wet" analysis will, in general, indicate a lower percentage of oxygen. The difference will be proportional to the water content of the sampled gas stream.

1-3

Instruction Manual

Oxymitter 4000 System Configuration

IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 units are available in seven length options, giving the user the flexibility to use an in situ penetration appropriate to the size of the stack or duct. The options on length are 18 in. (457 mm), 3 ft (0,91 m), 6 ft (1,83 m), 9 ft (2,7 m), 12 ft (3,66 m), 15 ft (4,57 m), and 18 ft (5,49 m). The electronics control probe temperature and provide an isolated output, 4-20 mA, that is proportional to the measured oxygen concentration. The power supply can accept voltages of 90-250 VAC and 48/62 Hz; therefore, no setup procedures for power are required. The oxygen sensing cell is maintained at a constant temperature by modulating the duty cycle of the probe heater portion of the electronics. The electronics accepts millivolt signals generated by the sensing cell and produces the outputs to be used by remotely connected user devices. The output is an isolated 4-20 mA linearized current. The Oxymitter 4000 transmitter is available with an integral or remote electronics package. Two calibration gas sequencers are available: the IMPS 4000 and the SPS 4001B (Figure 1-2). Systems with multiprobe applications may employ an optional IMPS 4000 Intelligent Multiprobe Test Gas Sequencer. The IMPS 4000 provides automatic calibration gas sequencing for up to four Oxymitter 4000 units and accommodates autocalibrations based on the CALIBRATION RECOMMENDED signal from the Oxymitter 4000, a timed interval set up in HART or the IMPS 4000, or whenever a calibration request is initiated. For systems with one or two Oxymitter 4000 units per combustion process, an optional SPS 4001B Single Probe Autocalibration Sequencer can be used with each Oxymitter 4000 to provide automatic calibration gas sequencing. The SPS 4001B is fully enclosed in a NEMA cabinet suited for wall-mounting. The sequencer performs autocalibrations based on the CALIBRATION RECOMMENDED signal from the Oxymitter 4000, a timed interval set up in HART, or whenever a calibration request is initiated.

System Features

1. The CALIBRATION RECOMMENDED feature detects when the sensing cell is likely out of limits. This may eliminate the need to calibrate on a "time since last cal" basis. 2. The cell output voltage and sensitivity increase as the oxygen concentration decreases.

1-4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 1-2. Oxymitter 4000 AutoCalibration System Options

OXYMITTER 4000

IMPS 4000 (1 to 4 Probes)

An aly tic al

SPS 4001B (1 Probe)

37260039

An aly tic al

3. Membrane keypad, Figure 1-3, and HART communication are standard. To use the HART capability, you must have either: a. HART Model 275/375 Communicator. b. Asset Management Solutions (AMS) software for the PC.

1-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 1-3. Membrane Keypad

DIAGNOSTIC ALARMS

HEATER T/C HEATER 02 CELL CALIBRATION

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

02 CELL mV + 02 CELL mv HEATER T/C + HEATER T/C -

CAL TEST GAS + PROCESS % 02

MEMBRANE KEYPAD

37260003

TEST POINTS

4. An optional Local Operator Interface, Figure 1-4, allows continuous O2 display and full interface capability.

37260004

Figure 1-4. Local Operator Interface (LOI)

5. Field replaceable cell, heater, thermocouple, and diffusion element. 6. The Oxymitter 4000 is constructed of rugged 316 L stainless steel for all wetted parts. 7. The electronics are adaptable for line voltages from 90-250 VAC; therefore, no configuration is necessary.

1-6

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 8. The Oxymitter 4000 membrane keypad is available in five languages: English French German Italian Spanish 9. An operator can calibrate and diagnostically troubleshoot the Oxymitter 4000 in one of four ways: a. Membrane Keypad. The membrane keypad, housed within the right side of the electronics housing, provides fault indication by way of flashing LEDs. Calibration can be performed from the membrane keypad. b. LOI. The optional LOI takes the place of the membrane keypad and allows local communication with the electronics. Refer to Section 6 for more information. c. Optional HART Interface. The Oxymitter 4000's 4-20 mA output line transmits an analog signal proportional to the oxygen level. The HART output is superimposed on the 4-20 mA output line. This information can be accessed through the following: i.

Rosemount Analytical Model 275/375 Handheld Communicator - The handheld communicator requires Device Description (DD) software specific to the Oxymitter 4000. The DD software will be supplied with many Model 275/375 units but can also be programmed into existing units at most Rosemount Analytical service offices. See Section 7, HART/ AMS, for additional information.

ii. Personal Computer (PC) - The use of a personal computer requires AMS software available from Rosemount Analytical. iii. Selected Distributed Control Systems - The use of distributed control systems requires input/output (I/O) hardware and AMS software which permit HART communications. d. Optional IMPS 4000. The Programmable Logic Controller (PLC) in the IMPS 4000 provides fault indications using flashing LEDs and LCD display messages. Refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Manual for more information.

1-7

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 1-5. Model 751 LCD Display Panel +

+

%

+

22220059

+

10. The optional Rosemount Analytical 751 remote-mounted LCD display panel shown in Figure 1-5 is loop-driven by the 4-20 mA output signal representing the O2 percentage. 11. Optional OxyBalance Display and Averaging System. Reviews up to eight 4-20 mA signals from individual probes. Trends individual outputs, calculates four programmable averages as additional 4-20 mA outputs. Figure 1-6. OxyBalance Display Displaying Outputs

An

aly

tic

38370013

al

Handling the Oxymitter 4000

It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to prevent possible equipment damage. The Oxymitter 4000 is designed for industrial applications. Treat each component of the system with care to avoid physical damage. Some probe components are made from ceramics, which are susceptible to shock when mishandled.

1-8

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 1-7. Oxymitter 4000 HART Communications and AMS Application

Hazardous Area Oxymitter 4000 with Integral Electronics

2 Calibration Gas Lines by Customer [300 ft (90 m) max]

Termination in Control Room Line Voltage

System Considerations

Asset Management Solutions

37260005

4-20 mA Output (Twisted Pairs)

HART Model 275/375 Handheld Interface

Prior to installing your Oxymitter 4000, make sure you have all the components necessary to make the system installation. Ensure all the components are properly integrated to make the system functional. After verifying that you have all the components, select mounting locations and determine how each component will be placed in terms of available line voltage, ambient temperatures, environmental considerations, convenience, and serviceability. Figure 1-7 shows a typical system wiring. A typical system installation for an Oxymitter 4000 with integral electronics is shown in Figure 1-8. A typical system installation for an Oxymitter 4000 with remote electronics is shown in Figure 1-9. A source of instrument air is optional at the Oxymitter 4000 for reference air use. Since the unit is equipped with an in place calibration feature, provisions can be made to permanently connect calibration gas bottles to the Oxymitter 4000. If the calibration gas bottles will be permanently connected, a check valve is required next to the calibration fittings on the integral electronics. This check valve is to prevent breathing of the calibration gas line and subsequent flue gas condensation and corrosion. The check valve is in addition to the stop valve in the calibration gas kit or the solenoid valves in the IMPS 4000 or SPS 4001B. NOTE: The electronics is rated NEMA 4X (IP66) and is capable of operation at temperatures up to 185°F (85°C). The optional LOI is also rated for operation at temperatures up to 185°F (85°C). The infrared keypad functionality will degrade at temperatures above 158°F (70°C). Retain the packaging in which the Oxymitter 4000 arrived from the factory in case any components are to be shipped to another site. This packaging has been designed to protect the product.

1-9

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 1-8. Typical System Installation - Oxymitter 4000 with Integral Electronics

Gases

STANDARD

Duct Stack Oxymitter 4000

Adapter Plate

Line Voltage

Instrument Air Supply (Reference Air)

Logic I/O

Flowmeter

4 to 20 mA Signal

Pressure Regulator

IMPS 4000* MULTIPROBE AUTOCALIBRATION OPTION

Calibration Gas Gases

Duct Stack Adapter Plate

SPS 4001B* SINGLE PROBE AUTOCALIBRATION OPTION (WITH REFERENCE AIR OPTION)

Calibration Gas

Oxymitter 4000

C Inst Caalibra . Air lib tio S rat n up ion G ply Gaas 2 s 1

Line Voltage

Gases

4 to 20 mA Signal

Duct

Logic I/O

Stack Adapter Plate

Reference Air

IMPS 4000 Calibration Gas

Oxymitter 4000

Line Voltage Logic I/O

C Ins Caalibr t. Air lib atio S rat n up ion G ply Gaas 2 s 1

37260047

4 to 20 mA Signal Reference Air SPS 4001B

1-10

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 1-9. Typical System Installation - Oxymitter 4000 with Remote Electronics Gases

STANDARD

Duct Stack

Oxymitter 4000

Adapter Plate Flowmeter

Remote Electronics

Instrument Air Supply (Reference Air) Pressure Regulator

Logic I/O

Calibration Gas

4 to 20 mA Signal

Line Voltage Gases

IMPS 4000* MULTIPROBE AUTOCALIBRATION OPTION

Duct Stack Adapter Plate

Calibration Gas

Oxymitter 4000

SPS 4001B* SINGLE PROBE AUTOCALIBRATION OPTION (WITH REFERENCE AIR OPTION)

Reference Air I Ca nst. Ca libra Air libr tio Su ati n G pp on a ly Ga s 2 s 1

Remote Electronics

Gases

Duct

Line Voltage

Stack

4 to 20 mA Signal

Adapter Plate Oxymitter 4000

Logic I/O

Line Voltage IMPS 4000

Calibration Gas Reference Air

Remote Electronics

C Ins Caalibr t. Air libr atio S ati n up on Ga ply Ga s 2 s 1

*Note: The IMPS 4000 or SPS 4001B must be installed in a non-hazardous, explosive-free environment.

4 to 20 mA Signal

37260006

Line Voltage Logic I/O

Line Voltage

SPS 4001B

1-11

Instruction Manual

Oxymitter 4000

IM-106-340, Rev. 4.0 February 2006

IMPS 4000 (OPTIONAL)

Information on the IMPS 4000 is available in the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Manual.

SPS 4001B (OPTIONAL)

The SPS 4001B Single Probe Autocalibration Sequencer provides the capability of performing automatic, timed or on demand, calibrations of a single Oxymitter 4000 without sending a technician to the installation site.

Mounting

The SPS 4001B is fully enclosed in a NEMA cabinet suited for wall-mounting. This cabinet provides added protection against dust and minor impacts. The SPS 4001B consists of a manifold and a calibration gas flowmeter. The manifold provides electrical feedthroughs and calibration gas ports to route power and signal connections and calibration gases to and from the sequencer. In addition, the manifold houses two calibration gas solenoids that sequence the gases to the Oxymitter 4000, a pressure switch that detects low calibration gas pressure, and two PC boards. A terminal strip housed within the terminal cover provides convenient access for all user connections. Components optional to the SPS 4001B include a reference air flowmeter and pressure regulator. The reference air flowmeter indicates the flow rate of reference air continuously flowing to the Oxymitter 4000. The reference air pressure regulator ensures the instrument air (reference air) flowing to the Oxymitter 4000 is at a constant pressure [20 psi (138 kPa)]. The regulator also has a filter to remove particulates in the reference air and a drain valve to bleed the moisture that collects in the filter bowl. Brass fittings and Teflon tubing are standard. Stainless steel fittings and tubing are optional. Also, disposable calibration gas bottles are available as an option or can be purchased through a local supplier.

Operation

1-12

The SPS 4001B works in conjunction with the Oxymitter 4000's CALIBRATION RECOMMENDED feature to perform an autocalibration. This feature automatically performs a gasless calibration check every hour on the Oxymitter 4000. If a calibration is recommended and its contact output signal is set for "handshaking" with the sequencer, the Oxymitter 4000 sends a signal to the sequencer. The sequencer automatically performs a calibration upon receiving the signal. Thus, no human interface is required for the automatic calibration to take place. For further SPS 4001B information, refer to the SPS 4001B Single Probe Autocalibration Sequencer Instruction Manual.

Instruction Manual IM-106-340, Rev. 4.0 February 2006

MODEL 751 REMOTE POWERED LOOP LCD DISPLAY

Oxymitter 4000 The display (Figure 1-10) provides a simple, economical means to obtain accurate, reliable, and remote indication of important process variables. This display operates on the 4-20 mA line from the Oxymitter 4000. Refer to Model 751 remote powered loop LCD manual for calibration and wiring.

Figure 1-10. Model 751 Remote Powered Loop LCD Display +

+

%

+ 22220059A

+

PROBE OPTIONS Diffusion Elements

Ceramic Diffusion Assembly The ceramic diffusion assembly, Figure 1-11, is the traditional design for the probe. Used for over 25 years, the ceramic diffusion assembly provides a greater filter surface area. This element is also available with a flame arrestor, and with a dust seal for use with an abrasive shield.

19280010

Figure 1-11. Ceramic Diffusion Assembly

1-13

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Snubber Diffusion Assembly

The snubber diffusion assembly, Figure 1-12, is satisfactory for most applications. This element is also available with a flame arrestor, and with a dust seal for use with an abrasive shield.

36210012

Figure 1-12. Snubber Diffusion Assembly

Cup-Type Diffusion Assembly The cup-type diffusion assembly, Figure 1-13, is typically used in high temperature applications where frequent diffusion element plugging is a problem. It is available with either a 5 or 40 micron, sintered, Hastelloy element. This element is also available with a dust seal for use with an abrasive shield.

36150001

Figure 1-13. Hastelloy Cup-Type Diffusion Assembly

Abrasive Shield Assembly The abrasive shield assembly, Figure 1-14, is a stainless steel tube that surrounds the probe assembly. The shield protects against particle abrasion, provides a guide for ease of insertion, and acts as a position support, especially for longer probes. The abrasive shield assembly uses a modified diffuser and vee deflector assembly, fitted with dual dust seal packing.

1-14

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 1-14. Abrasive Shield Assembly 2

.187 1 .187

B

A 15o

3.584 3.554 90o 90

o

On inside break for smooth rounded edge on both ends of chamfer

A .45 min

.187

B

125

6.00

o

Skin Cut Face for 90

VIEW B

VIEW A

22.5o

0.75 thru 4 pls, eq sp on 4.75 B.C.

2 Before welding, butt item 2 with Item 1 as shown.

16860033

1 Weld on both sides with expanding chill block.

.745 Dia on a 7.50 Dia B.C. (ref) .755

NOTE In highly abrasive applications, rotate the shield 90 degrees at normal service intervals to present a new wear surface to the abrasive flow stream.

1-15

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 SPECIFICATIONS Oxymitter Specifications O2 Range Standard Accuracy System Response to Calibration Gas Temperature Limits Process

Emerson Process Managrement has satisfied all obligations coming from European legislation to harmonize the product requirements in Europe

Electronics Housing Electronics Package

Local Operator Interface

Probe Lengths

Mounting and Mounting Position

0 to 10% O2, 0 to 25% O2, 0 to 40% O2 (via HART) ±0.75% of reading or 0.05% O2, whichever is greater Initial – less than 3 seconds, T90 – less than 8 seconds 0° to 704°C (32° to 1300°F) up to 1300°C (2400°F) with optional accessories -40° to 70°C (-40° to 158°F) ambient -40° to 85°C (-40° to 185°F) [Operating temperature of electronics inside of instrument housing, as measured by a HART communicator, Rosemount Analytical Asset Management Solutions software.] -40° to 70°C (-40° to 158°F), [above 70°C (158°F) the infrared keypad will cease to function, but the Oxymitter 4000 will continue to operate properly.] 18 in. (457 mm) 12 ft (3,66 m) 3 ft (0,91 m) 15 ft (4,57 m) 6 ft (1,83 m) 18 ft (5,49 m) 9 ft (2,74 m) Vertical or horizontal; a spool piece, (P/N 3D39761G02), is available to offset transmitter housing from hot ductwork.

Materials Probe Electronics Enclosure Calibration Calibration Gas Mixtures Recommended Calibration Gas Flow Reference Air Electronics Electric Noise

Line Voltage

Wetted or welded parts - 316L stainless steel (SS) Non-wetted parts - 304 SS, low-copper aluminum Low-copper aluminum Manual, semi-automatic, or automatic 0.4% O2, Balance N2 8% O2, Balance N2 2.5 l/m (5 scfh) 2 scfh (1 l/m), clean, dry, instrument-quality air (20.95% O2), regulated to 34 kPa (5 psi) NEMA 4X, IP66 with fitting and pipe on reference exhaust port to clear dry atmosphere Meets EN 55022 Generic Emissions Std., Includes EN 61000-4-2 for Electrostatic Discharge Includes EN 6100-4-3 for RFI Includes EN 6100-4-4 for Fast Transients Includes EN 6100-4-6 for RFI 90-250 VAC, 48/62 Hz. No configuration necessary. 3/4in. -14 NPT conduit port Table continued on next page

1-16

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Oxymitter Specifications Signals Analog Output/HART Logic I/O

Power Requirements: Probe Heater Electronics Maximum

SPS 4001B Materials of Construction: Box Manifold/Electronics Enclosure Door Hinge Pins Mounting Brackets Pneumatic Fittings Pneumatic Tubing Assembly Hardware Humidity Range Temperature Range in Electronics Housing Electrical Classification Explosion-Proof Option (both pending) Electrical Feedthroughs Input Power Power Consumption External Electrical Noise Handshake Signal to/from Oxymitter 4000 (self-powered) Cal Initiate Contact input from Control Room Relay Outputs to Control Room Cabling Distance between SPS 4001B and Oxymitter 4000 Piping Distance between SPS 4001B and Oxymitter 4000 Approximate Shipping Weight

4-20 mA isolated from power supply, 950 ohms maximum load Two-terminal logic contact configurable as either an alarm output or as a bi-directional calibration handshake signal to IMPS 4000 or SPS 4001B, self-powered (+5 V) in series with 340 ohms Conduit ports — 3/4 in.-14 NPT (for analog output and logic I/O signal lines) 175 W nominal 10 W nominal 500 W

Molded fiberglass reinforced polyester Aluminum 316 stainless steel (SS) 316 stainless steel (SS) 1/8 in. brass NPT (SS optional) 1/4 in. Teflon (SS optional) Galvanized and stainless steel 100% relative humidity -40 to 185 F (-40 to 85 C) NEMA 4X (IP56) ATEX EExd 11B + H2 (Class 1, Division 1, Group B,C,D) 1/2 in. NPT 90 to 250 VAC, 50/60 Hz 5 VA maximum EN 50 082-2, includes 4 kV electrostatic discharge 5 V (5 mA maximum) 5 VDC (self-powered) 5 to 30 VDC, Form A (SPST) (one "In-Cal", one "Cal Failed") Maximum 1000 ft (303 m) Maximum 300 ft (91 m) 10 lbs (4,5 kg)

1-17

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Table 1-1. Product Matrix OXT4A

Oxymitter 4000 In Situ Oxygen Transmitter Oxygen Transmitter - Instruction Book Code 1 2 3 4 5 6 7 8 9

Sensing Probe Type ANSI (N. American Std.) Probe with Ceramic Diffuser ANSI Probe with Flame Arrestor and Ceramic Diffuser ANSI Probe with Snubber Diffuser DIN (European Std.) Probe with Ceramic Diffuser DIN Probe with Flame Arrestor and Snubber Diffuser DIN Probe with Snubber Diffuser JIS (Japanese Std.) Probe with Ceramic Diffuser JIS Probe with Flame Arrestor and Ceramic Diffuser JIS Probe with Snubber Diffuser Code 0 1 2 3 4 5 6 7 8 9 A B

Probe Assembly 18 in. (457 mm) Probe 18 in. (457 mm) Probe with Abrasive Shield (1) 3 ft (0,91 m) Probe 3 ft (0,91 m) Probe with Abrasive Shield (1) 6 ft (1,83 m) Probe 6 ft (1,83 m) Probe with Abrasive Shield (1) 9 ft (2,74 m) Probe 9 ft (2,74 m) Probe with Abrasive Shield (1) 12 ft (3,66 m) Probe 12 ft (3,66 m) Probe with Abrasive Shield (1) 15 ft (4,57 m) Probe with Abrasive Shield (1) 18 ft (5,49 m) Probe with Abrasive Shield (1) Code 0 1 2 3 4 5

Mounting Hardware- Stack Side No Mounting Hardware ("0" must be chosen under "Mounting Hardware - Probe Side" below) New Installation - Square weld plate with studs Mounting to Model 218 Mounting Plate (with Model 218 Shield Removed) Mounting to Existing Model 218 Support Shield Mounting to Other Mounting(2) Mounting to Model 132 Adapter Plate Code 0 1 2 4 5 7 8

Mounting Hardware- Probe Side No Mounting Hardware Probe Only (ANSI) (N. American Std.) New Bypass or New Abrasive Shield (ANSI) Probe Only (DIN) New Bypass or New Abrasive Shield (DIN) Probe Only (JIS) (Japanese Std.) New Bypass or Abrasive Shield (JIS) Code 11 12 13 14

OXT4C

1-18

3

3

1

1

11

Electronic Housing & Filtered Customer Termination - NEMA 4X, IP66 HART Integral Electronics, Standard Filtered Termination, ATEX Certification HART Integral Electronics, Transient Protected Filtered Termination, ATEX Certification Remote Electronics with Standard Filtered Termination (requires cable) Remote Electronics with Transient Protected Filtered Termination (requires cable)

Example

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Cont’d Code 1 2 3

Operator Interface(3) HART with Membrane Keypad - blind cover HART with Membrane Keypad - glass cover HART with Local Operation Interface, glass cover, English only Code 1 2 3 4 5

Language English German French Spanish Italian Code 00

Termination Filtering Specified as part of Electronic Housing Code 00 01 02 03 04 05 06 07 08 09 10

Calibration Accessories No Hardware Calibration Gas Flowmeter and Reference Air Set Intelligent Multiprobe Sequencer (Refer to Table 1-3) Single Probe Sequencer, Horizontal Orientation, Brass/Teflon, no Reference Air Set Single Probe Sequencer, Horizontal Orientation, Brass/Teflon, with Reference Air Set Single Probe Sequencer, Horizontal Orientation, Stainless Steel, no Reference Air Set Single Probe Sequencer, Horizontal Orientation, Stainless Steel, with Reference Air Set Single Probe Sequencer, Vertical Orientation, Brass/Teflon, no Reference Air Set Single Probe Sequencer, Vertical Orientation, Brass/Teflon, with Reference Air Set Single Probe Sequencer, Vertical Orientation, Stainless Steel, no Reference Air Set Single Probe Sequencer, Vertical Orientation, Stainless Steel, with Reference Air Set Code 00 10 11 12 13 14 15 16

Cont’d

1

3

00

03

00

Electronics to Probe Cable No Cable 20 ft (6 m) Cable 40 ft (12 m) Cable 60 ft (18 m) Cable 80 ft (24 m) Cable 100 ft (30 m) Cable 150 ft (45 m) Cable 200 ft (61 m) Cable Example

NOTES: (1) Recommended uses: High velocity particulates in flue stream, installation within 11.5 ft (3,5 m) of soot blowers or heavy salt cake buildup. Applications: Pulverized coal, recovery boilers, lime kiln. (2) Where possible, specify ANSI or DIN designation; otherwise, provide details of the existing mounting plate as follows:

Plate with studs Plate without studs

Bolt circle diameter, number, and arrangement of studs; stud thread; and stud height above mounting plate. Bolt circle diameter, number, and arrangement of holes; thread; and depth of stud mounting plate with accessories.

1-19

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Table 1-2. Calibration Components

Part Number 1A99119G01 1A99119G02 1A99119G03

Description Two disposable calibration gas bottles - 0.4% and 8% O2, balance nitrogen - 550 liters each* Two flow regulators for calibration gas bottles Bottle rack

Notes: *Calibration gas bottles cannot be shipped via airfreight. When the bottles are used with CALIBRATION RECOMMENDED features, the bottles should provide 2 to 3 years of calibrations in normal service.

Table 1-3. Intelligent Multiprobe Test Gas Sequencer Versions

Part Number 3D39695G01 3D39695G02 3D39695G03 3D39695G04 3D39695G05 3D39695G06 3D39695G07 3D39695G08 3D39695G09 3D39695G10 3D39695G11 3D39695G12

1-20

Description IMPS IMPS IMPS IMPS IMPS w/115 V Heater IMPS w/115 V Heater IMPS w/115 V Heater IMPS w/115 V Heater IMPS w/220V Heater IMPS w/220V Heater IMPS w/220V Heater IMPS w/220V Heater

Number of Oxymitters 1 2 3 4 1 2 3 4 1 2 3 4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 2

Oxymitter 4000

Installation Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2 Electrical Installation (with Integral Electronics) . . . . . . . page 2-10 Electrical Installation (with Remote Electronics) . . . . . . . page 2-13 Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-16 IMPS 4000 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-18 SPS 4001B Connections . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-18

Before installing this equipment, read the "Safety instructions for the wiring and installation of this apparatus" at the front of this Instruction Manual. 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.

http://www.processanalytic.com

Instruction Manual

Oxymitter 4000

IM-106-340, Rev. 4.0 February 2006

MECHANICAL INSTALLATION Selecting Location

1. The location of the Oxymitter 4000 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The Oxymitter 4000 must be positioned so the gas it measures is representative of the process. Best results are normally obtained if the Oxymitter 4000 is positioned near the center of the duct (40-60% insertion). Longer ducts may require several Oxymitter 4000 units since the O2 can vary due to stratification. A point too near the wall of the duct, or the inside radius of a bend, may not provide a representative sample because of the very low flow conditions. The sensing point should be selected so the process gas temperature falls within a range of 32° to 1300°F (0° to 704°C). Figure 2-1 through Figure 2-8 provide mechanical installation references. The ambient temperature of the integral electronics housing must not exceed 185°F (85°C). For higher ambient temperatures, we recommend the remote mounted electronics option. 2. Check the flue or stack for holes and air leakage. The presence of this condition will substantially affect the accuracy of the oxygen reading. Therefore, either make the necessary repairs or install the Oxymitter 4000 upstream of any leakage. 3. Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance access to the membrane keypad or LOI. Allow adequate clearance for removal of the Oxymitter 4000.

Do not allow the temperature of the Oxymitter 4000 electronics to exceed 185°F (85°C) or damage to the unit may result.

Probe Installation

1. Ensure all components are available to install the Oxymitter 4000. If equipped with the optional ceramic diffusion element, ensure it is not damaged. 2. The Oxymitter 4000 may be installed intact as it is received. NOTE An abrasive shield is recommended for high velocity particulates in the flue stream (such as those in coal-fired boilers, kilns, and recovery boilers). Vertical and horizontal brace clamps are provided for 9 ft and 12 ft (2,75 m and 3,66 m) probes to provide mechanical support for the Oxymitter 4000. Refer to Figure 2-6. 3. Weld or bolt adapter plate (Figure 2-5) onto the duct. 4. If using the optional ceramic diffusion element, the vee deflector must be correctly oriented. Before inserting the Oxymitter 4000, check the direction of gas flow in the duct. Orient the vee deflector so the apex points upstream toward the flow (Figure 2-7). This may be done by loosening the setscrews and rotating the vee deflector to the desired position. Retighten the setscrews.

2-2

4.75 (121)

5.71 (145) 5.12 (130)

Bottom View

WHE N

CI R

CU

IT

12 (305)

Rosemount Analytical Inc. Orrville, OH 44667-0901 800-433-6076

R

500 VA 5 Amps

6.52 (166)

Ref Air ANSI 1/4 (6.35) Tube DIN 6 mm Tube JIS 6 mm Tube

Cal Gas

SMART FAMILY HART TM

Cover Removal and Access

2.89 (73)

1.55 (39)

12 (305)

R

TM

OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: 85-264 VAC WATTS: 48-62 Hz OUTPUT: 4-20 mALINE FUSE:

IG HT

WH E N

CI R

CU

VE ATM OS I O PL WA RN I NG - SPH EX -

18 in.

PROBE

18 ft

15 ft

12 ft

9 ft

6 ft

3 ft

REF. GAS

229.8 (5837)

193.8 (4923) 178 (4521) 214 (5436)

31.8 (808) 49.8 (1265) 85.8 (2179) 121.8 (3094) 157.8 (4008)

DIM "B"

16 (406) 34 (864) 70 (1778) 106 (2692) 142 (3607)

DIM "A"

Table 2. Installation/Removal

Elec Conn 3/4 NPT

IT

IM-106-340, Rev. 4.0 February 2006

36920001

Flange Dia Hole Dia (4) Holes Eq Sp on BC

Table 1. Mounting Flange DIN ANSI JIS 4512C17H01 4512C19H01 4512C18H01 6.10 6.00 7.28 (155) (185) (153) 0.75 0.71 0.59 (18) (15) (20)

12.50 (318) Dim "B” Removal Envelope

6.02 (153)

P

T

With Standard Snubber Diffuser

4.77 (121)

T

KEE

P

Add to Dim “A” for probe with Ceramic Diffuser and Flame Arrestor

Dim "A"

CAL. GAS

IG H

VE ATM OS I O PL WA RN I NG - SPH EX -

KEE

Add to Dim “A” for probe with Ceramic Diffuser 5.14(131)

3.80(96)

2.27 (58) Dia Max

Insulate if exposed to Ambient weather conditions

-

IN

-

I VE

0.062 THK Gasket ANSI 3535B18H02 JIS 3535B46H01 3535B45H01 DIN

-

IN

-

I VE

Note: Dimensions are in inches with millimeters in parentheses.

E ER AL

E ER AL

Process flow must be in this direction with respect to deflector 3534B48G01

Instruction Manual

Oxymitter 4000

Figure 2-1. Oxymitter 4000 Probe Installation

T

2-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 2-2. Oxymitter 4000 Remote Electronics Installation

REMOTE ELECTRONICS WITH MEMBRANE KEYPAD AND BLIND COVER

REMOTE ELECTRONICS WITH LOI AND WINDOW COVER

2.44 (62,0) DIA.

2.21 (56,0)

6.48 (164,6)

7.47 (189,8)

8.72 (221,5)

3.33 (84,6)

5.52 (140,2)

37260046

WALL MOUNT CONFIGURATION

2.68 (68,1)

PIPE MOUNT CONFIGURATION

2.62 (66,5)

Note: Dimensions are in inches with millimeters in parentheses.

2-4

36920002

18 ft

15 ft

12 ft

9 ft

Dim "A" 13 (330) 31 (787) 67 (1702) 103 (2616) 139 (3531) 175 (4445) 211 (5359) Dim "B" 32.5 (826) 50.5 (1283) 86.5 (2197) 122.5 (3112) 158.5 (4026) 194.5 (4940) 230.5 (5855) Hole Dia (8) Holes Eq Sp on BC

7.50 (190)

0.75 (19)

7.48 (190)

0.75 (19)

7.48 (190)

0.94 (24)

TABLE 4. Abrasive Shield -3D39003 ANSI DIN Flange JIS 9.25 9.00 9.25 Flange (235) (229) (235) Dia

Cal Gas*

U

IT

3/4 NPT Electrical Connection

*Add check valve in Cal Gas line

ANSI 1/4 in. Tube JIS 6 mm Tube 6 mm Tube DIN

Ref Air

C CI R

IM-106-340, Rev. 4.0 February 2006

6 ft

3 ft

18 in.

Probe

WHE N

VE ATM OS I O PL WARN I NG - SPH EX -

IG HT

T

TABLE 3. Installation/Removal Table

4.77 (121) 6.02 (153)

CAL. GAS

12.50 (318)

P

Diffuser/Dust Seal Assy

3.6 (91) Dia Nominal

7.00 (178)

Dim "B" Removal Envelope

KE E

Deflector Assy

Snubber/Dust Seal Assembly 0.2 (5)

3.9 (99)

Dim "A"

-

IN

I VE

2. Dimensions are in inches with millimeters in parentheses.

E ER AL

Notes: 1. These flat-faced flanges are manufactured to ANSI, DIN, and JIS bolt patterns and are not pressure rated.

Instruction Manual

Oxymitter 4000

Figure 2-3. Oxymitter 4000 with Abrasive Shield

2-5

2-6 0.625-11

4.75 (121)

"B" Thread

"C" Dia

35830004

B

C

45o

7.50 (191)

"D" Dia

A

B

Crosshatched area in 4 corners may be used to provide additional holes for field bolting of plate to outside wall surface.

A C

22.5o

*Part numbers for adapter plates include attaching hardware.

(M-16 x 2)

0.625-11

"C" Thread

7.48 (190)

3.94 (100)

9.25 (235)

7.894 (200)

(M-20 x 2.5)

4.92 (125)

9.25 (235)

JIS (P/N 3535B58G04)

Abrasive Shield Flange O.D.

8 threaded holes equally spaced on D Dia B.C.

DIN (P/N 3535B58G06)

4.75 (121)

9.00 (229)

ANSI (P/N 3535B58G02)

"B" Dia

"A"

Dimensions in. (mm)

Adapter plate for 3, 6, 9, and 12 ft. Abrasive Shield Installations. See figure 2-3.

4 studs, lockwashers and nuts equally spaced on C Dia B.C.

A

5.118 (130)

(M-12 x 1.75)

6.50 (165)

JIS (P/N 4512C35G01)

TABLE 6. ADAPTER PLATE* DIMENSIONS FOR OXYMITTER 4000 WITH ABRASIVE SHIELD

Oxymitter 4000

Adapter plate for Oxymitter 4000 Installation. See Figure 2-1.

2.500 Dia (63,5)

Note: Dimensions are in inches with millimeters in parentheses.

A

5.708 (145)

(M-16 x 2)

7.5 (191)

DIN (P/N 4512C36G01)

*Part numbers for adapter plates include attaching hardware.

6.00 (153)

ANSI (P/N 4512C34G01)

"A"

Dimensions in. (mm)

TABLE 5. ADAPTER PLATE* DIMENSIONS FOR OXYMITTER 4000

ADAPTOR PLATE OUTLINE

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Figure 2-4. Oxymitter 4000 Adapter Plate Dimensions

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 2-5. Oxymitter 4000 Adapter Plate Installation INSTALLATION FOR METAL WALL STACK OR DUCT CONSTRUCTION

INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION 0.50 (13)

0.50 (13)

Bolt mounting plate to outside wall surface

3.75 (95)

Field weld pipe to adapter plate

Minimum Dia hole in wall Mounting Holeso shown rotated 45 out of true position

Mounting holes shown rotated 45o out of true position Stack or duct metal wall

Joint must be air tight Weld or bolt mounting plate to metal wall of stack or duct; Joint must be air tight.

4.50 (114) O.D. Ref

Pipe 4.00 in. Sched 40 Pipe Sleeve (Not by Rosemount Analytical) length by Customer Masonry stack wall

Outside wall surface

Bolt adapter plate to outside wall surface

Field weld pipe to adapter plate

3.5 (89) O.D. Ref

2.50 (63,5) Minimum Dia hole in wall

Joint must be air tight Weld or bolt adapter plate to metal wall of stack or duct. Joint must be air tight.

Notes: 1. 2.

Dimensions are in inches with millimeters in parentheses. All masonry stack work and joints except adaptor plate are not furnished by Rosemont Analytical.

Outside wall surface

Pipe 3.00 in. Sched 40 Pipe Sleeve (Not by Rosemount Analytical) length by Customer Masonry stack wall

35830005

Stack or duct metal wall

2-7

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 2-6. Oxymitter 4000 Abrasive Shield Bracing Installation Brace Bars (Not by Rosemount Analytical)

Note: Dimensions are in inches with millimeters in parentheses.

2.00 (51) 60o Max 1.00 (25)

30o Min

}

Vertical brace clamp assy. By Rosemount Analytical Horizontal brace clamp assy. (Both brace clamp assemblies are the same. Installation and location of clamp assemblies and brace bars to be done in field.)

2 Holes - 0.625 (16) Dia for 0.50 (12) Dia Bolt

5.62 (143)

Abrasive Shield

4.12 (105)

4.12 (105)

0.375 (10) 1.00 (25) Max

5.62 (143)

Note: Bracing is for vertical and horizontal Oxymitter 4000 Installation. External bracing required for 9 ft. through 18 ft. (2,75 m through 5,49 m) probes as shown above.

36920003

36.00 (914)

5. In vertical installations, ensure the system cable drops vertically from the Oxymitter 4000 and the conduit is routed below the level of the electronics housing. This drip loop minimizes the possibility that moisture will damage the electronics (Figure 2-8). 6. If the system has an abrasive shield, check the dust seal gaskets. The joints in the two gaskets must be staggered 180°. Also, make sure the gaskets are in the hub grooves as the Oxymitter 4000 slides into the 15° forcing cone in the abrasive shield. 7. Insert probe through the opening in the mounting flange and bolt the unit to the flange. When probe lengths selected are 9 to 18 ft (2.74 to 5.49 m), special brackets are supplied to provide additional support for the probe inside the flue or stack (Figure 2-6). NOTE If process temperatures will exceed 392°F (200°C), use anti-seize compound on stud threads to ease future removal of Oxymitter 4000. For ambient temperatures that will exceed 185°F (85°C), we recommend the remote mounted electronics option.

2-8

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Figure 2-7. Orienting the Optional Vee Deflector

Oxymitter 4000 Gas Flow Direction Vee Deflector Apex

Diffusion Element Filter

Setscrew

22220020

Vee Deflector

Uninsulated stacks or ducts may cause ambient temperatures around the electronics to exceed 185°F (85°C), which may cause overheating damage to the electronics.

8. If insulation is being removed to access the duct work for Oxymitter 4000 mounting, make sure the insulation is replaced afterward (Figure 2-8).

Remote Electronics Installation

For an Oxymitter 4000 equipped with remote electronics, install the probe according to the instructions in "Probe Installation". Install the remote electronics unit on a stand pipe or similar structure, Figure 2-2.

2-9

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 2-8. Installation with Drip Loop and Insulation Removal

-

IVE

-

KEE

IG HT

WHE N

CI R

CU

VE ATM O OS I PL WARN I NG - SPH EX -

AL

E ER

IN

P

T

Drip Loop CAL. GAS

Replace Insulation after Installing Oxymitter 4000

Logic I/O, 4-20 mA Signal

IT

Line Voltage

Adapter Plate

ELECTRICAL INSTALLATION (WITH INTEGRAL ELECTRONICS)

Stack or Duct Metal Wall

29340005

Insulation

For Oxymitter 4000 with Integral Electronics All wiring must conform to local and national codes.

Disconnect and lock out power before connecting the power supply.

Install all protective covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death.

To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, connection to the main electrical power supply must be made through a circuit breaker (min 10 A) which will disconnect all current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 947.

2-10

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 NOTE To maintain CE compliance, ensure a good connection exists between the mounting flange bolts and earth. 1. Remove screw (32, Figure 9-3), gasket (33), and cover lock (34). Remove cover (27). 2. Connect Line Voltage a. Connect the line, or L1 wire to the L1 terminal and the neutral, or L2 wire, to the N terminal (Figure 2-9). The Oxymitter 4000 automatically will configure itself for 90-250 VAC line voltage and 50/60 Hz. The power supply requires no setup. 3. Connect 4-20 mA Signal and Calibration Handshake/Logic I/O Leads a. 4-20 mA Signal. The 4-20 mA signal represents the O2 value and can also operate the Model 751 Remote Powered Loop LCD Display or any other loop powered display. Superimposed on the 4-20 mA signal is HART information that is accessible through a Model 275/375 Handheld Communicator or AMS software. b. Calibration Handshake/Logic I/O. The output can either be an alarm or provide the handshaking to interface with an IMPS 4000 or SPS 4001B. For more information, refer to "Logic I/O" in Section 4: Configuration of Oxymitter 4000 with LOI, and either the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Manual or the SPS 4001B Single Probe Autocalibration Sequencer Instruction Manual. c. If autocalibration is not utilized, a common bi-directional logic contact is provided for any of the diagnostic alarms listed in Table 8-1. The assignment of alarms which can actuate this contact can be modified to one of seven additional groupings listed in Table 3-1 and Table 4-1. The logic contact is self-powered, +5 VDC, 340 ohm series resistance. An interposing relay will be required if this contact is to be utilized to annunciate a higher voltage device, such as a light or horn, and may also be required for certain DCS input cards. A Potter & Brumfield R10S-E1Y1-J1.0K 3.2 mA DC or an equal interposing relay will be mounted where the contact wires terminate in the control/relay room. d. Install cover (27, Figure 9-3). Secure with cover lock (34), gasket (33), and screw (32).

2-11

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 2-9. Electrical Installation - Oxymitter 4000 with Integral Electronics

INTEGRAL ELECTRONICS WITHOUT SPS 4001B Calibration Handshake/ Logic I/O

4-20 mA Signal

Line Voltage -

+

-

+

AC

AC

N

L1

Logic I/O + Logic I/O – 4-20 mA + 4-20 mA – Ground 90-250 VAC, 50-60 Hz Line Voltage Input

Terminal Block

Line 1 Neutral Ground Ground Lugs

INTEGRAL ELECTRONICS WITH REMOTE SPS 4001B

Line 1 Neutral Ground

90-250 VAC, 50-60 Hz Line Voltage Input

4-20 mA + Signal Ground

Calibration Handshake

90-250 VAC, 50-60 Hz Line Voltage Input

Refer to SPS 4001B Instruction Manual

Line 1 Neutral Ground

INTEGRAL ELECTRONICS WITH REMOTE IMPS 4000

Calibration Handshake Refer to IMPS 4000 Instruction Manual

2-12

90-250 VAC, 50-60 Hz Line Voltage Input

+ 4-20 mA – 4-20 mA Ground

37260051

Line 1 Neutral Ground

Instruction Manual IM-106-340, Rev. 4.0 February 2006

ELECTRICAL INSTALLATION (WITH REMOTE ELECTRONICS)

Oxymitter 4000 For Oxymitter 4000 with Remote Electronics All wiring must conform to local and national codes.

Disconnect and lock out power before connecting the power supply.

Install all protective covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death.

To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, connection to the main electrical power supply must be made through a circuit breaker (min 10 A) which will disconnect all current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 947.

NOTE To maintain CE compliance, ensure a good connection exists between the mounting flange bolts and earth. 1. Remove screw (32, Figure 9-4), gasket (33), cover lock (34), and cover (27) from remote electronics. 2. Connect Line Voltage a. Connect the line, or L1 wire to the L1 terminal and the neutral, or L2 wire, to the N terminal (Figure 2-10). The Oxymitter 4000 automatically will configure itself for 90-250 VAC line voltage and 50/60 Hz. The power supply requires no setup. 3. Connect 4-20 mA Signal and Calibration Handshake/Logic I/O Leads (Figure 2-10). a. 4-20 mA Signal. The 4-20 mA signal represents the O2 value and can also operate the Model 751 Remote Powered Loop LCD Display or any other loop powered display. Superimposed on the 4-20 mA signal is HART information that is accessible through a Model 275/375 Handheld Communicator or AMS software.

2-13

Instruction Manual

Oxymitter 4000

IM-106-340, Rev. 4.0 February 2006

b. Calibration Handshake/Logic I/O. The output can either be an alarm or provide the handshaking to interface with an IMPS 4000 or SPS 4001B. For more information, refer to "Logic I/O" in Section 4: Configuration of Oxymitter 4000 with LOI, and either the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Manual or the SPS 4001B Single Probe Autocalibration Sequencer Instruction Manual. c. If autocalibration is not utilized, a common bi-directional logic contact is provided for any of the diagnostic alarms listed in Table 8-1. The assignment of alarms which can actuate this contact can be modified to one of seven additional groupings listed in Table 4-1. The logic contact is self-powered, +5 VDC, 340 ohm series resistance. An interposing relay will be required if this contact is to be utilized to annunciate a higher voltage device, such as a light or horn, and may also be required for certain DCS input cards. A Potter & Brumfield R10S-E1Y1-J1.0K 3.2 mA DC or an equal interposing relay will be mounted where the contact wires terminate in the control/relay room. 4. Install cover (27, Figure 9-4). Secure with cover lock (34), gasket (33), and screw (32). 5. Install Interconnecting Cable a. Remove the cover (3) from the junction box (5). Connect the electronics end of the interconnecting cable to the "FROM PROBE" side of the terminal block (Figure 2-10). b. Remove screw (32, Figure 9-4), gasket (33), and cover lock (34) at the probe head. Remove housing cover (27). c. Connect the heater power leads, the thermocouple leads and the oxygen signal leads at the terminal block. The leads are tagged for polarity.

2-14

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 2-10. Electrical Installation - Oxymitter 4000 with Remote Electronics

WHT

YEL +

RED -

BLU -

ORN+

BLK

Type K Thermocouple Signal Heater Power (Below Cover)

Oxygen Signal

PROBE

Terminal Block

Ground Lugs

REMOTE ELECTRONICS

Calibration Handshake/ Logic I/O

4-20 mA Signal

Line Voltage -

+

-

+

4-20

AC

AC

N

L1

Terminal Block (BY FACTORY) TO ELECTRONICS GRN

YEL ORN

RED

BLK

BLK

Interconnecting Cable

1

2 3

4

5

6

Ground Lugs 2

T/C

O CELL

HTR

WHT

BLK

RED

YEL ORN

BLU

FROM PROBE

GRN GRN

To IMPS 4000 or SPS 4001B if used. Refer to IMPS 4000 or SPS 4001B Instruction Manual

GRN

Logic I/O + Logic I/O -

90-250 VAC, 50-60 Hz Line Voltage Input

Line 1 Neutral Ground

37260052

4-20 mA + 4-20 mA Ground

2-15

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Install Interconnecting Cable

NOTE If interconnect cable was not purchased with the Hazardous Area Oxymitter 4000, consult the factory for the proper wire type and gauge. 1. Remove cover (27, Figure 9-4) from the junction box (5). Connect the electronics end of the interconnecting cable (9) to the "FROM PROBE" side of the terminal block (Figure 2-10). 2. Loosen screw (32, Figure 9-3), cover lock (34) and gasket (33) at the probe head. Remove cover (27). 3. See (Figure 2-10). Connect the heater power leads, the thermocouple leads, and the oxygen signal leads of the interconnecting cable to the terminal block. The cable leads are tagged for polarity. To avoid a shock hazard, the heater power terminal cover must be installed. 4. Install covers (27, Figure 9-3 and Figure 9-4) and secure with gasket (33), cover locks (34), and screws (32).

PNEUMATIC INSTALLATION

OXYMITTER 4000 Reference Air Package After the Oxymitter 4000 is installed, connect the reference air set to the Oxymitter 4000. Refer to Figure 2-11. Instrument Air (Reference Air): 10 psig (68.95 kPag) minimum, 225 psig (1551.38 kPag) maximum at 2 scfh (56.6 L/hr) maximum; less than 40 parts per million total hydrocarbons. Regulator outlet pressure should be set at 5 psi (35 kPa). Reference air can be supplied by the reference air set of the IMPS 4000 or SPS 4001B. If using an IMPS 4000, refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Manual for the proper reference air connections. If using an SPS 4001B, refer to the SPS 4001B Single Probe Autocalibration Sequencer Instruction Manual for the proper reference air connections.

Do not use 100% nitrogen as a low gas (zero gas). It is suggested that gas for the low (zero) be between 0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

Calibration Gas Two calibration gas concentrations are used with the Oxymitter 4000, Low Gas - 0.4% O2 and High Gas - 8% O2. See Figure 2-12 for the Oxymitter 4000 connections.

2-16

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 2-11. Air Set, Plant Air Connection 0.125-27 NPT Female Outlet Connection 1

2

Outlet

3.12 (79,25) Max 2.250 (57,15)

3

4.81 (122,17)

0.25-18 NPT Female Inlet Connection

Flow Set Point Knob

1.19 (30,22)

2.0 (50,80) 1.50 (38,10)

Drain Valve 10.0 (254) REF

SMART FAMILY HARTTM

8.50 (215,90) Max

2 Mounting Holes 3.19 (81,03) Lg through Body for 0.312 (7,92) Dia Bolts

Replacement Parts 1 2 3

To Electronics Rosemount Analytical Inc. Orrville, OH 44667-0901 800-433-6076

Note: Dimensions are in inches with millimeters in parentheses.

Flowmeter 2" Pressure Gage Combination Filter-Reg.

0.2-2.0 scfh 0-15 psig 0-30 psig

771B635H02 275431-006 4505C21G01

R

TM

OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: 85-264 VAC 48-62 Hz OUTPUT: 4-20 mA LINE FUSE:

WATTS:

500 VA

5 Amps

Instrument Air Supply 10-225 psig Max Pressure Ref Air Set 263C152G01

Schematic Hookup for Reference Air Supply on Oxymitter 4000 Probe Head.

26170035

0.250 or 6 mm O.D. Tubing (Supplied by Customer)

Figure 2-12. Oxymitter 4000 Gas Connections Calibration Gas Connections

R

Rosemount Analytical Inc. Orrville, OH 44667-0901 800-433-6076

SMART FAMILY HARTTM

R

TM

500 VA 5 Amps

Reference Air Calibration Gas

26170025

OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: WATTS: 85-264 VAC 48-62 Hz OUTPUT: 4-20 mALINE FUSE:

2-17

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 IMPS 4000 CONNECTIONS

See the IMPS 4000 Intelligent Multiprobe Sequencer Instruction Manual for wiring and pneumatic connection.

SPS 4001B CONNECTIONS

See the SPS 4001B Single Probe Autocalibration Sequencer Instruction Manual for wiring and pneumatic connection.

NOTE: Upon completing installation, make sure that the Oxymitter 4000 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold Oxymitter 4000 exposed to the process gases. During outages, and if possible, leave all Oxymitter 4000 units running to prevent condensation and premature aging from thermal cycling.

If the ducts will be washed down during outage, MAKE SURE to power down the Oxymitter 4000 units and remove them from the wash areas.

2-18

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 3

Oxymitter 4000

Configuration of Oxymitter 4000 with Membrane Keypad

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1 Logic I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-5

VERIFY INSTALLATION

Install all protective equipment covers and safety ground leads before equipment startup. Failure to install covers and ground leads could result in serious injury or death.

Mechanical Installation Terminal Block Wiring

Ensure the Oxymitter 4000 is installed correctly. See Section 2: Installation. 1. Remove screw (32, Figure 9-3 or Figure 9-4), gasket (33), and cover lock (34) that secure the housing cover (27). Remove the cover to expose the terminal block (25). 2. Check the terminal block wiring (Figure 3-1). Be sure the power, 4-20 mA signal, and the logic outputs are properly connected and secure. To avoid a shock hazard, the power terminal cover must be installed. For units with remote electronics, check the terminal block wiring at the probe and at the remote electronics unit. 3. Install the housing cover (27, Figure 9-3 or Figure 9-4) on the terminal block (25) and secure with cover lock (34), gasket (33), and screw (32).

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 3-1. Electronics Housing Terminals and Membrane Keypad Oxymitter 4000 Electronics Housing Rosemount Analytical Inc. Orrville, OH 44667-0901 800-433-6076

SMART FAMILY HARTTM

R

TM

OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: 85-264 VAC 48-62 Hz WATTS: OUTPUT: 4-20 mA LINE FUSE:

500 VA 5 Amps

L1

N

INC

Terminal Block

INC

HIGH GAS

LOW GAS

DEC

DEC

02 CELL mV + 02 CELL mv HEATER T/C + HEATER T/C -

TP1

J1

TP2 TP3 TP4

CAL TEST GAS + PROCESS % 02

TP5 TP6

37260009

Logic I/O

Ground Lugs

Oxymitter 4000 Configuration

SW2 ON

AC

AC

TEST POINTS

4-20 mA Signal

HEATER T/C HEATER 02 CELL CALIBRATION

RED YEL GRN ORG

-

+

-

+

4-20

DIAGNOSTIC ALARMS

CALIBRATION RECOMMENDED

Located on the microprocessor board, the top board, are two switches that configure outputs for the Oxymitter 4000 (Figure 3-2). SW1 determines if the 4-20 mA signal is internally or externally powered. SW2 determines: 1. Oxymitter 4000 status, HART or LOCAL. 2. Oxygen range, 0 to 10% O2 or 0 to 25% O2. (0 to 40% O2 is also configurable only through HART/AMS.) 3. The 4-20 mA signal, at fault or power up, 3.5 mA or 21.6 mA.

Remove power from the Oxymitter 4000 before changing defaults. If defaults are changed under power, damage to the electronics package may occur.

SW1 Setting The two settings are internally or externally powering the 4-20 mA signal. The factory setting is for the 4-20 mA signal to be internally powered.

3-2

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 SW2 Setting The factory sets this switch as follows: 1. Position 1 is HART/LOCAL. This switch setting controls the configuration of the Oxymitter 4000. The defaults cannot be changed via HART/AMS unless the switch is in the HART position. Placing SW2, position 1 in the LOCAL position forces the O2 range to the setting of position 2. The position 1 switch must be placed in the LOCAL position or changes in SW2, position 2 will have no effect. 2. Position 2 determines the O2 range. This can be set to either 0 to 10% O2 or 0 to 25% O2. The factory setting is 0 to 10% O2. If necessary, the O2 range can be configured from 0 to 40% O2. To select values within this range, set SW2, position 1 to HART and then enter the range via HART/AMS. Do not change SW2, position 1 to LOCAL unless you want to operate in the range specified by SW2, position 2.

Typically, the probe's sensing cell, in direct contact with the process gases, is heated to approximately 736°C (1357°F). The external temperature of the probe body may exceed 450°C (842°F). If operating conditions also contain high oxygen levels and combustible gases, the Oxymitter 4000 may self-ignite.

3. Position 3 determines the output at startup or at an alarm. The settings are 3.5 mA or 21.6 mA. The factory setting is 3.5 mA. At startup, the current at the analog output is 3.5 mA or 21.6 mA. 4. Position 4 can be used to set the heater for 115 or 220 VAC operation. This switch is functional only when the software is set for manual voltage selection (Auto Tune = No). Otherwise, the internal electronics auto detect the input line voltage and sets the heater voltage accordingly (Auto Tune = Yes).

3-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 3-2. Defaults - Oxymitter 4000 with Membrane Keypad

HART: O2 Range set by HART/AMS (From 0 to 40% O2) Local: O2 Range set by Pos 2 0 to 10% O2 / 0 to 25% O2: O2 Range 3.5 mA/21.6 mA: When alarm exists, or on powerup, output current goes to this value

ON

OFF

4-20 mA is internally powered (Default)

Local

HART

0 to 25% O2

0 to 10% O2

21.6 mA

3.5 mA

115 V

220 V Default position (Ex-factory)

4-20 mA requires external power

SW 1

HEATER T/C HEATER O2 CELL CALIBRATION

SW2 ON

DIAGNOSTIC ALARMS

Note:

1 2 3 4

CALIBRATION RECOMMENDED

INC

HIGH GAS

LOW GAS

DEC

DEC

J1

TP2 TP3 TP4

CAL TEST GAS + PROCESS % O2

TP5 TP6

37260010

INC

TP1

RED YEL GRN ORG

TEST POINTS

O2 CELL mV + O2 CELL mV HEATER T/C + HEATER T/C -

The 115 V option at switch SW2 position 4 is active only when the heater voltage option is set to manual in the software (auto tune = no).

Read O2 Concentration Once the cell is up to operating temperature, the O2 percentage can be read: 1. Access TP5 and TP6 next to the membrane keypad. Attach a multimeter across TP5 and TP6. The calibration and process gases can now be monitored. Pressing the INC or DEC once will cause the output to switch from the process gas to the calibration gas. Pressing INC or DEC a second time will increase or decrease the calibration gas parameter. If the keys have been inactive for one minute, the output reverts to the process gas. If the keys have been inactive for one minute, the output reverts to the process gas.

3-4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 When a calibration has been initiated, the value at TP5 and TP6 is the % O2 seen by the cell. Oxygen levels, as seen on the multimeter, are: 8.0% O2 = 8.0 VDC 0.4% O2 = 0.4 VDC 2. HART/AMS. 3. Model 751. The loop-driven LCD display.

LOGIC I/O

Table 3-1. Logic I/O Configuration (as set at HART/AMS or LOI)

This two-terminal logic contact can be configured either as a solid-state relay-activated alarm or as a bi-directional calibration handshake signal to an IMPS 4000 or SPS 4001B. The configuration of this signal depends on the setting of the LOGIC I/O PIN MODE via HART/AMS or LOI. The ten different modes available are explained in Table 3-1.

Mode

Configuration

0 1 2 3 4

The unit is not configured for any alarm condition. The unit is configured for a Unit Alarm. The unit is configured for Low O2. The unit is configured for both a Unit Alarm and Low O2. The unit is configured for a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for both a Unit Alarm and a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for both a Low O2 and High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for a Unit Alarm, a Low O2, and a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for a calibration handshake with IMPS 4000 or SPS 4001B. CALIBRATION RECOMMENDED will initiate the calibration cycle. The unit is configured for a calibration handshake. CALIBRATION RECOMMENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4001B.

5* 6 7 8** 9

*The default condition for an Oxymitter 4000 without an IMPS 4000 or SPS 4001B. **The default condition for an Oxymitter 4000 with an IMPS 4000 or SPS 4001B.

Alarm When configured as an alarm, this signal alerts you to an out-of-spec condition. The output is 5 V in series with a 340 ohm resistor. For optimum performance, Emerson Process Management recommends connecting the output to a Potter & Brumfield 3.2 mA DC relay (P/N R10S-E1Y1-J1.0K). Of the ten modes in Table 3-1, mode 1 through mode 7 are the alarm modes. The factory default is mode 5 for Oxymitter 4000 units without an IMPS 4000 or SPS 4001B. In this mode, the output will signal when a unit alarm or a CALIBRATION RECOMMENDED indication occurs.

3-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Calibration Handshake Signal

If using an optional IMPS 4000 or SPS 4001B, the logic I/O must be configured for calibration handshaking. Of the ten modes in Table 3-1, only modes 8 and 9 are configured for calibration handshaking. For an Oxymitter 4000 with an IMPS 4000 or an SPS 4001B, the factory sets the default to mode 8. In this mode, the logic I/O will be used to communicate between the Oxymitter 4000 and sequencer and to signal the sequencer when a CALIBRATION RECOMMENDATION indication occurs.

Recommended Configuration

4-20 mA Signal Upon Critical Alarm Rosemount Analytical recommends that the factory default be utilized. The 4-20 mA signal will go to the 3.5 mA level upon any critical alarm which will cause the O2 reading to be unusable. Customer can also select 21.6 mA as the failure setting if normal operations cause O2 readings to go below the zero % O2 (3.5 mA) level. If the O2 measurement is being utilized as part of an automatic control loop, the loop should be placed into manual upon this failure event or other appropriate action should be taken. Calibration Rosemount Analytical recommends utilizing an autocalibration system, actuated by the "calibration recommended" diagnostic. New O2 cells may operate for more than a year, but older cells may require recalibration every few weeks as they near the end of their life. This strategy ensures that the O2 reading is always accurate, and eliminates many unnecessary calibrations based on calendar days or weeks since previous calibration. When utilizing the SPS 4001B or IMPS 4000, consider wiring some or all associated alarm contacts. 1. CALIBRATION INITIATE. Contact from the control room to an SPS 4001B or IMPS 4000 (one per probe) provides the ability to manually initiate a calibration at any time from the control room. Note that calibrations can also be initiated from a HART handheld communicator, from Asset Management Solutions software, or from the keypad on the Oxymitter 4000. 2. IN CALIBRATION. One contact per probe provides notification to the control room that the "calibration recommended" diagnostic has initiated an automatic calibration through the SPS 4001B or IMPS 4000. If the O2 signal is being utilized in an automatic control loop, this contact should be utilized to place the control loop into manual during calibration. 3. CALIBRATION FAILED. One contact per probe from an SPS 4001B or IMPS 4000 to the control room for notification that the calibration procedure failed. Grouped with this alarm is an output from a pressure switch which indicates when the calibration gas bottles are empty. 4. 4-20 mA SIGNAL DURING CALIBRATION. The 4-20 mA signal can be configured to respond normally during any calibration, or it can be configured to hold the last O2 value upon the initiation of calibration. The factory default is for the 4-20 mA signal to operate normally throughout calibration. Holding the last O2 value may be useful if several probes are being averaged for the purpose of automatic control. Unless several probes are being averaged, always place control loops that are using the O2 signal into the manual mode prior to starting the calibration.

3-6

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 4

Oxymitter 4000

Configuration of Oxymitter 4000 with LOI Verify installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1 Logic I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-4

VERIFY INSTALLATION

Install all protective equipment covers and safety ground leads before equipment startup. Failure to install covers and ground leads could result in serious injury or death.

Mechanical Installation Terminal Block Wiring

Ensure the Oxymitter 4000 is installed correctly. See Section 2: Installation. 1. Remove screw (32, Figure 9-3 or Figure 9-4), gasket (33), and cover lock (34) that secure the housing cover (27). Remove the cover to expose the terminal block (25). 2. Check the terminal block wiring, Figure 4-1. Be sure the power, 4-20 mA signal, and logic outputs are properly connected and secure. 3. Install the housing cover (27, Figure 9-3 or Figure 9-4) on the terminal block and secure with cover lock (34), gasket (33), and screw (32).

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 4-1. Electronics Housing Terminals with LOI Oxymitter 4000 Electronics Housing Rosemount Analytical Inc. Orrville, OH 44667-0901 800-433-6076

SMART FAMILY HARTTM

R

TM

OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: 85-264 VAC 48-62 Hz WATTS: OUTPUT: 4-20 mA LINE FUSE:

500 VA 5 Amps

-

+

-

+

4-20

AC

AC

N

L1

4-20 mA Signal

Terminal Block LOI Ground Lugs

Oxymitter 4000 Configuration

37260011

Logic I/O

Located on the microprocessor board are two switches that configure outputs (Figure 4-2). To access these switches, the LOI module must be removed. SW1 determines if the 4-20 mA signal is internally or externally powered. SW2 determines: 1. Range control, HART or LOCAL. 2. Oxygen range, 0 to 10% O2 or 0 to 25% O2. (0 to 40% O2 is also configurable only through HART/AMS.) 3. The 4-20 mA signal, at fault or power up, 3.5 mA or 21.6 mA.

Remove power before changing defaults. If defaults are changed under power, damage to the electronics package may occur.

SW1 Setting The two settings are internally or externally powering the 4-20 mA signal. The factory setting is for the 4-20 mA signal to be internally powered.

4-2

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 SW2 Setting The factory sets this switch as follows: 1. Position 1 is HART/LOCAL. This switch setting controls the configuration of the Oxymitter 4000. The defaults cannot be changed via HART/AMS or the LOI unless the switch is in the HART position. Placing SW2, position 1 in the LOCAL position forces the O2 range to the setting of position 2. The position 1 switch must be in the LOCAL position or changes in SW2, position 2 will have no effect. 2. Position 2 determines the O2 range. This can be set to either 0 to 10% O2 or 0 to 25% O2. The factory setting is 0 to 10% O2. If necessary, the O2 range can be configured from 0 to 40% O2. To select values within this range, set SW2, position 1 to HART and then enter the range via HART/AMS or the LOI. Do not change SW2, position 1 to LOCAL unless you want to operate in the range specified by SW2, position 2.

Typically, the probe's sensing cell, in direct contact with the process gases, is heated to approximately 1357°F (736°C). The external temperature of the probe body may exceed 842°F (450°C). If operating conditions also contain high oxygen levels and combustible gases, the Oxymitter 4000 may self-ignite.

3. Position 3 determines the output at startup or at an alarm. The settings are 3.5 mA or 21.6 mA. The factory setting is 3.5 mA. At startup, the current at the analog output is 3.5 mA or 21.6 mA. 4. Position 4 can be used to set the heater for 115 or 220 VAC operation. This switch is functional only when the software is set for manual voltage selection (Auto Tune = No). Otherwise, the internal electronics auto detect the input line voltage and sets the heater voltage accordingly (Auto Tune = Yes). Read O2 Concentration Once the cell is up to operating temperature, the O2 percentage can be read: 1. To access TP5 and TP6 under the LOI module (Figure 4-2), power down the Oxymitter 4000 and remove the LOI module. Attach alligator leads from a multimeter across TP5 and TP6. Install the LOI module and power up the Oxymitter 4000. Allow time for the cell to reach operating temperature. The calibration and process gases can now be monitored. When a calibration has been initiated, the value at TP5 and TP6 is the % O2 seen by the cell. Oxygen levels, as seen on the multimeter, are: 8.0% O2 = 8.0 VDC 0.4% O2 = 0.4 VDC 2. HART/AMS. 3. Model 751. The loop-driven LCD display.

4-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 4-2. Defaults - Oxymitter 4000 with LOI

HART: O2 Range set by HART/AMS (From 0 to 40% O2) Local: O2 Range set by Pos 2 0 to 10% O2/ 0 to 25% O2: O2 Range 3.5 mA/21.6 mA When alarm exists, or on power up, current output goes to this value

ON

OFF

4-20 mA is internally powered (Default)

Local

HART

0 to 25% O2

0 to 10% O2

21.6 mA

3.5 mA 220 V

115 V Default position (Ex-factory)

4-20 mA requires external power

SW 1

SW2

Note:

1 2 3 4

TP1

J1

TP2

The 115 V option at switch SW2 position 4 is active only when the heater voltage option is set to manual in the software.

TP4

RED YEL GRN ORG

TP3

TP5

37260012

TP6

LOGIC I/O

This two-terminal logic contact can be configured either as a solid-state relay-activated alarm or as a bi-directional calibration handshake signal to an IMPS 4000 or SPS 4001B. The configuration of this signal depends on the setting of the LOGIC I/O PIN MODE via HART/AMS or LOI. The ten different modes available are explained in Table 4-1. Alarm When configured as an alarm, this signal alerts you to an out-of-spec condition. The output is +5 Vdc in series with a 340 ohm resistor. For optimum performance, Rosemount Analytical recommends connecting the output to a Potter & Brumfield 3.2 mA DC relay (P/N R10S-E1Y1-J1.0K).

4-4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Of the ten modes in Table 4-1, mode 1 through mode 7 are the alarm modes. The factory default is mode 5 for Oxymitter 4000 units without an IMPS 4000 or SPS 4001B. In this mode, the output will signal when a unit alarm or a CALIBRATION RECOMMENDED indication occurs. Calibration Handshake Signal If using an optional IMPS 4000 or SPS 4001B, the logic I/O must be configured for calibration handshaking. Of the ten modes in Table 4-1, only modes 8 and 9 are configured for calibration handshaking. For an Oxymitter 4000 with an IMPS 4000 or an SPS 4001B, the factory sets the default to mode 8. In this mode, the logic I/O will be used to communicate between the Oxymitter 4000 and the sequencer and to signal the sequencer when a CALIBRATION RECOMMENDED indication occurs.

Table 4-1. Logic I/O Configuration (as set at HART/AMS or LOI)

Mode

Configuration

0 1 2 3 4

The unit is not configured for any alarm condition. The unit is configured for a Unit Alarm. The unit is configured for Low O2. The unit is configured for both a Unit Alarm and Low O2. The unit is configured for a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for both a Unit Alarm and a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for both a Low O2 and High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for a Unit Alarm, a Low O2, and a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for a calibration handshake with IMPS 4000 or SPS 4001B. CALIBRATION RECOMMENDED will initiate the calibration cycle. The unit is configured for a calibration handshake. CALIBRATION RECOMMENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4001B.

5* 6 7 8** 9

*The default condition for an Oxymitter 4000 without an IMPS 4000 or SPS 4001B. **The default condition for an Oxymitter 4000 with an IMPS 4000 or SPS 4001B.

4-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Recommended Configuration

Recommended Configuration 4-20 mA Signal The 4-20 mA signal is linear, and can be ranged by the user for O2 range from 0-40% O2. It should be noted that the 4-20 mA signal will go to one of several default values under certain conditions: Condition

Default

Option

In calibration

4-20 mA signal responds normally to cal gas

4-20 mA signal holds last value during cal. (recommended only if several O2 probes are being averaged together) none

O2 over preset range

4-20 mA signal defaults to 20.5 mA

Critical alarm

4-20 mA signal defaults to 3.5 mA

4-20 mA signal dfaults to 21.1 mA

Dead Instrument

4-20 mA signal goes to zero mA

none

It is very important that the control system be configured to recognize these various signal levels, and operators be briefed as to their meaning. Calibration Rosemount Analytical recommends utilizing an autocalibration system, actuated by the "calibration recommended" diagnostic. New O2 cells may operate for more than a year, but older cells may require recalibration every few weeks as they near the end of their life. This strategy ensures that the O2 reading is always accurate, and eliminates many unnecessary calibrations based on calendar days or weeks since previous calibration. When utilizing the SPS 4001B or IMPS 4000, consider wiring some or all associated alarm contacts. 1. CALIBRATION INITIATE. Contact from the control room to an SPS 4001B or IMPS 4000 (one per probe) provides the ability to manually initiate a calibration at any time from the control room. Note that calibrations can also be initiated from a HART handheld communicator, from Asset Management Solutions software, or from the keypad on the Oxymitter 4000. 2. IN CALIBRATION. One contact per probe provides notification to the control room that the "calibration recommended" diagnostic has initiated an automatic calibration through the SPS 4001B or IMPS 4000. If the O2 signal is being utilized in an automatic control loop, this contact should be utilized to place the control loop into manual during calibration. 3. CALIBRATION FAILED. One contact per probe from an SPS 4001B or IMPS 4000 to the control room for notification that the calibration procedure failed. Grouped with this alarm is an output from a pressure switch which indicates when the calibration gas bottles are empty. 4. 4-20 mA SIGNAL DURING CALIBRATION. The 4-20 mA signal can be configured to respond normally during any calibration, or it can be configured to hold the last O2 value upon the initiation of calibration. The factory default is for the 4-20 mA signal to track (operate normally) throughout calibration. Holding the last O2 value may be useful if several probes are being averaged for the purpose of automatic control. Unless several probes are being averaged, always place control loops that are using the O2 signal into the manual mode prior to starting the calibration. 4-6

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Section 5

Startup and Operation of Oxymitter 4000 with Membrane Keypad Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-2

POWER UP

Startup Display When power is applied to the probe, the cell heater turns on. It takes approximately one half hour for the cell to heat to operating temperature. This condition is indicated by the top four LEDs (DIAGNOSTIC ALARMS) on the membrane keypad (Figure 5-1). Starting with the CALIBRATION LED, the LEDs light in ascending order until all four LEDs are on. At this point, all four turn off and the cycle starts again. This ramp cycle continues until the cell is up to operating temperature. Operating Display The ramp cycle turns into a cycle where the diagnostic LEDs light in sequence from the top to the bottom, one at a time. After the bottom LED turns on, the sequence starts again at the top with the HEATER T/C LED (Figure 5-1).

Figure 5-1. Startup and Normal Operation HEATER T/C HEATER HEATER T/C HEATER O2 CELL CALIBRATION

O2 CELL SW2

CALIBRATION

ON

DIAGNOSTIC ALARMS

CALIBRATION RECOMMENDED

INC

HIGH GAS

LOW GAS

DEC

DEC

TP1

1

J1

TP3 TP4

2

3

4

1

2

3

4

Lighting sequence during warm-up (Startup display)

TP2

HEATER T/C CAL

HEATER TEST GAS + PROCESS % O2

TP5

O2 CELL

TP6

CALIBRATION

1

2

3

4

1

2

3

4

Lighting sequence during normal operation (Operating display)

http://www.processanalytic.com

22220056

INC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

RED YEL GRN ORG

TEST POINTS

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Error

If there is an error condition at startup, one of the diagnostics LEDs will be blinking. Refer to Section 8: Troubleshooting, to determine the cause of the error. Clear the error, cycle power, and the operating display should return. Keypad The five membrane keys on the membrane keypad are only used during calibration to adjust the high and low gas and to initiate the calibration sequence (Figure 5-2). Reference Air Ensure reference air, if used, is set to 0.25 l/min (0.5 scfh)

OPERATION Overview

Ensure the Oxymitter 4000 is at normal operation. The diagnostic LEDs will display the operating cycle. All other LEDs should be off (See Figure 5-1). DIAGNOSTIC ALARM LEDs If there is an error in the system, one of these LEDs will flash various blink codes (See Section 8: Troubleshooting). In the case of multiple errors, only one will be displayed based on a priority system. Correct the problem and cycle power. The operating display will return or the next error will be displayed. The alarms are: HEATER T/C HEATER O2 CELL CALIBRATION CALIBRATION RECOMMENDED LED Turns on when the system determines that a calibration is recommended. Further information is available in Section 9: Maintenance and Service. TEST POINTS Test points 1 through 6 will allow you to monitor with a multimeter: the heater thermocouple, O2 cell millivolt, and the process O2. 1. TP1 and TP2 monitor the oxygen cell millivolt output which equates to the percentage of oxygen present. 2. TP3 and TP4 monitor the heater thermocouple. 3. TP5 and TP6 monitor the process gas or the calibration gas parameter. CAL LED The CAL LED is on steady or flashing during calibration. Further information is available in Section 9: Maintenance and Service.

5-2

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 5-2. Calibration Keys Diagnostic LEDs

Membrane Keys DIAGNOSTIC ALARMS

HEATER T/C HEATER 02 CELL CALIBRATION

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

02 CELL mV + 02 CELL mv HEATER T/C + HEATER T/C -

CAL TEST GAS + PROCESS % 02

Membrane Key Membrane Keys

22220023

TEST POINTS

Keys INC and DEC. The INC and DEC keys are used to set the values of the calibration gases. Attach a multimeter across TP5 and TP6. The calibration and process gases can now be monitored. Pressing the INC or DEC once will cause the output to switch from the process gas to the calibration gas. Pressing INC or DEC a second time will increase or decrease the calibration gas parameter. If the keys have been inactive for one minute, the output reverts to the process gas. When a calibration has been initiated, the value at TP5 and TP6 is the % O2 seen by the cell. Oxygen levels, as seen on the multimeter, are: 8.0% O2 = 8.0 volts DC 0.4% O2 = 0.4 volts DC CAL The CAL key can: • Initiate a calibration. • Sequence through calibration. • Abort the calibration. NOTE Refer Section 9: Maintenance and Service, for calibration instructions. Model 751 Remote Powered Loop LCD Display (Optional) Refer to Remote Powered Loop LCD manual for calibration and operation.

5-3

Instruction Manual

Oxymitter 4000

5-4

IM-106-340, Rev. 4.0 February 2006

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 6

Oxymitter 4000

Startup and Operation of Oxymitter 4000 with LOI Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-1 Start Up Oxymitter 4000 Calibration . . . . . . . . . . . . . . . . . page 6-3 Navigating the Local Operator Interface . . . . . . . . . . . . . page 6-3 LOI Key Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-4 LOI Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-4 Oxymitter 4000 Setup at the LOI . . . . . . . . . . . . . . . . . . . . page 6-6 LOI Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-9 Oxymitter 4000 Test Points . . . . . . . . . . . . . . . . . . . . . . . . page 6-10 Remote Powered Loop LCD Display (Optional) . . . . . . . . page 6-10

POWER UP

Startup Display When power is applied to the probe, the cell heater turns on. It takes approximately one half hour for the cell to heat to operating temperature. This condition is indicated by a "warm up" display on the LOI (Figure 6-1). This message will continue to display until the cell is up to operating temperature. Operating Display The normal operating display is the % O2 concentration. The "normal" display is shown in Figure 6-2. Error If there is an error condition at startup, an alarm message will be displayed. Refer to Section 8: Troubleshooting, to determine the cause of the error. Clear the error, cycle power, and the % O2 display should return. LOI The Local Operator Interface can be used to change the software and alarm settings, to adjust the high and low gas settings, and to initiate the calibration sequence. Refer to the LOI menu (Figure 6-4).

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 6-1. Startup Display

37260035

O2: Ø.ØØ% LK warm up 367dgC

Figure 6-2. O2 Concentration Display

LK

37260036

O2: 2.59% normal

6-2

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 6-3. LOI Features

Selection Arrow

Touch Confirmation LED

Selection Arrow

Selection Arrows

START UP OXYMITTER 4000 CALIBRATION

37260054

LCD Display Window

Refer to Section 9: Maintenance and Service, for calibration instructions.

NAVIGATING THE LOCAL OPERATOR INTERFACE Overview

The Local Operator Interface (LOI), shown in Figure 6-3, utilizes a bright blue gas-fluorescent display. Intensity is adjustable. There is an Infrared LED source and a detector for each key. The detectors can detect a finger placed above the button through the glass window. There is no need to open the instrument in bad weather in order to access the electronics. It should be noted that the Oxymitter 4000 also utilizes HART communications, permitting access to all instrument functionality anywhere the 4-20 mA signal terminates via a HART model 275/375 handheld communicator.

Lockout

The Local Operator Interface (LOI) has a lockout feature that prevents nuisance actuation by someone brushing against the glass window, raindrops, dirt, insects, etc. This lockout mode is automatically established when no buttons are pushed for 30 seconds (default). This countdown to lockout is configurable.

6-3

Instruction Manual

Oxymitter 4000

IM-106-340, Rev. 4.0 February 2006

In order to unlock the display, input a "Z" pattern. First, push the top left (gray) arrow, then the top right, followed by the bottom left and finally the bottom right. The "LK" notation in the upper right corner of the display will now disappear. Push the gray arrow at the top left hand corner once more to enter into the menu structure. Once one moves deeper into the menu structure, additional time is provided to the user so that the lockout initiation does not become a nuisance. This additional "revert" time is defaulted at one hour and is also user configurable.

LOI KEY DESIGNATIONS

The gray key (top left) will move one level higher in the menu structure. When entering numbers, this key will move the cursor to the left. This key also doubles as an "Enter" key, once numbers are entered, and when the cursor is moved to it's left-most position. The new data entry value will appear in the top line of the LOI display once it is accepted. The blue key (bottom left) acts as a selector when choosing from among a number of menu items. This key also will move the cursor to the right when entering numbers. Up/Down keys (to the left side of the keypad) are used to increment up and down when selecting from a series of menu picks. They are also used for incrementing values up and down for data input.

LOI MENU TREE

This LOI menu for the Oxymitter 4000 is shown in Figure 6-4. This menu tree is specific to the Oxymitter 4000. The menu tree will assist in navigating the LOI. Menu items in normal text display information, only. Menu Items in italics permit data entry. Menu items in bold text are procedures.

6-4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 6-4. Menu Tree for Local Operator Interface on the Oxymitter 4000 (Sheet 1 of 2) O2 Temp O2 Temp-MAX Board Temp Board Temp-MAX

Temperatures

SENSOR DATA

_____dgC _____dgC _____dgC _____dgC

Voltages

O2 Sensor O2 Sensor T/C Board Temp IC

_____mV _____mV _____mV

Output Values

O2 Analog % O2 Analog mA

_____% ____mA

O2 Slope O2 Constant O2 Cell Imped

____ mV/D ____ mV ____ ohm

Pre O2 Slope Pre O2 Constant

_____mV/D _______mV

O2% 2.59% LK normal Start Calib

NOTE Use Z pattern touch command to unlock menu.

Current Calib

Previous

CALIBRATION Cal Constants

Failed Calib

Cal Status

(CONTINUED ON SHEET 2)

Bad O2 Slope Bad O2 Constant

Calib Step Calib Time Next O2 Cal

_____mV/D _______mV

_______ ___Sec. ___H

NOTE For this menu column, the selections in Italics are user configurable. All other parameters are display only.

Idle Recommend Cal Apply Gas 1 Flow Gas 1 Read Gas 1 Done Gas 1 Apply Gas 2 Flow Gas 2 Read Gas 2 Done Gas 2 Cal Abort Stop Gas Purge

37260017

Abort Calib

6-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 6-4. Menu Tree for Local Operator Interface (LOI) on the Oxymitter 4000 (Sheet 2 of 2)

O2 Gas 1 O2 Gas 2 O2-Reset Vals O2 Out Tracks O2 Cal Intervl O2-Next Cal Gas Time Purge Time Auto Calib?

Calib Setup

Analog Input/Output

Digital

SYSTEM

_____% _____% Yes/No Yes/No ____H ____H ___Sec. ___Sec. Yes/No

O2 Type O2 Range O2 Alarm Level Do O2 Trim

_______ ______% _____mA

Logic IO Mode See Table 4-1 Low O2 Alarm See “Abort Calibration” in Section 9. Input State Force Output

Parameters

O2 Slope O2 Constant O2 T90 Time Auto Tune? Lockout Time Revert Time Luminance

____ mV/D ____ mV 0:00 Yes/No 0:00 0:00 ______

Software

Version Checksum Build Number Build Date Test Code SW Err File SW Err Line

xxx xxx xxx xxxxxx xx xx xx

Status

Alarms __________ PID Parameters 115/220 Reset Device? Yes/No (Cal. required after reset)

NOTE In column four of this menu, the selections in Italics are user configurable. Bold text selections are procedures; related instructions are displayed on the LOI. All other parameters are display only.

OXYMITTER 4000 SETUP AT THE LOI

37260018

(CONTINUED FROM SHEET 1)

In setting up the Oxymitter 4000 from the LOI, it is best to start at the SYSTEM/Calibration Setup menu, Figure 6-4. SYSTEM/Calibration Setup O2 Gas #1 - Enter the high or low cal gas value (the order is not important). O2 Gas #2 - Enter the second cal gas value. NOTE Refer to Section 9: Maintenance and Service, for calibration instructions.

6-6

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 NOTE Rosemount Analytical recommends 0.4% O2 and 8% O2 for calibration gases. O2 Reset Values - Resets factory default values. O2 Output Tracks - 4 to 20 mA signal can be held at the last value during calibration, or the signal can be left to track the cal gases. O2 Cal Interval - If automatic calibration is selected, this selects the interval between calibrations. O2 Next Cal - If automatic calibration is selected, this selects the time until the first initial calibration takes place. Gas Time - How long should each cal gas flow. Factory default is 300 seconds, but the user may want to vary this depending upon the length of calibration gas tubing runs. Purge Time - Used if the O2 output is selected to hold the last value during calibration. After the second cal gas is removed, how long until the sensor comes back to the normal process reading, and the 4-20 mA signal can be released. Auto Calib? - Select "Yes" if an SPS or IMPS autocalibration system is part of the system. SYSTEM/Input/Output Analog Pertaining to the analog 4-20 mA signal representing O2. O2 Type - 4-20 mA signal may be configured to increase with increasing O2 or the reverse. O2 Range - Upper O2 range is user selectable. O2 Alarm Level - User can configure the digital output to alarm at a given O2 level. Do O2 Trim - Procedure for calibrating the 4-20 mA signal to a precision mA source. Procedure is intuitive. Digital A bi-directional logic signal may be configured as an alarm, or as a calibration handshake signal. Logic I/O Mode - One of 9 different sets of conditions can be set for the digital signal. See Table 8-2. Low O2 Alarm - If any of the conditions noted above include a low O2 process alarm, set the value here. Input State - Notes the current condition of the bi-directional digital signal. Force Output - Forces the output state of the signal to either open or closed. This is used primarily when diagnosing potential problems with this signal.

6-7

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 SYSTEM/Parameters

O2 Slope - O2 slope is data regarding the strength of the sensing cell output. This information is automatically calculated after a calibration, and the user does not normally input this data. O2 Constant - O2 constant is the amount of voltage a cell generates with ambient air as the calibration gas. Again, this is normally calculated as a result of calibration, and is not normally input by the user. O2 T90 Time - Some users may feel that the O2 reading is too active for certain processes. This feature permits the user to dampen the O2 signal. The default value is zero seconds dampening. Auto Tune - The electronics detects the line voltage powering the instrument automatically, and picks proper algorithms for heater control. User can force a high voltage algorithm, or a low, but Auto Tune is the default, and is recommended. Lockout Time - Keypad lockout time default is 30 sec., but it is user configurable. A "Z" keypad pattern will unlock the keypad. Revert Time - Once a user goes one level deep into the menu structure, an additional "revert time" is provided to prevent nuisance lockouts. One hour is the default, and it is user configurable. Luminance - Gas fluorescence brightness is user adjustable. SYSTEM/Status Alarms - Diagnostic alarms. Section 8: Troubleshooting. PID Parameter - Displays the line voltage, powering the Oxymitter, and infers the temperature control algorithm being used to control heater temperature. Reset Device - Device can be reset here as opposed to re-powering. Calibration parameters will be lost. SYSTEM/Software This is data regarding the Oxymitter 4000 software version, and errors that may have occurred. SENSOR DATA Displays information about the O2 cell and thermocouple.

6-8

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Temperatures O2 Temp - Indicates the thermocouple temperature at the sensing cell; this should always be 736°C. O2 Temp Max - Maximum temperature the cell has seen. (Some process temperatures can exceed the 736°C setpoint temperature, and this will indicate this condition.) Board Temp - The temperature inside the Oxymitter electronics housing (85°C is the max.). Board Temp Max - This is the maximum temperature that the electronics has experienced over time. Voltages The raw mV signals feeding the temperature indications listed in the previous paragraph. Output Values Indication of the current readings for O2 and mA.

LOI INSTALLATION

The LOI module connects to the top of the electronic assembly in the electronics housing. There are four matching connectors (Figure 6-5) on the back of the LOI module that allow the user to orient (rotate) the LOI as desired.

Figure 6-5. LOI Module Connectors

LOI Module Rear View

37260055

Connector Receptacles

6-9

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 OXYMITTER 4000 TEST POINTS

Refer to Figure 6-6. System test points are located on the board below the LOI module. Test points 1 through 6 allow you to monitor with a multimeter: the heater thermocouple, the O2 cell millivolt, and the process O2. • TP1 and TP2 monitor the oxygen cell millivolt output which equates to the percentage of oxygen present. • TP3 and TP4 monitor the heater thermocouple. • TP5 and TP6 monitor the process gas or the calibration gas parameter.

REMOTE POWERED LOOP LCD DISPLAY (OPTIONAL)

Refer to Remote Powered Loop LCD manual for calibration and operation.

Figure 6-6. Oxymitter 4000 Test Points

TP1

J1

TP2 TP4

RED YEL GRN ORG

TP3

TP5

37260037

TP6

6-10

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 7

Oxymitter 4000

HART/AMS Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-1 HART Communicator Signal Line Connections . . . . . . . page 7-2 HART Communicator PC Connections . . . . . . . . . . . . . . . page 7-2 Off-Line and On-Line Operations . . . . . . . . . . . . . . . . . . . page 7-4 Logic I/O Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-4 HART/AMS Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-4 HART Communicator O2 Cal Method . . . . . . . . . . . . . . . . page 7-8 Defining a Timed Calibration via HART . . . . . . . . . . . . . . page 7-9 D/A Trim Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-9

OVERVIEW

The HART Communicator is a handheld communications interface device. It provides a common communications link to all microprocessor-based instruments that are HART compatible. The handheld communicator contains an 8 x 21 character liquid crystal display (LCD) and 25 keys. A pocket-sized manual, included with the HART Communicator, details the specific functions of all the keys. To interface with the Oxymitter 4000, the HART Communicator requires a termination point along the 4-20 mA current loop and a minimum load resistance of 250 ohms between the communicator and the power supply. The HART Communicator accomplishes its task using a frequency shift keying (FSK) technique. With the use of FSK, high-frequency digital communication signals are superimposed on the Oxymitter 4000's 4-20 mA current loop. The HART communicator does not disturb the 4-20 mA signal, since no net energy is added to the loop. The HART Communicator may be interfaced with a personal computer (PC), providing that special software has been installed. To connect the HART Communicator to a PC, an interface adapter is required. Refer to the proper HART Communicator documentation in regard to the PC interface option.

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 HART COMMUNICATOR SIGNAL LINE CONNECTIONS

The HART Communicator can connect to the Oxymitter 4000's analog output signal line at any wiring termination in the 4-20 mA current loop. There are two methods of connecting the HART Communicator to the signal line. For applications in which the signal line has a load resistance of 250 ohms or more, refer to method 1. For applications in which the signal line load resistance is less than 250 ohms, refer to method 2. Method 1, For Load Resistance

≥ 250 Ohms

Refer to Figure 7-1 and the following steps to connect the HART Communicator to a signal line < 250 ohms or more of load resistance.

Explosions can result in death or serious injury. Do not make connections to the HART Communicator's serial port, 4-20 mV signal line, or NiCad recharger jack in an explosive atmosphere.

Using the supplied lead set, connect the HART Communicator in parallel with to the Oxymitter 4000. Use any wiring termination points in the analog output 4-20 mA signal line. Method 2, For Load Resistance < 250 ohms Refer to Figure 7-2 and the following steps to connect the HART Communicator to a signal line with < 250 ohms load resistance.

Explosions can result in death or serious injury. Do not make connections to the HART Communicator's serial port, 4-20 mV signal line, or NiCad recharger jack in an explosive atmosphere.

1. At a convenient point, break the analog output 4-20 mA signal line and install the optional 250 ohm load resistor. 2. Plug the load resistor into the loop connectors (located on the rear panel of the HART Communicator).

HART COMMUNICATOR PC CONNECTIONS

There is an option to interface the HART Communicator with a personal computer. Load the designated AMS software into the PC. Then link the HART Communicator to the PC using the interface PC adapter that connects to the serial port (on the communicator rear panel). Refer to the proper HART Communicator documentation in regard to the PC interface option.

7-2

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 7-1. Signal Line Connections, ≥ 250 Ohms Load Resistance

AC

L1

AC

N

RL ≥ 250Ω

+ -

4-20 mA Signal Line

+ 4-20

-

Terminal Block

Analog Output Device

Loop Connectors

SERIAL PORT & BATTERY

LOOP CONNECTORS

CHARGER MUST

USE INTERFACE 00275 0013 ONLY

SERIAL PORT

NOT BE USED IN HAZARDOUS AREAS

23230001

HART Communicator Lead Set HART Communicator Rear Panel

Figure 7-2. Signal Line Connections, < 250 Ohms Load Resistance

AC

L1

AC

N

RL < 250Ω + -

4-20 mA Signal Line

+ 4-20

-

Terminal Block

Analog Output Device

Loop Connectors

SERIAL PORT & BATTERY CHARGER MUST

LOOP CONNECTORS

250 Ohm Load Resistor (Note)

USE INTERFACE 00275 0013 ONLY

SERIAL PORT

NOT BE USED IN

HART Communicator HART Communicator Rear Panel

Note: The signal loop must be broken to insert the optional 250 Ohm load resistor.

23230002

HAZARDOUS AREAS

7-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 OFF-LINE AND ON-LINE OPERATIONS

The HART Communicator can be operated both off-line and on-line. Off-line operations are those in which the communicator is not connected to the Oxymitter 4000. Off-line operations can include interfacing the HART Communicator with a PC (refer to applicable HART documentation regarding HART/PC applications. In the on-line mode, the communicator is connected to the 4-20 mA analog output signal line. The communicator is connected in parallel to the Oxymitter 4000 or in parallel to the 250 ohm load resistor. NOTE If the HART Communicator is turned on while connected to the 4-20 mA analog output signal line, an undefined status indication appears while the communicator warms up. Wait until the warm-up period ends to continue. The opening menu displayed on the LCD is different for on-line and off-line operations. When powering up a disconnected (off-line) communicator, the LCD will display the Main Menu. When powering up a connected (on-line) communicator, the LCD will display the On-line Menu. Refer to the HART Communicator manual for detailed menu information.

LOGIC I/O CONFIGURATIONS

The Oxymitter 4000 logic I/O output can be configured for ten different modes through HART/AMS. The factory default condition is Mode 5. A list of possible configurations appear in Table 7-1. The Unit Alarm configuration available for Modes 1, 3, 5, and 7 refers to the diagnostic alarm faults in Table 8-1.

HART/AMS MENU TREE

Table 7-1. Logic I/O Configuration (as set at HART/AMS or LOI)

This section consists of a menu tree for the HART Communicator. This menu is specific to Oxymitter 4000 applications.

Mode

Configuration

0 1 2 3 4

The unit is not configured for any alarm condition. The unit is configured for a Unit Alarm. The unit is configured for Low O2. The unit is configured for both a Unit Alarm and Low O2. The unit is configured for a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for both a Unit Alarm and a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for both a Low O2 and High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for a Unit Alarm, a Low O2, and a High AC Impedance/CALIBRATION RECOMMENDED. The unit is configured for a calibration handshake with IMPS 4000 or SPS 4001B. CALIBRATION RECOMMENDED will initiate the calibration cycle. The unit is configured for a calibration handshake. CALIBRATION RECOMMENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4001B.

5* 6 7 8** 9

*The default condition for an Oxymitter 4000 without an IMPS 4000 or SPS 4001B. **The default condition for an Oxymitter 4000 with an IMPS 4000 or SPS 4001B.

7-4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 7-3. HART/AMS Menu Tree (Sheet 1 of 3)

VIEW FLD DEV VARS

PROCESS VARIABLES

O2 value O2 cell temp CJ temp

VIEW PV-Aout

PV is PV O2 value PV % rnge PV AO

VIEW SV

SV is Cold Junct SV __ mV

VIEW TV

TV is Cell TV __ mV

VIEW 4V

4V is Cell TC 4V __ mV

VIEW OUTPUT VARS

VIEW FLD DEV mV

Cell mV Cell TC mV CJ mV Status Group 1

DEVICE SETUP PV PV AO PV LRV PV URV

STATUS

Status Group 2

Cell Temp Low Cell Temp High Cell Open High Cell Imp. CK.ER - EEPROM Cal.Error Slope Cal. Recommended

Status Group 3

Cal. Error Const. Last Cal. Failed

Operate Model AO Saturated

DIAG/SERVICE

Open T/C Shorted T/C Reversed T/C Heater Open Cell Temp Very HI High Case Temp

AO1 Out Rnge lim

AO Fixed Max Case Temp LOOP TEST

Loop test method...

O2 CALIBRATE

PERFORM O2 CAL

O2 Cal Optrak TG? CalState

O2 CAL STATUS

CalState TimeRemain Present O2

LAST CALCONSTANTS

Cal slope Cal const Cell Imp

RESET CALCONSTANTS

Reset CalConstants method...

O2 Cal method... Refer to “HART Communicator O2 Cal Method” for the complete O2 calibration method using the HART Communicator.

D/A TRIM

D/A trim method

26170028

(CONTINUED ON SHEET 2)

7-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 7-3. HART/AMS Menu Tree (Sheet 2 of 3) (CONTINUED FROM SHEET 1)

BASIC SETUP

Tag ASSIGN PV & SV

SELECT O2 RANGE

DEVICE INFORMATION

S/W VERSION INFO

SENSORS

SIGNAL CONDITION

PV is SV is TV is 4V is

URV LRV

Oxygen Cold Junct Cell Cell TC

____% ____%

Dev id Descriptor Message Date Final asmbly num Snsr s/n

Ver Chk sum Bld num Bld date

O2 O2 CELLTEMP COLDJUNCTEMP O2 CELL MV O2 CELLTCMV COLD JUNC MV

LIMITS DISPLAYED

PV URV PV LRV PV % rnge PV AO ____ mA PV AO Alrm typ

DEVICE SETUP PV PV AO PV LRV PV URV

OUTPUT CONDITION

DETAILED SETUP

ANALOG OUTPUT

HART OUTPUT

ALARM OUTPUT

O2

LOOP TEST

Loop test method...

D/A TRIM

D/A trim method...

Poll addr Num req preams Logic I/O Pin State Logic I/O Pin Mode

SLOPE

No Alarm Unit Alarm Low O2 Alarm Low O2/Unit Alarm Cal Rec Cal Rec/Unit Alarm Low O2/Cal Rec Low O2/Unit/Cal Rec Cal Rec/Handshake Handshake

CONSTANT

O2 CALIBRATION

O2 ALARMS

7-6

HighTG LowTG OPtrak TG? TGtime PurgeTime Cal Mode Cal Intrvl h Next CalTime h LoAlarmSP

OP locks OP tracks Manual Auto 35830006

(CONTINUED ON SHEET 3)

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 7-3. HART/AMS Menu Tree (Sheet 3 of 3)

DEVICE INFORMATION

CAL INFO

Optrak TG? Tgtime PurgeTime LowTG HighTG Cal slope Cal const CellImp Imp Delta

DEVICE CONFIG

Slope Constant

OUTPUTS CONFIG

URV LRV LoAlarmSP I/O Pin Mode Poll addr Num req preams

REVIEW

DEVICE SETUP PV PV AO PV LRV PV URV

26170030

(CONTINUED FROM SHEET 2)

Manufacturer Model Dev id Tag Descriptor Message Date Final asmbly num Snsr s/n Fld dev rev Hardware rev Software rev Universal rev

7-7

Instruction Manual

Oxymitter 4000 HART COMMUNICATOR O2 CAL METHOD

IM-106-340, Rev. 4.0 February 2006

Use the following procedure to perform a calibration using the HART Communicator. If necessary, use the menu tree in Figure 7-3 (sheet 1 of 3) for reference. NOTE To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number. To return to a preceding menu, press the left arrow key. 1. From the PERFORM O2 CAL screen, select menu item 1, O2 CAL, to access the O2 calibration procedure.

Failure to remove the Oxymitter 4000 from automatic control loops prior to performing this procedure may result in a dangerous operating condition.

2. In the first O2 CAL screen, a "Loop should be removed from automatic control" warning appears. Remove the Oxymitter 4000 from any automatic control loops to avoid a potentially dangerous operating condition and press OK. 3. The next several screens indicate the calibration status. At each of the following status prompts, select menu item 2, NEXT CAL STEP: COMPLETE CAL RECOMMENDED APPLY GAS 1 GAS 1 FLOW 4. At this point, select menu item 4, EXIT, to leave the O2 CAL procedure. 5. From the PERFORM O2 CAL screen, view menu item 3, CALSTATE, to monitor the calibration status as it updates. Or, access the O2 CALIBRATE screen and select menu item 2, O2 CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O2, as the calibration status updates. 6. When CALSTATE displays APPLY GAS 2, return to the O2 CAL procedure. 7. When the "Loop should be removed from automatic control" warning appears, return the Oxymitter 4000 to the automatic control loops previously removed and press OK. 8. At the STOP GAS status prompt, select menu item 2, NEXT CAL STEP. When the status displays PURGING, select menu item 4, EXIT, to leave the O2 CAL procedure. 9. From the PERFORM O2 CAL screen, view menu item 3, CALSTATE, to monitor the calibration status as it updates. Or, access the O2 CALIBRATE screen and select menu item 2, O2 CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O2, as the calibration status updates. 10. When CALSTATE displays STOP GAS, return to the O2 CAL procedure.

7-8

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 11. When the "Loop should be returned to automatic control" message appears, return the Hazardous Area Oxymitter 4000 to the automatic control loops previously removed and press OK. 12. At the STOP GAS status prompt, select menu item 2, NEXT CAL STEP When the status displays PURGING, select menu item 4, EXIT, to leave the O2 CAL procedure. 13. From the PERFORM O2 CAL screen, view menu item 3, CALSTATE, to monitor the calibration status as it updates. Or, access the O2 CALIBRATE screen and select menu item 2, O2 CAL STATUS, to view menu item 1, CAL-STATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O2, as the calibration status updates. 14. When CALSTATE displays COMPLETE, the calibration is finished.

DEFINING A TIMED CALIBRATION VIA HART

Use the following procedure to specify a time interval (in hours) at which the Oxymitter 4000 will be automatically calibrated. If necessary, use the menu tree in Figure 7-3 (Sheet 2 of 3) for reference. NOTE To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number. To return to a preceding menu, press the left arrow key. 1. From the DEVICE SETUP screen, select DETAILED SETUP. 2. From the DETAILED SETUP screen, select O2 CALIBRATION. 3. From the O2 CALIBRATION screen, select menu item 6, CAL MODE. Set the CAL MODE to AUTO. 4. Return to the O2 CALIBRATION screen and select menu item 7, CAL INTRVL. 5. At the prompt, input a time interval (in hours) at which an automatic calibration will occur; then press ENTER.

D/A TRIM PROCEDURE

The D/A trim procedure is used to calibrate the 4-20 mA output signal to a precision mA measurement device (calibrated digital ammeter, etc.). The procedure is interactive and stored in the Oxymitter software. Use one of the following communication methods to access the D/A trim procedure: LOI Menu 1. Use the "Z" pattern key entry to access the LOI menu. 2. Press the down key two times to access the SYSTEM menu. 3. Press the down key once to access the Input/Output menu. 4. From the Analog selection, press the right-pointing key to display the Analog submenu listing. 5. Press the down key as needed to access Trim O2 Out. 6. Press the Enter key to start the trim procedure. Follow the LOI display prompts to perform the trim procedure.

7-9

Instruction Manual

Oxymitter 4000

7-10

IM-106-340, Rev. 4.0 February 2006

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 8

Oxymitter 4000

Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-3 Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-3 Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8-4 Identifying And Correcting Alarm Indications . . . . . . . . . page 8-5 Calibration Passes, but Still Reads Incorrectly . . . . . . . . page 8-22

OVERVIEW

While the Oxymitter 4000 electronics provides a significant number of diagnostic alarms to assist in troubleshooting potential problems, it is good to place these alarms in perspective with respect to the instrument's operating principles: When the Zirconium Oxide sensing cell is heated to its setpoint [1357°F (736°C)], the cell will generate a voltage that represents the difference between the process O2% and the reference O2% inside the probe (20.95% O2 ambient air). Test points, Figure 8-1, are provided to read the raw millivolt value generated by the thermocouple that controls the cell temperature and also the raw cell signal. The cell temperature at test points 3 and 4 should always be stable at approximately 29 to 30 millivolts, which represents the [1357°F (736°C)] setpoint temperature. When flowing calibration gasses, the raw cell millivolt value at test points 1 and 2 should represent the levels on the chart in Figure 8-1. Note that the raw cell millivolt value increases logarithmically as the O2 concentration decreases.

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-1. O2 Sensor mV Reading vs. % O2 at 1357°F (736°C) (Reference Air, 20.9% O 2)

200

O

O O2 Sensor Performance at 1357 F (736 C)

EMF (mV)

150

100

0

0

0.01

0.1

1

10

100

Concentration O2 (%)

O2 %

100

20

15

10

9

8

7

6

5

4

EMF(mV)

-34

1.0

7.25

16.1

18.4

21.1

23.8

27.2

31.2

36.0

3

2

1

0.8

0.6

0.5

0.4

0.2

0.1

0.01

42.3

51.1

66.1

71.0

77.5

81.5

86.3

101.4

116.6

166.8

O2 % EMF(mV)

8-2

37260043

50

Instruction Manual IM-106-340, Rev. 4.0 February 2005

Oxymitter 4000

Install all protective equipment covers and safety ground leads after troubleshooting. Failure to install covers and ground leads could result in serious injury or death.

GENERAL

The troubleshooting section describes how to identify and isolate faults that may develop in the Oxymitter 4000. When troubleshooting, reference the following. Grounding It is essential that adequate grounding precautions are taken when installing the system. Thoroughly check both the probe and electronics to ensure the grounding quality has not degraded during fault finding. The system provides facilities for 100% effective grounding and the total elimination of ground loops. Electrical Noise The Oxymitter 4000 has been designed to operate in the type of environment normally found in a boiler room or control room. Noise suppression circuits are employed on all field terminations and main inputs. When fault finding, evaluate the electrical noise being generated in the immediate circuitry of a faulty system. Ensure all cable shields are connected to earth. Loose Integrated Circuits The Oxymitter 4000 uses a microprocessor and supporting integrated circuits (IC). If the electronics are handled roughly during installation or located where subjected to severe vibration, the ICs could work loose. Before troubleshooting the system, ensure all ICs are fully seated. Electrostatic Discharge Electrostatic discharge can damage the ICs used in the electronics. Before removing or handling the processor board or the ICs, ensure you are at ground potential.

ALARM INDICATIONS

The majority of the fault conditions for the Oxymitter 4000 will be indicated by one of the four LEDs referred to as diagnostic, or unit alarms on the operator's keypad (Figure 8-2). An LED will flash a code that will correspond to an error message. Only one LED will blink at a time. An alarm code guide is provided inside the screw-on cover for the electronics. Alarm indications will be also available via the optional LOI or the HART Model 275/375 hand-held communicator and Rosemount Analytical's Asset Management software. When the error is corrected and/or power is cycled, the diagnostic alarms will clear or the next error on the priority list will appear.

8-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-2. Diagnostic LEDs

Diagnostic LEDs

DIAGNOSTIC ALARMS

HEATER T/C HEATER 02 CELL CALIBRATION

CALIBRATION RECOMMENDED TEST POINTS

INC LOW GAS

DEC

DEC

CAL TEST GAS + PROCESS % 02 37260044

INC HIGH GAS

02 CELL mV + 02 CELL mv HEATER T/C + HEATER T/C -

ALARM CONTACTS

If autocalibration is not utilized, a common bidirectional logic contact is provided for any of the diagnostic alarms listed in Table 8-1. The assignment of alarms which can actuate this contact can be modified to one of seven additional groupings (mode 0 through mode 7) listed in Table 7-1. The logic contact is self-powered, +5 VDC, with a 340 ohm series resistance. An interposing relay will be required if this contact is to be utilized to annunciate a higher voltage device, such as a light or horn. An interposing relay may also be required for certain DCS input cards. A Potter & Brumfield R10S-E1Y1-J1.0K 3.2 mA DC or an equal interposing relay will be mounted where the contact wires terminate in the control/relay room. If autocalibration systems are utilized, the bidirectional logic contact is utilized as a "hand-shake" signal between the autocalibration system (SPS 4001B or IMPS 4000) and is unavailable for alarming purposes. The following additional contacts are provided through the autocalibration systems:

8-4

Instruction Manual IM-106-340, Rev. 4.0 February 2005

Oxymitter 4000 SPS 4001B and IMPS 4000, 1-4 probes • One contact closure per probe from the control room to the SPS 4001B or IMPS 4000 for "calibration initiate". • One contact output per probe from the SPS 4001B or IMPS 4000 to the control room for "in calibration" notification. • One contact output per probe from the SPS 4001B or IMPS 4000 to the control room for "calibration failed" notification. (Includes output from pressure switch indicating "cal gas bottles empty"). Additional IMPS 4000 Alarm Contacts • One contact per IMPS 4000 for "low calibration gas flowing". • One contact per IMPS 4000 for "high calibration gas flowing". NOTE The 4-20 mA signal can be configured to respond normally during any calibration, or can be configured to hold the last O2 value upon the initiation of calibration. Factory default is for the 4-20 mA signal to operate normally throughout calibration.

NOTE Holding the last O2 value may be useful if several probes are being averaged for the purpose of automatic control. Unless several probes are being averaged, always place any control loops using the O2 signal into manual prior to calibrating.

IDENTIFYING AND CORRECTING ALARM INDICATIONS

For an Oxymitter 4000 with a membrane keypad, faults are indicated by four diagnostic, or unit, alarm LEDs. A pattern of repeating blinks define the problem. A condensed table of the errors and the corresponding blink codes can be found on the inside right cover of the electronics housing. Table 8-1 also identifies the blink code and fault status of each LED as well as the output of the 4-20 mA signal line and a fault number that corresponds to the troubleshooting instructions provided in this section. For an Oxymitter 4000 with the optional LOI, alarm messages are displayed on the LOI display window when the alarm status display is accessed via the LOI menu. A listing of the alarm/fault messages and the related fault status descriptions and fault numbers are shown in Table 8-2.

8-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Table 8-1. Diagnostic/Unit Alarm Fault Definitions Membrane Keypad Only LED HEATER T/C

HEATER

O2 CELL

CALIBRATION

Flashes 1 2 3 4 1 2 3 4 5 1 3 4 1 2 3 **

Status Open Shorted Reversed A/D Comm Error Open High High Temp High Case Temp Low Temp High Temp High mV Bad EEprom Corrupt Invalid Slope Invalid Constant Last Calibration Failed Calibration Recommended

4-20 mA Line

Fault

Recoverable

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

No No No No No No Yes Yes Yes Yes Yes No Yes Yes Yes Yes

Dependent on position 3 of SW2* Dependent on position 3 of SW2* Dependent on position 3 of SW2* Dependent on position 3 of SW2* Dependent on position 3 of SW2* Dependent on position 3 of SW2* Dependent on position 3 of SW2* Dependent on position 3 of SW2* Dependent on position 3 of SW2* Dependent on position 3 of SW2* Track O2 Dependent on position 3 of SW2* Track O2 Track O2 Track O2 Track O2

*Critical alarm conditions will render the O2 measurement as unusable, and any of these events will cause the 4-20 mA signal to go to a user-selectable limit of 3.5 mA or 21.6 mA (position 3 of SW2). Factory default value is 3.5 mA. Alarms which are not self-clearing (Self-Clearing = NO) will require a reset. Perform the Reset Procedure in Section 3: Configuration of Oxymitter 4000 with Membrane Keypad to continue operation. **The CALIBRATION RECOMMENDED alarm flashes the Calibration Recommended LED on the operator's keypad.

Table 8-2. Diagnostic/Unit Alarm Fault Definitions - LOI Message

Status

O2 T/C OPEN O2 T/C SHORTED O2 T/C REVERSED ADC ERROR O2 HEATER OPEN VERY HI O2 TEMP BOARD TEMP HI O2 TEMP LOW O2 TEMP HI O2 CELL OPEN O2 CELL BAD EEPROM CORRUPT CALIB FAILED LINE FREQ ERROR

Heater T/C Open Heater T/CShorted Heater T/C Polarity Reversed A/D Comm Error O2 Heater Open Very High Process Temperature Electronics Overheated Low Process Temperature High Process Temperature O2 Cell Open O2 Cell Failed EEprom Failed Last Calibration Failed Incorrect Input Line Frequency Detected on Power Up

8-6

Fault Number

Self Clearing

1 2 3 4 5 6 7 8 9 10 11, 13, 14 12 15

No No No No No No Yes Yes Yes Yes Yes No Yes No

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 8-3. Fault 1, Open Thermocouple Fault 1, Open Thermocouple

HEATER T/C HEATER O2 CELL CALIBRATION

SW2 ON

DIAGNOSTIC ALARMS

Figure 8-3 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and a Oxymitter 4000 with an LOI (lower view). The upper view also shows J1 and test points TP1 through TP6, located on the microprocessor board, below the membrane keypad or the LOI module. Membrane Keypad

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1

When Fault 1 is detected, the HEATER T/C LED flashes once, pauses for three seconds, and repeats.

TP2 TP3 TP4

RED YEL GRN ORG

TEST POINTS

J1

1. Check connector J1. Ensure the connector is properly seated.

CAL TEST GAS + PROCESS % O2

2. Using a multimeter, measure the voltage from TP3+ to TP4-. If the reading is 1.2 VDC ±0.1 VDC, the thermocouple is open.

TP5 TP6

3. Remove power. Disconnect J1. Measure the resistance across the red and yellow thermocouple leads. The resistance should be approximately 1 ohm.

KEYPAD

4. If the thermocouple is open, see "Heater Strut Replacement" in Section 9: Maintenance and Service. LOI When Fault 1 is detected, the LOI displays the "O2 T/C Open" message. 1. Remove power. Unscrew and remove the LOI module from the electronic assembly. 2. Reconnect power to the Oxymitter 4000. 3. Perform the diagnostic steps 1 through 4 shown for the membrane keypad.

LOI

37260019

Alarms O2 T/C Open

8-7

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-4. Fault 2, Shorted Thermocouple

Fault 2, Shorted Thermocouple

HEATER T/C HEATER O2 CELL CALIBRATION

SW2 ON

DIAGNOSTIC ALARMS

Figure 8-4 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). The upper view also shows J1 and test points TP1 through TP6, located on the microprocessor board, below the membrane keypad or the LOI module. Membrane Keypad

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1 TP2 TP3 TP4

RED YEL GRN ORG

TEST POINTS

J1

CAL TEST GAS + PROCESS % O2

TP5

When Fault 2 is detected, the HEATER T/C LED flashes twice, pauses for three seconds, and repeats. 1. Using a multimeter, measure the voltage from TP3+ to TP4-. If the reading is 0 ±0.5 mV, then a shorted thermocouple is likely. 2. Remove power and disconnect J1.

TP6

3. Measure the resistance from TP3+ to TP4-. The reading should be approximately 20K ohms. 4. If so, the short is not on the PC board. The thermocouple wiring or the thermocouple is shorted. See "Heater Strut Replacement" in Section 9: Maintenance and Service.

KEYPAD

LOI When Fault 2 is detected, the LOI displays the "O2 T/C Shorted" message. 1. Remove power. Unscrew and remove the LOI module from the electronic assembly. 2. Reconnect power to the Oxymitter 4000. 3. Perform the diagnostic steps 1 through 4 shown for the membrane keypad.

LOI

8-8

37260020

Alarms O2 T/C Shorted

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 8-5. Fault 3, Reversed Thermocouple Fault 3, Reversed Thermocouple Wiring or Faulty PC Board

HEATER T/C HEATER O2 CELL CALIBRATION

SW2 ON

DIAGNOSTIC ALARMS

Figure 8-5 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). The upper view also shows J1 and test points TP1 through TP6, located on the microprocessor board, below the membrane keypad or the LOI module.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1

J1

Membrane Keypad

TP2 TP3 TP4

RED YEL GRN ORG

TEST POINTS

CAL TEST GAS + PROCESS % O2

When Fault 3 is detected, the HEATER T/C LED flashes three times, pauses for three seconds, and repeats. 1. Using a multimeter, measure the voltage from TP3+ to TP4-. If the reading is negative, the thermocouple wiring is reversed.

TP5 TP6

2. Check red and yellow wires in the J1 connector for the proper placement. 3. If the wiring is correct, the fault is in the PC board. See "Electronic Assembly Replacement" in Section 9: Maintenance and Service.

KEYPAD

LOI When Fault 3 is detected, the LOI displays the "O2 T/C Reversed" message. 1. Remove power. Unscrew and remove the LOI module from the electronic assembly. 2. Reconnect power to the Oxymitter 4000. 3. Perform the diagnostic steps 1 through 3 shown for the membrane keypad.

LOI

37260021

Alarms O2 T/C Reversed

8-9

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-6. Fault 4, A/D Comm Error Fault 4, A/D Comm Error Membrane Keypad

HEATER T/C HEATER O2 CELL CALIBRATION

SW2

1. Call the factory for assistance.

ON

DIAGNOSTIC ALARMS

When Fault 4 is detected, the HEATER T/C LED flashes four times, pauses for three seconds, and repeats (Figure 8-6).

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mV HEATER T/C + HEATER T/C -

TP1

J1

TP2 TP3 TP4

RED YEL GRN ORG

TEST POINTS

CAL TEST GAS + PROCESS % O2

TP5 TP6

KEYPAD

LOI When Fault 4 is detected, the LOI displays the "ADC Error" message. 1. Call the factory for assistance.

37260022

Alarms ADC Error

LOI

8-10

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 8-7. Fault 5, Open Heater Fault 5, Open Heater Figure 8-7 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and a Oxymitter 4000 with an LOI (lower view). HEATER T/C HEATER O2 CELL CALIBRATION

Membrane Keypad

SW2 ON

DIAGNOSTIC ALARMS

When Fault 5 is detected, the HEATER LED flashes once, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED TEST POINTS

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

TP1

J1

1. Remove power.

TP2 TP3 TP4

RED YEL GRN ORG

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

CAL TEST GAS + PROCESS % O2

2. Remove the electronic assembly per "Electronic Assembly Replacement" in Section 9: Maintenance and Service. 3. Using a multimeter, measure the resistance across the terminals of heater connector, J8.

TP5 TP6

4. The measurement should be approximately 72 ohms. If the heater is open, see "Heater Strut Replacement" in Section 9: Maintenance and Service.

KEYPAD

LOI When Fault 5 is detected, the LOI displays the "O2 Heater Open" message. 1. Remove power. Unscrew and remove the LOI module from the electronic assembly. 2. Perform the diagnostic steps 2 through 4 shown for the membrane keypad.

LOI

37260023

Alarms O2 Heater Open

8-11

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-8. Fault 6, High High Heater Temp

Fault 6, High High Heater Temp Figure 8-8 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). HEATER T/C HEATER O2 CELL CALIBRATION

Membrane Keypad

SW2 ON

DIAGNOSTIC ALARMS

When Fault 6 is detected, the HEATER LED flashes twice, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1

J1

TP2

1. The High High Heater Temp alarm will activate when the thermocouple produces a voltage of 37.1 mV [1652°F (900°C)].

TP3 TP4

RED YEL GRN ORG

TEST POINTS

2. The triac and the temperature control may be at fault.

CAL TEST GAS + PROCESS % O2

3. Remove power. Allow Oxymitter 4000 to cool for five minutes. Restore power.

TP5 TP6

4. If the condition repeats, replace the electronic assembly per "Electronic Assembly Replacement" in Section 9: Maintenance and Service.

KEYPAD

LOI When Fault 6 is detected, the LOI displays the "Very Hi O2 Temp" message. 1. The very high O2 temperature alarm will activate when the thermocouple produces a voltage of 37.1 mV [1652°F (900°C)]. 2. The triac and the temperature control may be at fault. 3. Remove power. Allow the Oxymitter 4000 to cool for five minutes. Restore power.

Alarms Very Hi O2 Temp

8-12

37260024

LOI

4. If the condition repeats, replace the electronic assembly per "Electronic Assembly Replacement" in Section 9: Maintenance and Service.

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 8-9. Fault 7, High Case Temp Fault 7, High Case Temp

HEATER T/C HEATER O2 CELL CALIBRATION

SW2

Membrane Keypad

ON

DIAGNOSTIC ALARMS

Figure 8-9 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view).

When Fault 7 is detected, The HEATER LED flashes three times, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1

J1

TP2 TP3 TP4

RED YEL GRN ORG

TEST POINTS

CAL TEST GAS + PROCESS % O2

DEC

1. If the case temperature exceeds [185°F (85°C)], the temperature control will shut off and the 4-20 mA signal output will go to the default value. 2. This signifies that the environment where the Oxymitter 4000 is installed exceeds the ambient temperature requirements or that heat due to convection is causing case temperature to rise above the limit.

TP5 TP6

3. Placing a spool piece between the stack flange and the Oxymitter 4000 flange may eliminate this problem.

KEYPAD

4. If a spool piece does not solve the problem, relocation is the only solution. LOI When Fault 7 is detected, the LOI displays the "Board Temp Hi" message. Refer to the comments in paragraphs 1 through 4 above.

LOI

37260025

Alarms Board Temp Hi

8-13

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-10. Fault 8, Low Heater Temp Fault 8, Low Heater Temp

Figure 8-10 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). HEATER T/C HEATER O2 CELL CALIBRATION

Membrane Keypad

SW2 ON

DIAGNOSTIC ALARMS

When Fault 8 is detected, the HEATER LED flashes four times, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1

J1

TP2 TP3 TP4

RED YEL GRN ORG

TEST POINTS

2. If the thermocouple reading continues to ramp downward for one minute and does not return to the temperature set point of approximately 29.3 mV, then an Open Heater fault will be displayed.

CAL TEST GAS + PROCESS % O2

1. The low heater temperature alarm is active when the thermocouple reading has dropped below 28.6 mV.

TP5 TP6

3. Power down the electronics. Remove the electronic assembly per "Electronic Assembly Replacement" in Section 9: Maintenance and Service. Using a multimeter, measure the resistance across the terminals of heater connector, J8.

KEYPAD

4. If the heater is good, the reading will be approximately 70 ohms. If the heater is open, see "Heater Strut Replacement" in Section 9: Maintenance and Service. LOI When Fault 8 is detected, the LOI displays the "O2 Temp Low" message. Refer to the comments and procedures in paragraphs 1 through 4 above.

LOI

8-14

37260026

Alarms O2 Temp Low

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 8-11. Fault 9, High Heater Temp Fault 9, High Heater Temp Figure 8-11 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). HEATER T/C HEATER O2 CELL CALIBRATION

Membrane Keypad

SW2 ON

DIAGNOSTIC ALARMS

When Fault 9 is detected, the HEATER LED flashes five times, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

TP1

J1

TP2 TP3 TP4

RED YEL GRN ORG

TEST POINTS

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

2. The 4-20 mA signal returns to the default value (4 or 20 mA).

CAL TEST GAS + PROCESS % O2

1. If the thermocouple produces a voltage in excess of approximately 30.7 mV, the high heater temp alarm activates.

3. This alarm is self-clearing. When temperature control is restored and the thermocouple voltage returns to the normal range, the alarm clears.

TP5 TP6

4. If the temperature continues to rise, the next alarm will be the High High Heater Temp alarm.

KEYPAD

LOI When Fault 9 is detected, the LOI displays the "O2 Temp Hi" message. Refer to the comments and procedures in paragraphs 1 through 4 above.

LOI

37260027

Alarms O2 Temp Hi

8-15

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-12. Fault 10, High Cell mV Fault 10, High Cell mV

SW2 ON

HEATER T/C HEATER O2 CELL CALIBRATION

DIAGNOSTIC ALARMS

Figure 8-12 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). The upper view also shows J1 and test points TP1 through TP6, located on the microprocessor board, below the membrane keypad or the LOI module.

CALIBRATION RECOMMENDED TEST POINTS

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

Membrane Keypad TP1

J1

When Fault 10 is detected, the O2 CELL flashes once, pauses for three seconds, and repeats.

TP2 TP3 TP4

RED YEL GRN ORG

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

CAL TEST GAS + PROCESS % O2

TP5 TP6

1. Using a multimeter, measure across TP1+ to TP2-. If you measure 204 mV to 1 volt DC, the cell reading is due to high combustibles. This is a self-clearing alarm, once the combustible conditions go away. If you measure 1.2 VDC, the cell wires, either orange or green, have become detached from the input. 2. One possible cause is connector J1. The orange or green wire has come loose from the crimped connection.

KEYPAD

3. The platinum pad could also be at fault. The pad could have broken free from the back of the cell. 4. Replace heater strut per "Heater Strut Replacement" in Section 9: Maintenance and Service. If necessary, replace the cell and flange assembly per "Cell Replacement" in Section 9: Maintenance and Service. LOI

Alarms O2 Cell Open

When Fault 10 is detected, the LOI displays the "O2 Cell Open" message. 1. Remove power. Unscrew and remove the LOI module from the electronic assembly. 2. Reconnect power to the Oxymitter 4000.

LOI

8-16

37260028

3. Perform the diagnostic steps 1 through 4 shown for the membrane keypad.

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 8-13. Fault 11, Bad Cell Fault 11, Bad Cell Figure 8-13 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). HEATER T/C HEATER O2 CELL CALIBRATION

Membrane Keypad

SW2 ON

DIAGNOSTIC ALARMS

When Fault 11 is detected, the O2 CELL flashes three times, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1

J1

TP2 TP3 TP4

RED YEL GRN ORG

TEST POINTS

CAL TEST GAS + PROCESS % O2

TP5

1. The bad cell alarm activates when the cell exceeds the maximum resistance value. 2. The cell should be replaced. See "Cell Replacement" in Section 9: Maintenance and Service, for cell replacement instructions.

TP6

KEYPAD LOI When Fault 11 is detected, the LOI displays the "O2 Cell Bad" message. Refer to the comments and procedures in paragraphs 1 and 2 above.

LOI

37260029

Alarms O2 Cell Bad

8-17

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-14. Fault 12, EEprom Corrupt Fault 12, EEprom Corrupt

Figure 8-14 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). HEATER T/C HEATER O2 CELL CALIBRATION

Membrane Keypad

SW2 ON

DIAGNOSTIC ALARMS

When Fault 12 is detected, the O2 CELL LED flashes four times, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1

J1

TP2

1. This alarm can occur if the EEprom is changed for a later version. At power up, the EEprom is not updated.

TP3 TP4

RED YEL GRN ORG

TEST POINTS

2. To correct this problem, power down and then restore power. The alarm should clear.

CAL TEST GAS + PROCESS % O2

3. If the alarm occurs while the unit is running, there is a hardware problem on the microprocessor board.

TP5 TP6

4. If cycling the power does not clear the alarm, see "Electronic Assembly Replacement" in Section 9: Maintenance and Service.

KEYPAD

LOI When Fault 12 is detected, the LOI displays the "EEprom Corrupt" message. Refer to the comments and procedures in paragraphs 1 through 4 above.

LOI

8-18

37260030

Alarms EEprom Corrupt

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 8-15. Fault 13, Invalid Slope Fault 13, Invalid Slope Figure 8-15 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). Membrane Keypad

SW2 ON

HEATER T/C HEATER O2 CELL CALIBRATION

DIAGNOSTIC ALARMS

When Fault 13 is detected, the CALIBRATION LED flashes once, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

TP1

J1

TP2 TP3 TP4

RED YEL GRN ORG

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TEST POINTS

CAL TEST GAS + PROCESS % O2

1. During a calibration, the electronics calculates a slope value. If the value of the slope is less than 35 mV/dec or more than 52 mV/dec, the slope alarm will be active until the end of the purge cycle. 2. See "Calibration with Keypad" in Section 9: Maintenance and Service. Verify the calibration by carefully repeating it. Ensure the calibration gases match the calibration gas parameters. If you attach a multimeter to TP1+ and TP2-, sample gas measurements are:

TP5 TP6

KEYPAD

8% O2 23 mV 0.4% O2 85 mV 3. Power down the Oxymitter 4000 and remove it from the stack. 4. Replace the cell per "Cell Replacement" in Section 9: Maintenance and Service. LOI When Fault 13 is detected, the LOI displays the "O2 Cell Bad" message. Refer to the comments and procedures in paragraphs 1 through 4 above.

LOI

37260031

Alarms O2 Cell Bad

8-19

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 8-16. Fault 14, Invalid Constant Fault 14, Invalid Constant

Figure 8-16 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view). Membrane Keypad

SW2 ON

HEATER T/C HEATER O2 CELL CALIBRATION

DIAGNOSTIC ALARMS

When Fault 14 is detected, the CALIBRATION LED flashes twice, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED TEST POINTS

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

TP1

J1

TP2

1. After a calibration has been performed, the electronics calculates a cell constant value.

TP3 TP4

RED YEL GRN ORG

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

2. If the cell constant value is outside of the range, -4 mV to 10 mV, the alarm will activate. See "Calibration with Keypad" in Section 9: Maintenance and Service, and verify the last calibration was performed correctly.

CAL TEST GAS + PROCESS % O2

TP5 TP6

3. Power down the Oxymitter 4000 and remove it from the stack. 4. Replace the cell per "Cell Replacement" in Section 9: Maintenance and Service.

KEYPAD

LOI When Fault 14 is detected, the LOI displays the "O2 Cell Bad" message. Refer to the comments and procedures in paragraphs 1 through 4 above.

LOI

8-20

37260032

Alarms O2 Cell Bad

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 8-17. Fault 15, Last Calibration Failed Fault 15, Last Calibration Failed

SW2

Membrane Keypad

ON

HEATER T/C HEATER O2 CELL CALIBRATION

DIAGNOSTIC ALARMS

Figure 8-17 shows the electronic assembly for an Oxymitter 4000 with a membrane keypad (upper view) and an Oxymitter 4000 with an LOI (lower view).

When Fault 15 is detected, the CALIBRATION LED flashes three times, pauses for three seconds, and repeats.

CALIBRATION RECOMMENDED

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

TP1

J1

TP2

1. The last calibration failed alarm activates when the slope and constant values calculated are out of range and the unit reverts to using the previous calibration values.

TP3 TP4

RED YEL GRN ORG

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TEST POINTS

CAL TEST GAS + PROCESS % O2

TP5

2. The cell should be replaced. See "Cell Replacement" in Section 9: Maintenance and Service, for cell replacement instructions.

TP6

KEYPAD LOI When Fault 15 is detected, the LOI displays the "Calib Failed" message. Refer to the comments in paragraphs 1 and 2 above.

LOI

37260033

Alarms Calib Failed

8-21

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 CALIBRATION PASSES, BUT STILL READS INCORRECTLY

There are a few fault conditions where no alarm indication is present and the probe passes calibration, but the O2 reading may still be incorrect:

Probe passes calibration, but still appears to read high There may be a leak that is permitting ambient air to mix with the process gases. Since many combustion processes are slightly negative in pressure, ambient air can be sucked into the cell area, biasing the O2 reading upward. 1. Make sure that the calibration gas line is capped tightly between calibrations. If autocal is used, make sure the check valve is seating properly. 2. If an abrasive shield is installed to protect the entire probe from particulate erosion, a leak in the probe flange gasket can allow ambient air to migrate down the annular space between the probe and shield, and then into the cell. Always install a new probe flange gasket when reinstalling a probe. There may be a leak inside the probe itself, permitting the reference air (20.95% O2) to mix with the process gases at the cell. To confirm this leak condition, instrument air will need to be connected for reference. Pressurize the inside (reference side) of the probe by plugging the reference air exhaust port with your finger for 1 minute. The O2 reading should decrease slightly. If the O2 reading increases during this test, there is a leak inside the probe. 1. Acid condensation inside the probe can degrade the red silicon tube (item 38, Figure 9-3) that carries the cal gas to the cell. Remove the housing (11) to inspect this hose. (See Section 9: Maintenance and Service). Black vitan material is optionally available with greater chemical resistance. Figure 8-18. Probe Leakage Paths

Corrugated Seal

Probe Flange Gasket

Reference Air Exhaust Port

PROBE HEAD

BOTTOM VIEW

2. The sensing cell is bolted to the end of the probe, and uses a corrugated metallic seal (item 25, Figure 9-3) to separate the process gases from the ambient reference air. This seal can be used only one time, so always replace this seal when a cell is removed or replaced. Always apply anti-seize compound on both sides of the corrugations.

8-22

Instruction Manual IM-106-340, Rev. 4.0 February 2005

Oxymitter 4000 Probe passes calibration, but still appears to read low The diffusion element at the end of the probe is a passive filter. It plugs very slowly, since there is no active flow being drawn across it. In applications that have a heavy particulate loading (coal or wood fired boilers, cement and lime kilns, catalyst regeneration, recovery boilers, etc.), this diffusion element will eventually plug. It is important not to pressurize the sensing cell during calibrations by flowing excessive cal gas against a plugged diffuser. Calibration flow rates should be set only when a new diffuser is installed. As the diffuser plugs, do not adjust the flow rates upward.

How do I detect a plugged diffuser? The O2 signal's speed of response will degrade. The O2 trend in the control room will become smoother. When calibrating, the calibration gas flow rate will be noted to be lower. Never readjust this flow upwards. Adjust this flow only when a new diffuser is installed. Always note the time it takes for the cell to recover to the normal process value after the cal gas is removed. As the diffuser plugs, this recovery time will get longer and longer. Use the Calibration Record form provided in this manual.

Can I calibrate a badly plugged diffuser? It may not be possible to immediately replace a plugged diffuser while the process is on line. One can calibrate the probe without pressurizing the cell by adjusting the calibration gas flow rate downward before calibration. For instance, say the process is at 3%, and the first calibration gas is 8%. Adjust the flow of cal gas downward until the reading begins to migrate from 8% to lower values, indicating that process gases are now mixing in with the calibration gases. Adjust the flow rate back up until this mixing is just eliminated. Calibrate at this flow rate. Replace the diffuser at the first opportunity.

Install all protective equipment covers and safety ground leads after troubleshooting. Failure to install covers and ground leads could result in serious injury or death.

8-23

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Calibration Record For Rosemount Analytical In Situ O2 Probe

Probe Serial Number: ______________________________________________________________________ Probe Tag Number: _______________________________________________________________________ Probe Location: __________________________________________________________________________ Date Placed Into Service: __________________________________________________________________ Date

Slope

Constant

Impedance

Responseinitial

Responsefinal

Notes: Responseinitial When the second calibration gas is turned off, note the number of seconds required for the O2 value to begin migrating back to the process value. Responsefinal

9-0

When the second calibration gas is turned off, note the number of seconds required for the O2 value to settle out at the process value.

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 9

Oxymitter 4000

Maintenance and Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9-1 Calibration with Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9-1 Calibration with LOI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9-5 Oxymitter 4000 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9-7

OVERVIEW

This section identifies the calibration methods available and provides the procedures to maintain and service the Oxymitter 4000.

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.

CALIBRATION WITH KEYPAD

During a calibration, two calibration gases with known O2 concentrations are applied to the Oxymitter 4000. Slope and constant values calculated from the two calibration gases determine if the Oxymitter 4000 is correctly measuring the net concentration of O2 in the industrial process. A calibration record sheet has been provided at the back of this section to track performance. Before calibrating, verify that the calibration gas parameters are correct by setting the gas concentrations used when calibrating the unit (see "Overview" in Section 5: Startup and Operation of Oxymitter 4000 with Membrane Keypad, or Section 6: Startup and Operation of Oxymitter 4000 with LOI) and by setting the calibration gas flowmeter. The calibration gas flowmeter regulates the calibration gas flow and must be set to 5 scfh. Only adjust the flowmeter to 5 scfh after placing a new diffusion element on the end of the Oxymitter 4000. Adjusting the flowmeter at any other time can pressurize the cell and bias the calibration. In applications with a heavy dust loading, the O2 probe diffusion element may become plugged over time, causing a slower speed of response. The best way to detect a plugged diffusion element is to note the time it takes the Oxymitter 4000 to return to the normal process reading after the last calibration gas is removed and the calibration gas line is blocked off. A plugged diffusion element also can be indicated by a slightly lower reading on the flowmeter. Change the diffusion element when the calibration gas flowmeter reads slightly lower during calibration or when response to the process flue gases becomes very slow. Each time the diffusion element is changed, reset the

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 9-1. Membrane Keypad

DIAGNOSTIC ALARMS

HEATER T/C HEATER O2 CELL CALIBRATION

CALIBRATION RECOMMENDED TEST POINTS

INC LOW GAS

DEC

DEC

CAL TEST GAS + PROCESS % O2 22220067

INC HIGH GAS

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

calibration gas flowmeter to 5 scfh and calibrate the Oxymitter 4000. To change the diffusion element, refer to "Ceramic Diffusion Element Replacement". Three types of calibration methods are available: automatic, semi-automatic, and manual. NOTE A calibration can be aborted any time during the process. Press the CAL key (Figure 9-1) on the Oxymitter 4000 keypad three times within three seconds, or abort via the LOI, HART/AMS, or an IMPS 4000. An aborted calibration will retain the values of the previous good calibration.

Automatic Calibration

Automatic calibrations require no operator action. However, the calibration gases must be permanently piped to the Oxymitter 4000, an SPS 4001B or IMPS 4000 must be installed to sequence the gases, and the logic I/O must be set to mode 8 via HART/AMS so the sequencer and Oxymitter 4000 can communicate. Depending on your system setup, an automatic calibration can be initiated by the following methods: 1. The Oxymitter 4000's CALIBRATION RECOMMENDED alarm signals that a calibration is required. 2. Enter a "time since last cal" parameter (CAL INTRVL) via HART/AMS or the LOI that will initiate an automatic calibration at a scheduled time interval (in hours). To configure the CAL INTRVL parameter, refer to "Defining a Timed Calibration via HART" in Section 7: HART/AMS, or "Navigating the Local Operator Interface" in Section 6: Startup and Operation of Oxymitter 4000 with LOI.

9-2

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 3. If using an IMPS 4000, enter a time interval via the IMPS 4000 keypad that will initiate an automatic calibration at a scheduled time interval (in hours). To set the CalIntvX parameter of the CHANGE PRESETS display mode, refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Manual for more information. Once an automatic calibration is initiated, by any of the methods previously described, the Oxymitter 4000's CALIBRATION RECOMMENDED alarm signals an IMPS 4000 or SPS 4001B to initiate a calibration. The sequencer sends an "in cal" signal to the control room so that any automatic control loops can be placed in manual. Then, the sequencer begins to sequence the calibration gases.

Semi-Automatic Calibration

Semi-automatic calibrations only require operator initiation. However, the calibration gases must be permanently piped to the Oxymitter 4000, an SPS 4001B or IMPS 4000 must be installed to sequence the gases, and the logic I/O must be set to mode 8 or 9 via HART/AMS to allow the sequencer and the Oxymitter 4000 to communicate. Depending on your system setup, a semi-automatic calibration can be initiated by the following methods: 1. Oxymitter 4000 with membrane keypad. Press the CAL key on the Oxymitter 4000 keypad. 2. Oxymitter 4000 with LOI. Select "Start Calib" from the CALIBRATION menu. 3. IMPS 4000. Use the IMPS 4000 keypad to change the InitCalX parameter of the CHANGE PRESETS display mode from 0000 to 0001. Refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Manual for more information. 4. HART. Use the HART Communicator to access the O2 CALIBRATE menu and perform the O2 CAL method. Refer to "HART Communicator O2 Cal Method" in Section 7: HART/AMS for the complete calibration procedure. 5. AMS. Refer to AMS documentation for more information. 6. Remote Contact. Initiate a calibration from a remote location via the remote contact input connection provided by an IMPS 4000 or SPS 4001B. Refer to the documentation available for the control system in use for more information. Once a semi-automatic calibration is initiated by any of the methods previously described, the Oxymitter 4000's CALIBRATION RECOMMENDED alarm signals an IMPS 4000 or SPS 4001B to initiate a calibration. The sequencer sends an "in cal" signal to the control room so that any automatic control loops can be placed in manual. Then, the sequencer begins to sequence the calibration gases.

Manual Calibration with Membrane Keypad

Manual calibrations must be performed at the Oxymitter 4000 site and will require operator intervention throughout the process. Manual calibration instructions, in condensed form, can also be found on the inside of the right electronics housing cover. See Figure 9-2. Use the following procedure to perform a manual calibration: 1. Place control loop in manual.

9-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 9-2. Inside Right Cover

MANUAL CALIBRATION

ALARMS LED

FLASHES 1

HEATER T/C

SHORTED

3

REVERSED A/D COMM ERROR OPEN HIGH HIGH TEMP HIGH CASE TEMP LOW TEMP

1 2 3 4 5

O2 CELL

1 3 4 1

CALIBRATION

OPEN

2

4

HEATER

STATUS

2 3

HIGH TEMP OPEN BAD EPROM CORRUPT INVALID SLOPE INVALID CONSTANT LAST CAL FAILED

CONTROL LOOP * PLACE IN MANUAL LED ON * IFGOCAL TO STEP 2 1 PUSH CAL CAL LED ON 2 PUSH CAL CAL LED FLASH 3 APPLY TG1 PUSH CAL CAL LED ON SOLID WAIT FOR FLASH 5 REMOVE TG1 & APPLY TG2 4

PUSH CAL CAL LED ON SOLID WAIT FOR FLASH 2 FLASH-VALID CAL 3 FLASH-INVALID CAL 7 REMOVE TG2 PUSH CAL CAL LED ON FOR 8 PURGE TIME CAL LED OFF 6

SW2 DIP SWITCH LOCAL 0-25%

20mA NOT USED

29770005

HART 0-10% 4mA NOT USED

2. Verify the calibration gas parameters are correct per "Calibration with Keypad". 3. If performing a manual calibration with the CALIBRATION RECOMMENDED LED off and the CAL LED off, start at step a. 4. If performing a manual calibration with the CALIBRATION RECOMMENDED LED on and the CAL LED on, start at step b. a. Push the CAL key. The CALIBRATION RECOMMENDED LED will come on and the CAL LED will be on solid. If a multimeter is attached across TP5 and TP6, the reading will display the percentage of oxygen seen by the cell. b. Push the CAL key. The CALIBRATION RECOMMENDED LED will turn off and the CAL LED will flash continuously. The Oxymitter 4000 can be configured so that the 4-20 mA signal will hold the last value. The default condition is for the output to track. A flashing LED indicates that the Oxymitter 4000 is ready to accept the first calibration gas. c. Apply the first calibration gas. (Electronics will abort the calibration if step 4 is not done within 30 minutes). d. Push the CAL key; the CAL LED will be on solid. A timer is activated to allow the calibration gas adequate time to flow (default time of five minutes). When the timer times out, the Oxymitter 4000 has taken the readings using the first calibration gas and the CAL LED will flash continuously. The flashing indicates the Oxymitter 4000 is ready to take readings using the second calibration gas.

9-4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 e. Remove the first calibration gas and apply the second calibration gas. (Electronics will abort the calibration if step f is not done within 30 minutes). f. Push the CAL key; the CAL LED will be on solid. The timer is activated for the second calibration gas flow. When the timer times out, the CAL LED will flash a 2 pattern flash or a 3 pattern flash (2 pattern flash equals a valid calibration, 3 pattern flash equals an invalid calibration). If the slope or the constant is out of specification, a diagnostic alarm LED will be flashing. The diagnostic alarm will remain active until the purge cycle is over. If the three pattern flash occurs without a diagnostic alarm, the calibration gases could be the same or the calibration gas was not turned on. A flashing CAL LED indicates the calibration is done. (See Section 8: Troubleshooting, for an explanation of the 2 pattern and 3 pattern flashes). g. Remove the second calibration gas and cap off the calibration gas port. h. Push the CAL key; the CAL LED will be on solid as the unit purges. (Default purge time is three minutes). When the purge is complete, the CAL LED will turn off and the Oxymitter 4000 output unlocks from its held value and begins to read the process O2. If the calibration was valid, the DIAGNOSTIC ALARMS LEDs will indicate normal operation. If either new calibration value (slope or constant) is not within parameters, the DIAGNOSTIC ALARMS LED will indicate an alarm. (See Section 8: Troubleshooting, for alarm codes). If the calibration was invalid, the Oxymitter 4000 will return to normal operation, as it was before a calibration was initiated, and the parameters will not be updated. 5. Place control loop in automatic.

CALIBRATION WITH LOI

Refer to Figure 6-4 for a view of the LOI menu tree. To calibrate the Oxymitter 4000 from the LOI, access the CALIBRATION/ Start Calibration menu. CALIBRATION/Start Calibration This is the starting point for calibrations. The LOI will instruct the user through this entire procedure. You can select "Abort Calib" at any time to abort the calibration. 1. The LOI displays the following: Apply Gas 1 Hit E when ready The Oxymitter 4000 is ready to accept the first calibration gas. Apply the first calibration gas. (Electronics will abort the calibration if this step is not done within 30 minutes). 2. Touch the Enter key to start the Gas 1 flow. A timer is activated to allow the calibration gas adequate time to flow (default time of five minutes). The LOI displays: Flow Gas 1 xxxxs Read Gas 1 xxxxs Done Gas 1

9-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

The display counts down the seconds remaining to flow Gas 1, then the time remaining for sensing the O2 concentration of Gas 1. Done Gas 1 indicates completion. 3. Remove the first calibration gas and apply the second calibration gas. (Electronics will abort the calibration if this step is not done within 30 minutes). The LOI displays the following: Apply Gas 2 Hit E when ready 4. Touch the Enter arrow to start the Gas 2 flow. The timer is activated and the LOI displays: Flow Gas 2 xxxxs Read Gas 2 xxxxs Done Gas 2 Stop Gas Hit E when ready 5. Remove the second calibration gas and cap off the calibration gas port. Then, touch the Enter arrow to indicate completion. The timer is activated and the LOI displays: Purge xxxxs The default purge time is three minutes. When the gas purge timer times out, the Oxymitter 4000 begins to read the process O2. Abort Calibration Exits the calibration. After calibration gases are removed, and the purge times out, the instrument goes back to normal operational mode. Cal Constants - Results of the Calibration Current calibration If the calibration passed these values will be updated. Log these values onto the calibration log sheet supplied. If the process has high levels of particulate, the response back to the process after cal gas is also removed. Previous Calibration Values from the prior good calibration. Failed Calibration Bad calibration values are not loaded into the electronics. Calibration Status Calibration Step The current step in an active calibration procedure. Calibration Time Time until the next scheduled calibration. Next O2 Cal Time until the next O2 calibration, if different than the next scheduled calibration.

9-6

Instruction Manual IM-106-340, Rev. 4.0 February 2006

OXYMITTER 4000 REPAIR

Oxymitter 4000 Each of the following procedures details how to remove and replace a specific component of the Oxymitter 4000.

It is recommended that the Oxymitter 4000 be removed from the stack for all service activities. The unit should be allowed to cool and be taken to a clean work area. Failure to comply may cause severe burns.

Disconnect and lock out power before working on any electrical components. There is voltage up to 115 VAC.

Removal and Replacement of Probe

1. Remove. a. Turn off power to the system. b. Shut off the calibration gases at the cylinders and the instrument air. c. Disconnect the calibration gas and instrument air lines from the Oxymitter 4000. d. While facing the Oxymitter 4000 and looking at the Rosemount label, remove screw (32, Figure 9-3 or Figure 9-4), gasket (33), and cover lock (34) securing left housing cover (27). Remove the cover to expose the terminal block. e. Remove all signal and power wiring to the probe. f. Remove insulation to access the mounting bolts. g. Unbolt the Oxymitter 4000 from the stack and take it to a clean work area. h. Allow the unit to cool to a comfortable working temperature. 2. Replace. a. Bolt the Oxymitter 4000 to the stack and install the insulation. b. Connect all signal and power leads at the probe. Refer to Section 2: Installation, for detailed wiring instructions. c. Install left housing cover (27, Figure 9-3 or Figure 9-4) and ensure it is tight. Secure the cover using cover lock (34), gasket (33), and screw (32). d. Connect the calibration gas and instrument air lines to probe. e. Turn on instrument air. f. Restore power to the system; refer to "Power Up" in Section 5: Startup and Operation of Oxymitter 4000 with Membrane Keypad or "Power Up" in Section 6: Startup and Operation of Oxymitter 4000 with LOI. When the probe is at operating temperature, calibrate the probe per "Calibration with Keypad". NOTE Recalibration is required whenever electronic cards or sensing cell is replaced.

9-7

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Figure 9-3. Oxymitter 4000 with Integral Electronics - Exploded View

26

22 25 23 24

Note: The Electronic Assembly, item 12, consists of items 13 through 20.

21 27 32

33

12

27A

20 17 18

19

34

14

13 27A DIA

GN O AL STIC AR MS

CAL

IBR

AT

34

HEA TE R T/ HEA C CAL 02 TE IBR CELR AT L IO OM N MEN DED 02 C 02 ELL HEACEL mV + L HEATER mv TE T/C INC R T/ + C-

IO

NR

EC

TE PO ST INTS INC HIGH GA S

DEC

LO W GA S

DEC

33 32

15

CAL TE ST PR GAS OC ES + % 02 S -

16 7 11

14A

11A

6 10

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 11A. 12. 13. 14. 14A. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Heater Strut Assembly Diffusion Assembly (Snubber) Retainer Screw Cell and Flange Assembly Corrugated Seal Probe Tube Assembly Screw Tube Connector Gas Port O-Ring Blind Cover Window Cover (Optional) Electronic Assembly Screw Membrane Keypad LOI Module (Optional) Snap Connector Captive Screw Microprocessor Board Fuse Cap Fuse Power Supply Board Housing Screw Lock Washer Cable Clamp Terminal Block Captive Screw 5

28 9

4 3

8

2

29 30 31

Note: Not all parts shown.

9-8

27. 27A. 28. 29. 30. 31. 32. 33. 34.

Left Housing Cover O-Ring Silicon Tube Tube Clamp Screw Washer Screw Gasket Cover Lock

37260015

1

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 9-4. Oxymitter 4000 with Remote Electronics - Exploded View 22

REMOTE ELECTRONICS

26

23 25 24

21 27 14A 27A 20

11A

1

32

2

34

17

18 19

33

14

13 27A

34 32

DIAG

NO AL STIC HE AR AT MS ER CA LIB HE T/C AT RA TION CALIB02 ER CE RA LL RE TI CO MM ON TE EN PO ST DE INTS 02 D CE 02 LL HE CELL mV + AT INC HE ER mv AT T/ ER C + INC HIG T/C GA H S LO W GA DE S CA C L DE C TE ST PR GA OC S ES + % 02 S -

10 33

7 6

15

3 4

5

16 12

27A

Note: The electronic assembly, item 12, consists of items 13 through 20.

11 35

27A 26

22

36

23

27

24 21 32

INTERCONNECTING CABLE

PROBE HEAD 9 34

27A 33 11 Mounting Kit Screw Housing Cover Wiring Diagram Label Junction Box Jumper Assembly, Power Jumper Assembly, Signal Connecting Cable, Signal Connecting Cable, Heater O-Ring Blind Cover Window Cover (Optional) Electronic Assembly Screw Membrane Keypad LOI Module (Optional) Snap Connector Captive Screw Microprocessor Board Fuse Cap Fuse

2

33 34 8

20. 21. 22. 23. 24. 25. 26. 27A. 27. 32. 33. 34. 35. 36.

32

Power Supply Board Housing Screw Lock Washer Cable Clamp Terminal Block, Remote Electronics Captive Screw O-Ring Left Housing Cover Screw Gasket Cover Lock Interconnecting Cable Terminal Block, Remote Probe Head

10

PROBE Refer to Figure 9-3 for component parts of probe.

37260034

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 11A. 12. 13. 14. 14A. 15. 16. 17. 18. 19.

9-9

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Replace Entire Integral Electronics (with Housing)

NOTE Only perform this procedure on units with integral electronics.

NOTE Recalibration is required whenever electronic cards or sensing cell is replaced. 1. Follow the instructions in "Removal and Replacement of Probe", to remove the Oxymitter 4000 from the stack or duct. 2. Remove the right housing cover uncovering the electronic assembly (Figure 9-5). 3. Depress and remove the J1 (cell and T/C) connector from the J1 socket. Loosen the three captive mounting screws (16, Figure 9-3 or Figure 9-4) on the microprocessor board (top board). 4. The J8 connector (heater leads) can be accessed by moving the J1 connector leads out of the slot on the microprocessor board (17) and sliding the electronic assembly (12) partially out of the housing (Figure 9-6). 5. Squeeze the J8 connector on the sides and carefully remove. The electronic assembly can now be completely removed from the housing. 6. Remove the four screws (7, Figure 9-3) from the probe finned housing. The probe and the electronic housing can now be separated. 7. When reinstalling or replacing the electronic housing, make sure that O-ring (10) is in good condition. Place the J1 and J8 connectors in the hole on the flat side of the electronic housing. 8. Hold the J1 and J8 connectors out and to the probe side of the electronic housing. Make sure that the conduit port of the electronic housing is on the same side as the CAL and REF gas ports. Replace the four screws and tighten. 9. Reconnect the J8 connector to the power supply board. Make sure the connector is secure. 10. Holding the J1 connector leads, slide the electronic assembly the rest of the way into the housing. Align the electronic assembly so that it fits flush on the pins. To ensure that it is flush, gently try to rotate the electronics. If the electronics rotates, repeat the alignment. 11. Reconnect the J1 connector to the microprocessor board. Ensure the connector is secure and tighten the three captive screws on the microprocessor board (top board). 12. Replace the housing cover and ensure it is tight. 13. Follow the instructions in "Removal and Replacement of Probe" to install the Oxymitter 4000 into the stack or duct.

9-10

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 9-5. Electronic Assembly Mounting Screw

SMART FAMILY HARTTM

TM

OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: 85-264 VAC WATTS: 48-62 Hz OUTPUT: 4-20 mALINE FUSE:

500 VA 5 Amps

J1

CALIBRATION RECOMMENDED

R

TEST POINTS

INC

INC

HIGH GAS

LOW GAS

DEC

DEC

O2 CELL mV + O2 CELL mv HEATER T/C + HEATER T/C -

TP1

J1

TP2 TP3 TP4

CAL TEST GAS + PROCESS % O2

TP5 TP6

Mounting Screw

26170018

Rosemount Analytical Inc. Orrville, OH 44667-0901 800-433-6076

SW2

RED YEL GRN ORG

R

HEATER T/C HEATER O2 CELL CALIBRATION

ON

Mounting Screw

DIAGNOSTIC ALARMS

Figure 9-6. J8 Connector Power Supply Board

22220061

J8

9-11

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Electronic Assembly Replacement (Figure 9-5)

1. Remove the right housing cover uncovering the electronic assembly. 2. Depress and remove the J1 (cell and T/C) connector from the J1 socket. Loosen the three captive mounting screws (16, Figure 9-3 or Figure 9-4) on the microprocessor board (top board). 3. The J8 connector (heater leads) can be accessed by moving the J1 connector leads out of the slot on the microprocessor board (17) and sliding the electronic assembly (12) partially out of the housing (Figure 9-6). 4. Squeeze the J8 connector on the sides and carefully remove. The electronic assembly can now be completely removed from the housing. 5. Reconnect the J8 connector to the power supply board. Make sure the connector is secure. 6. Holding the J1 connector leads, slide the electronic assembly the rest of the way into the housing. Align the electronic assembly so that it fits flush on the pins. To ensure that it is flush, gently try to rotate the electronics. If the electronics rotates, repeat the alignment. 7. Reconnect the J1 connector to the microprocessor board. Ensure the connector is secure and tighten the three captive mounting screws on the microprocessor board (top board). 8. Replace the housing cover and ensure it is tight. Terminal Block Replacement 1. Unscrew left housing cover (27, Figure 9-3). 2. Loosen the mounting screws (26) on the terminal block (25) and carefully lift the block out of the housing. 3. Carefully align the new terminal block on the pins so that it sits flat in the housing. The round end of the terminal block should be on the opposite side of the housing conduit ports and should not be able to rotate. 4. Tighten the three mounting screws and ensure the terminal block is secure in the housing. Fuse Replacement (Figure 9-7) 1. Remove the right housing cover uncovering the electronic assembly. 2. Depress and remove the J1 (cell and T/C) connector from the J1 socket. Loosen the three captive mounting screws (16, Figure 9-3 or Figure 9-4) on the microprocessor board (top board). 3. The J8 connector (heater leads) can be accessed by moving the J1 connector leads out of the slot on the microprocessor board (17) and sliding the electronic assembly (12) partially out of the housing (Figure 9-6). 4. Squeeze the J8 connector on the sides and carefully remove. The electronic assembly can now be completely removed from the housing. 5. Completely remove the three mounting screws (16) on the microprocessor board (17).

9-12

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 9-7. Fuse Location Power Supply Board

22220058

Fuse

6. Turn the electronic assembly over so that you are looking at the bottom of the power supply printed circuit board. Gently depress the two white posts one at a time. Carefully separate the power supply board (20) from the microprocessor board (17). 7. Remove the fuse (19) and replace it with a new one (Figure 9-7). 8. Align the white posts with the post holes on the power supply board and the pin connector on the power supply board with the connector port on the back of the microprocessor board. Gently push the boards together until the white posts snap in place. Ensure the assembly is secure by gently trying to separate the boards. 9. Reconnect connector J8 to the power supply board. Make sure the connector is secure. 10. Holding the J1 connector leads, slide the electronic assembly the rest of the way into the housing. Align the electronic assembly so that it fits flush on the pins. To ensure that it is flush, gently try to rotate the electronics. If the electronics rotates, repeat the alignment. 11. Reconnect the J1 connector to the microprocessor board. Ensure the connector is secure and tighten the three captive screws on the microprocessor board (top board). 12. Replace the housing cover and ensure that it is tight. Entire Probe Replacement (Excluding Probe Head) 1. Do not attempt to replace the probe until all other possibilities for poor performance have been considered. If probe replacement is needed, see Table 11-1 for part numbers. 2. Follow the instructions in "Removal and Replacement of Probe" to remove the Oxymitter 4000 from the stack or duct. 3. Separate the probe and the probe head per "Replace Entire Integral Electronics (with Housing)", steps 2 through 6. 4. Reinstall the probe head on the new probe per "Replace Entire Integral Electronics (with Housing)", steps 7 through 13.

9-13

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Heater Strut Replacement

This paragraph covers heater strut replacement. Do not attempt to replace the heater strut until all other possibilities for poor performance have been considered. If heater strut replacement is needed, order a replacement heater strut. (Table 10-1). Refer to Figure 9-3 or Figure 9-4 to view the component parts of the Oxymitter 4000.

Use heat resistant gloves and clothing when removing probe. Do not attempt to work on the probe until it has cooled to room temperature. The probe can be as hot as 800°F (427°C). This can cause severe burns.

1. Follow the instructions in "Removal and Replacement of Probe" to remove the Oxymitter 4000 from the stack or duct. 2. For a unit with integral electronics, disconnect electronics per "Replace Entire Integral Electronics (with Housing)", steps 2 through 5. 3. For a unit with remote electronics, remove cover (11, Figure 9-4) from housing (21), and disconnect signal and heater connecting cables (8 and 9) from heater strut assembly (1, Figure 9-4). 4. Remove the four screws (7, Figure 9-4). Remove the probe from the housing (21). 5. Remove tube clamps (29) and silicon tubes (28) from the CAL and REF gas ports and the CAL and REF gas lines. 6. Loosen, but do not remove, the three screws (30, Figure 9-3). The spring tension will release and the heater strut assembly should move up. 7. When the spring tension is released, remove the three screws (30). Grasp the wire loop and carefully slide the heater strut assembly (Figure 9-8) out of the probe tube. 8. When replacing the strut, orient the probe so the small calibration gas tube is at the 6 o'clock position of the probe tube. Align the slot on the heater plate with the calibration gas line in the probe tube. Slide the strut into the probe tube. It will turn to align the hole on the back plate of the strut with the calibration gas line. When the hole and the calibration gas line are aligned correctly, the strut will slide in the rest of the way. 9. As the strut installation nears completion, install the guide rod into the calibration gas tube to assist in guiding the calibration gas tube through the hole in the end of the strut. 10. Push down on the back plate of the strut to make sure you have spring tension and then tighten the three screws on the back plate. 11. Replace the CAL and REF gas silicon tubes. 12. For units with integral electronics, install the entire electronics per "Replace Entire Integral Electronics (with Housing)", steps 7 through 13.

9-14

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 9-8. Heater Strut Assembly Wire Loop V-Deflector Ceramic Support Rod

Cell Flange

22220050

Ceramic Diffuser Assembly

Heater

Figure 9-9. Probe to Probe Head Assembly - Remote Electronics Only

O-Ring (10)

Probe (6)

Housing (21) Signal Cable (9)

Probe Signal Wire Connector

Heater Cable (8)

2 Wire Probe Heater Wire Connector

37260058

4 Wire

9-15

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

13. For units with remote electronics, install the probe head as follows: a. See Figure 9-9. Make sure that the O-ring (10) is in good condition. Seat the O-ring in the mating groove of the probe (6). b. Insert the probe signal cables (8 and 9, into the housing 21). c. Turn the conduit ports of the housing (21) to the CAL and REF gas ports side of the probe (6) and position the housing on the probe d. Install and tighten four screws (12, Figure 9-4). e. Reconnect the probe signal cables (8 and 9) to the probe signal and heater wire connectors, Figure 9-9. Make sure the connectors are secure. f. Install and tighten cover. 14. Follow the instructions in "Removal and Replacement of Probe" to install the Oxymitter 4000 into the stack or duct. Cell Replacement This paragraph covers oxygen sensing cell replacement. Do not attempt to replace the cell until all other possibilities for poor performance have been considered. If cell replacement is needed, order the cell replacement kit (Table 10-1). Refer to Figure 9-3 or Figure 9-4 to view the component parts of the Oxymitter 4000. The cell replacement kit (Figure 9-10) contains a cell and flange assembly, corrugated seal, setscrews, socket head cap screws, and anti-seize compound. The items are carefully packaged to preserve precise surface finishes. Do not remove items from the packaging until they are ready to be used. Spanner wrenches and hex wrenches needed for this procedure are part of an available special tools kit (Table 10-1 and Figure 10-2). Figure 9-10. Cell Replacement Kit Probe Tube (Not Included in Kit)

Corrugated Seal Cell and Flange Assembly

Socket H Cap Scre

22220028

Calibration Gas Passage

9-16

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Use heat-resistant gloves and clothing when removing the probe. Do not attempt to work on these components until they have cooled to room temperature. Probe components can be as hot as 572°F (300°C). This can cause severe burns. Disconnect and lock out power before working on any electrical components. There is voltage of up to 115 VAC.

Do not remove the cell unless certain it needs to be replaced. Removal may damage the cell and platinum pad. Go through the complete troubleshooting procedure to make sure the cell needs to be replaced before removing it.

1. Follow the instructions in "Removal and Replacement of Probe" to remove the Oxymitter 4000 from the stack or duct. 2. If the probe uses the standard diffusion element, use a spanner wrench to remove the diffuser assembly. NOTE To determine if the diffuser needs to be replaced, refer to "Calibration with Keypad". 3. If equipped with the optional ceramic diffusion assembly, remove and discard the setscrews and remove the vee deflector (Figure 9-11). Use spanner wrenches from the probe disassembly kit (Table 10-1), to turn the hub free from the retainer. Inspect the diffusion element. If damaged, replace the element. 4. Loosen the four socket head cap screws from the cell and flange assembly and remove the assembly and the corrugated seal. The cell flange has a notch that may be used to gently pry the flange away from the probe. Note that the contact pad inside of the probe will sometimes fuse to the oxygen sensing cell. If the cell is fused to the contact pad, push the cell assembly back into the probe (against spring pressure) and quickly twist the cell assembly. The cell and contact pad should separate. If the contact pad stays fused to the cell, a new contact/ thermocouple assembly must be installed. Disconnect the cell and the thermocouple wires at the crimp connections and withdraw the cell with the wires still attached. 5. For units with integral electronics, disconnect the entire electronics per "Replace Entire Integral Electronics (with Housing)", steps 2 through 5. 6. Remove the four screws (7, Figure 9-3) from the probe finned housing. The probe and the probe head can now be separated. 7. If the contact assembly is damaged, replace the strut or the contact pad. Instructions for replacing the contact pad are in the cell replacement kit. 8. Remove and discard the corrugated seal. Clean the mating faces of the probe tube and retainer. Remove burrs and raised surfaces with a block of wood and crocus cloth. Clean the threads on the retainer and hub.

9-17

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

9. Rub a small amount of anti-seize compound on both sides of the new corrugated seal. 10. Assemble the cell and flange assembly, corrugated seal, and probe tube. Make sure the calibration tube lines up with the calibration gas passage in each component. Apply a small amount of anti-seize compound to the screw threads and use the screws to secure assembly. Torque to 35 in-lbs (4 N·m). 11. Install the entire electronics per "Replace Entire Integral Electronics (with Housing)", steps 7 through 13. 12. Apply anti-seize compound to the threads of the cell assembly, hub, and setscrews. Reinstall the hub on the cell assembly. Using pin spanner wrenches, torque to 10 ft-lbs (14 N·m). If applicable, reinstall the vee deflector, orienting apex toward gas flow. Secure with the setscrews and anti-seize compound. Torque to 25 in-lbs (2.8 N·m). 13. On systems equipped with an abrasive shield, install the dust seal gaskets, with joints 180° apart. 14. Reinstall the probe and gasket on the stack flange. 15. Follow the instructions in "Removal and Replacement of Probe" to install the Oxymitter 4000 into the stack or duct. If there is an abrasive shield in the stack, make sure the dust seal gaskets are in place as they enter the 15° reducing cone. 16. Turn on power and monitor thermocouple output. It should stabilize at 29.3+0.2 mV. Set reference air flow at 2 scfh (56.6 l/hr). After the Oxymitter 4000 stabilizes, calibrate the unit. If new components have been installed, repeat calibration after 24 hours of operation. Ceramic Diffusion Element Replacement NOTE This refers to the ceramic diffusion element only. General The diffusion element protects the cell from particles in process gases. Normally, it does not need to be replaced because the vee deflector protects it from particulate erosion. In severe environments, the filter may be broken or subject to excessive erosion. Examine the ceramic diffusion element whenever removing the probe for any purpose. Replace if damaged. Damage to the ceramic diffusion element may become apparent during calibration. Compare probe response with previous response. A broken diffusion element will cause a slower response to calibration gas. Hex wrenches needed to remove setscrews and socket head screws in the following procedure are available as part of a Probe Disassembly Kit, Table 10-1. Replacement Procedure a. Follow the instructions in "Removal and Replacement of Probe" to remove the Oxymitter 4000 from the stack or duct.

9-18

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 b. Loosen setscrews, Figure 9-11, using hex wrench from Probe Disassembly Kit, Table 10-1, and remove vee deflector. Inspect setscrews. If damaged, replace with stainless setscrews coated with anti-seize compound.

Figure 9-11. Ceramic Diffuser Element Replacement Retainer

Spanner Wrench

Optional Ceramic Diffusion Element Set Screw

Hub Cement Fillet Vee Deflector

Heater (black) Heater (black)

Oxygen Cell (green) Thermocouple (yellow) Thermocouple + (red)

Oxygen Cell + (orange)

36940005

Figure 9-12. Contact and Thermocouple Assembly Replacement

22220029

Cement Port

Termination Housing Wiring (Remote Electronics Probe Head Only) Under normal circumstances, the right termination housing cover should not need to be removed. This side of the housing contains only two wire harnesses that connect the internal electrical barrier to pins in the housing wall. If these jumper wires should become disconnected or need to be replaced, use the diagram in Figure 9-12 to connect the wires.

9-19

Instruction Manual

Oxymitter 4000

9-20

IM-106-340, Rev. 4.0 February 2006

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Section 10

Replacement Parts Probe Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . page 10-1 Electronics Replacement Parts . . . . . . . . . . . . . . . . . . . . . page 10-6

PROBE REPLACEMENT PARTS Table 10-1. Replacement Parts for Probe Part Number

Figure and Index Number

Dust Seal

No Dust Seal

Description

9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31

3D39648G01 3D39648G02 3D39648G03 3D39648G04 3D39648G05 --3D39648G06 3D39648G07 3D39648G08 3D39648G09 3D39648G10 3D39648G11 3D39648G12 3D39648G13 3D39648G14 3D39648G15

3D39649G01 3D39649G02 3D39649G03 3D39649G04 3D39649G05 3D39649G53 3D39649G54 3D39649G06 3D39649G07 3D39649G08 3D39649G09 3D39649G10 3D39649G11 3D39649G12 3D39649G13 3D39649G14 3D39649G15

18" ANSI Probe with Ceramic Diffuser 3' ANSI Probe with Ceramic Diffuser 6' ANSI Probe with Ceramic Diffuser 9' ANSI Probe with Ceramic Diffuser 12' ANSI Probe with Ceramic Diffuser 15' ANSI Probe with Ceramic Diffuser 18' ANSI Probe with Ceramic Diffuser 18" JIS Probe with Ceramic Diffuser 3' JIS Probe with Ceramic Diffuser 6' JIS Probe with Ceramic Diffuser 9' JIS Probe with Ceramic Diffuser 12' JIS Probe with Ceramic Diffuser 18" DIN Probe with Ceramic Diffuser 3' DIN Probe with Ceramic Diffuser 6' DIN Probe with Ceramic Diffuser 9' DIN Probe with Ceramic Diffuser 12' DIN Probe with Ceramic Diffuser

9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31

3D39648G17 3D39648G18 3D39648G19 3D39648G20 3D39648G21 --3D39648G22 3D39648G23 3D39648G24 3D39648G25

3D39648G17 3D39648G18 3D39648G19 3D39648G20 3D39648G21 3D39649G55 3D39649G56 3D39649G22 3D39648G23 3D39648G24 3D39648G25

18" ANSI Probe with Flame Arrestor and Ceramic Diffuser 3' ANSI Probe with Flame Arrestor and Ceramic Diffuser 6' ANSI Probe with Flame Arrestor and Ceramic Diffuser 9' ANSI Probe with Flame Arrestor and Ceramic Diffuser 12' ANSI Probe with Flame Arrestor and Ceramic Diffuser 15' ANSI Probe with Flame Arrestor and Ceramic Diffuser 18' ANSI Probe with Flame Arrestor and Ceramic Diffuser 18" JIS Probe with Flame Arrestor and Ceramic Diffuser 3' JIS Probe with Flame Arrestor and Ceramic Diffuser 6' JIS Probe with Flame Arrestor and Ceramic Diffuser 9' JIS Probe with Flame Arrestor and Ceramic Diffuser

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Table 10-1. Replacement Parts for Probe (Continued) Figure and Index Number

Part Number

9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 1 thru 6, 8,9,28 thru 31 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 6 9-3, 1 9-3, 1 9-3, 1 9-3, 1 9-3, 1 9-3, 1

3D39648G26 3D39649G26 3D39648G27 3D39649G27 3D39648G28 3D39649G28 3D39648G29 3D39649G29 3D39648G30 3D39649G30 3D39648G31 3D39649G31 3D39648G33 3D39649G33 3D39648G34 3D39649G34 3D39648G35 3D39649G35 3D39648G36 3D39649G36 3D39648G37 3D39649G37 -3D39649G49 -3D39649G50 3D39648G38 3D39649G38 3D39648G39 3D39649G39 3D39648G40 3D39649G40 3D39648G41 3D39649G41 3D39648G42 3D39649G42 3D39648G43 3D39649G43 3D39648G44 3D39649G44 3D39648G45 3D39649G45 3D39648G46 3D39649G46 3D39648G47 3D39649G47 3D39644G01 3D39644G02 3D39644G03 3D39644G04 3D39644G05 3D39644G17 3D39644G18 3D39644G06 3D39644G07 3D39644G08 3D39644G09 3D39644G10 3D39644G11 3D39644G12 3D39644G13 3D39644G14 3D39644G15 3D39645G01 3D39645G02 3D39645G03 3D39645G04 3D39645G05 3D39645G07 3D39645G08

10-2

Description 12' JIS Probe with Flame Arrestor and Ceramic Diffuser 18" DIN Probe with Flame Arrestor and Snubber Diffuser 3' DIN Probe with Flame Arrestor and Snubber Diffuser 6' DIN Probe with Flame Arrestor and Snubber Diffuser 9' DIN Probe with Flame Arrestor and Snubber Diffuser 12' DIN Probe with Flame Arrestor and Snubber Diffuser 18" ANSI Probe with Snubber Diffuser 3' ANSI Probe with Snubber Diffuser 6' ANSI Probe with Snubber Diffuser 9' ANSI Probe with Snubber Diffuser 12' ANSI Probe with Snubber Diffuser 15' ANSI Probe with Snubber Diffuser 18' ANSI Probe with Snubber Diffuser 18" JIS Probe with Snubber Diffuser 3' JIS Probe with Snubber Diffuser 6' JIS Probe with Snubber Diffuser 9' JIS Probe with Snubber Diffuser 12' JIS Probe with Snubber Diffuser 18" DIN Probe with Snubber Diffuser 3' DIN Probe with Snubber Diffuser 6' DIN Probe with Snubber Diffuser 9' DIN Probe with Snubber Diffuser 12' DIN Probe with Snubber Diffuser 18" ANSI Probe Tube Assy. 3' ANSI Probe Tube Assy. 6' ANSI Probe Tube Assy. 9' ANSI Probe Tube Assy. 12' ANSI Probe Tube Assy 15' ANSI Probe Tube Assy. 18' ANSI Probe Tube Assy. 18" JIS Probe Tube Assy. 3' JIS Probe Tube Assy. 6' JIS Probe Tube Assy 9' JIS Probe Tube Assy. 12' JIS Probe Tube Assy. 18" DIN Probe Tube Assy. 3' DIN Probe Tube Assy. 6' DIN Probe Tube Assy. 9' DIN Probe Tube Assy. 12' DIN Probe Tube Assy. 18" Heater Strut Assy. 3' Heater Strut Assy. 6' Heater Strut Assy. 9' Heater Strut Assy. 12' Heater Strut Assy. 15' Heater Strut Assy. 18' Heater Strut Assy.

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Figure 10-1. Cell Replacement Kit ANSI Gasket

Wire and Pad Assembly Anti-Seize Compound Probe Tube (Not Included in Kit)

Corrugated Seal

22 Ga. Wire

Closed end Connector

Cell and Flange Assembly Socket Head Cap Screws

Set Screws Teflon Tubing

35830009

Calibration Gas Passage

Table 10-1. Replacement Parts for Probe (Continued) Figure and Index Number

Part Number

10-1 10-1 10-1 10-1 10-1 10-1 10-1 10-1 10-1 10-1 10-1 10-1 10-1

4847B61G02 4847B61G03 4847B61G04 4847B61G05 4847B61G06 4847B61G27 4847B61G28 4847B61G08 4847B61G09 4847B61G10 4847B61G11 4847B61G12 4847B61G14

ANSI 18" Cell Replacement Kit* ANSI 3' Cell Replacement Kit* ANSI 6' Cell Replacement Kit* ANSI 9' Cell Replacement Kit* ANSI 12' Cell Replacement Kit* ANSI 15' Cell Replacement Kit* ANSI 18' Cell Replacement Kit* JIS 18" Cell Replacement Kit* JIS 3' Cell Replacement Kit* JIS 6' Cell Replacement Kit* JIS 9' Cell Replacement Kit* JIS 12' Cell Replacement Kit* DIN 18" Cell Replacement Kit*

10-1 10-1 10-1 10-1

4847B61G15 4847B61G16 4847B61G17 4847B61G18

DIN 3' Cell Replacement Kit* DIN 6' Cell Replacement Kit* DIN 9' Cell Replacement Kit* DIN 12' Cell Replacement Kit*

Description

* Includes pad and wire

10-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 Table 10-1. Replacement Parts for Probe (Continued) Figure and Index Number

Part Number

10-1

4849B94G01 4849B94G02

10-1 10-1 10-1 10-1

4849B94G03 4849B94G04 4849B94G05 4849B94G06

10-1

4849B94G19

10-1

4849B94G20

10-1 10-1 10-1 10-1 10-1

4849B94G07 4849B94G08 4849B94G09 4849B94G10 4849B94G11 4849B94G12 4849B94G13 4849B94G14 4849B94G15 4849B94G16 4849B94G17 4849B94G18

ANSI 18' Cell Replacement Kit, High Sulfur/HCl Resistant* JIS High Sulfur/HCl Resistant Cell Only JIS 18" Cell Replacement Kit, High Sulfur/HCl Resistant* JIS 3' Cell Replacement Kit, High Sulfur/HCl Resistant* JIS 6' Cell Replacement Kit, High Sulfur/HCl Resistant* JIS 9' Cell Replacement Kit, High Sulfur/HCl Resistant* JIS 12' Cell Replacement Kit, High Sulfur/HCl Resistant* DIN High Sulfur/HCl Resistant Cell Only DIN 18" Cell Replacement Kit, High Sulfur/HCl Resistant* DIN 3' Cell Replacement Kit, High Sulfur/HCl Resistant* DIN 6' Cell Replacement Kit, High Sulfur/HCl Resistant* DIN 9' Cell Replacement Kit, High Sulfur/HCl Resistant* DIN 12' Cell Replacement Kit, High Sulfur/HCl Resistant*

2-4

3D39003G09

JIS 9' Abrasive Shield Assy.

2-4 2-4 2-4 2-4 2-4 2-4 2-4 2-4

3D39003G10 3D39003G11 3D39003G12 3D39003G13 3D39003G14 3D39003G15 3D39003G25 3D39003G28

JIS 12' Abrasive Shield Assy. DIN 9' Abrasive Shield Assy. DIN 12' Abrasive Shield Assy. ANSI 18" Abrasive Shield Assy JIS 18" Abrasive Shield Assy. DIN 18" Abrasive Shield Assy. ANSI 15' Abrasive Shield Assy. ANSI 18' Abrasive Shield Assy.

9-12 9-12 9-12 9-12 9-12 9-12 9-12

4513C61G03 4513C61G04 4513C61G05 4513C61G06 4513C61G07 4513C61G08 4513C61G09

18" Contact and Thermocouple Replacement Assembly 3' Contact and Thermocouple Replacement Assembly 6' Contact and Thermocouple Replacement Assembly 9' Contact and Thermocouple Replacement Assembly 12' Contact and Thermocouple Replacement Assembly 15' Contact and Thermocouple Replacement Assembly 18' Contact and Thermocouple Replacement Assembly

10-1 10-1 10-1 10-1 10-1

*Includes pad and wire

10-4

Description ANSI High Sulfur/Hl Resistant Cell Only ANSI 18" Cell Replacement Kit, High Sulfur/HCl Resistant* ANSI 3' Cell Replacement Kit, High Sulfur/HCl Resistant* ANSI 6' Cell Replacement Kit, High Sulfur/HCl Resistant* ANSI 9' Cell Replacement Kit, High Sulfur/HCl Resistant* ANSI 12' Cell Replacement Kit, High Sulfur/HCl Resistant* ANSI 15' Cell Replacement Kit, High Sulfur/HCl Resistant*

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Table 10-1. Replacement Parts for Probe (Continued) Figure and Index Number

Part Number

1-11 1-11 1-11 1-11 1-12 1-12 1-12 1-12 9-11 9-11 1-13 1-13 1-13 1-13 10-2

3534B18G01 3535B60G01 3535B62G01 3535B63G01 4843B37G01 4843B38G02 4846B70G01 4846B71G01 3534B18G01 3534B48G01 4851B89G04 4851B89G05 4851B90G04 4851B90G05 3535B42G02

Description Ceramic Diffuser Ceramic Diffuser with Dust Seal Flame Arrestor Ceramic Diffuser Flame Arrestor Ceramic Diffuser with Dust Seal Snubber Diffuser Snubber Diffuser with Dust Seal Flame Arrestor Snubber Diffuser Flame Arrestor Snubber Diffuser with Dust Seal Ceramic Diffuser Hub Assy. Vee Deflector Assy. Cup Type Diffusion Assembly, 5 microns Cup Type Diffusion Assembly, 40 microns Cup Type Diffusion Assembly/Dust Seal, 5 microns Cup Type Diffusion Assembly/Dust Seal, 40 microns Probe Disassembly Kit

Figure 10-2. Probe Disassembly Kit

Hex Keys Philips Screwdriver Spanner Wrench Wrench

Tube Insertion Tube

37250001

Anti-Seize Compound

10-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 ELECTRONICS REPLACEMENT PARTS Table 10-2. Replacement Parts for Electronics Figure and Index Number

10-6

Part Number

Description

9-3, 10 9-3, 11 9-3, 11A 9-3, 12 9-3, 14 9-3, 14 9-3, 14 9-3, 14 9-3, 14 9-3, 14A 9-3, 21 9-3, 25 9-3, 25 9-3, 27A

120039076 5R10145G01 5R10199G01 3D39861G01 4849B72H01 4849B72H02 4849B72H03 4849B72H04 4849B72H05 6A00115G01 4849B95G01 08732-0002-0001 08732-0002-0002 120039078

O-Ring Cover Cover, with Window Electronic Assembly Membrane Keypad English Membrane Keypad German Membrane Keypad French Membrane Keypad Spanish Membrane Keypad Italian LOI Module (Local Operator Interface) Housing Termination Block Standard Termination Block Transient Protected O-Ring

9-4, 5 9-4, 8 9-4, 9 9-4, 10 9-4, 11 9-4, 11A 9-4, 12 9-4, 14A 9-4, 21 9-4, 25 9-4, 25 9-4, 27A 9-4, 35 9-4, 35 9-4, 35 9-4, 35 9-4, 35 9-4, 35 9-4, 35 9-4, 36 9-4, 36

6A00091G01 4849B92G20 4849B92G21 120039076 5R10145G01 5R10199G01 3D39861G01 6A00115G01 4849B95G01 08732-0002-0001 08732-0002-0002 120039078 6A00121G01 6A00121G02 6A00121G03 6A00121G04 6A00121G05 6A00121G06 6A00121G07 3D39866G01 3D39866G02

Junction Box Connecting Cable, Signal Connecting Cable, Heater O-Ring Cover Cover, with Window Electronic Assembly LOI Module (Local Operator Interface) Housing Termination Block, Standard Termination Block, Transient Protected O-Ring Cable Assembly, 20 ft. (6 m) Cable Assembly, 40 ft. (12 m) Cable Assembly, 60 ft. (18 m) Cable Assembly, 80 ft. (24 m) Cable Assembly, 100 ft. (30 m) Cable Assembly, 150 ft. (46 m) Cable Assembly, 200 ft. (61 m) Termination Block, Standard, Remote Probe Head Termination Block, Transient Protected, Remote Probe Head

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Table 10-3. Replacement Parts for SPS 4001B Figure and Index Number 9-13, 4 9-15, 19 9-13, 15 9-15, 17 9-15, 16 9-15, 8 9-13, 17 9-13, 19 9-13, 18 9-13, 12 9-13, 13 and 20 9-13, 8 9-13, 28 9-13, 25

Part Number 1A99093H01 6292A97H03 1A99089H01 771B635H01 771B635H02 1A99094H01 1A97913H03 4850B56G02 4850B54G01 7305A67H01 3D39435G01 120039-0077 4850B75H01 1A99147H01

Description Bushing Gasket Check Valve Cover O-Ring Flowmeter Assembly, Calibration Gas Flowmeter Assembly, Reference Air (Optional) Pressure Regulator, Reference Air (Optional) Fuse, 5A, 250V, 5 20 mm, Slow Blow Interface Board Power Supply Board Pressure Switch Solenoid O-Ring Terminal Cover Gasket Terminal Strip

Table 10-4. Replacement Parts for Calibration Components Figure and Index Number

Part Number

11-5

1A99119G01

11-5 11-5

1A99119G02 1A99119G03

Description Calibration Gas Bottles - 0.4% and 8% O2, balance nitrogen - 550 liters each* Two Flow Regulators (for calibration gas bottles) Bottle rack

*Calibration gas bottles cannot be shipped via airfreight.

10-7

Instruction Manual

Oxymitter 4000

10-8

IM-106-340, Rev. 4.0 February 2006

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Section 11

Oxymitter 4000

Optional Accessories HART Handheld 375 Communicator . . . . . . . . . . . . . . . . . page 11-1 Asset Management Solutions (AMS) . . . . . . . . . . . . . . . . page 11-2 By-Pass Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11-2 IMPS 4000 Intelligent Multiprobe Test gas Sequencer . . page 11-3 SPS 4001B Single Probe Autocalibration Sequencer . . . page 11-4 O2 Calibration Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11-5 Catalyst Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11-6

HART HANDHELD 375 COMMUNICATOR Figure 11-1. HART Model 375 Handheld Communicator MAN 4275A00 English

HART Communicator

37260059

o

The HART Handheld 275/375 Communicator is an interface device that provides a common communication link to HART-compatible instruments, such as the Oxymitter 4000. HART Communications Protocol permits all the information available from the Oxymitter 4000's electronics to be transmitted over standard 4-20 mA signal wires. By attaching the HART handheld communicator at a termination point along the 4-20 mA signal line, a technician can diagnose problems and configure and calibrate the Oxymitter 4000 as if he or she were standing in front of the instrument. For more information, call Emerson Process Management at 1-800-433-6076.

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 ASSET MANAGEMENT SOLUTIONS (AMS)

Asset Management Solutions (AMS) software works in conjunction with the HART Communication Protocol and offers the capability to communicate with all HART plant devices from a single computer terminal. For more information, call Emerson Process Management at 1-800-433-6076.

BY-PASS PACKAGES

I VE

IG H

T

WHE N

CI R

CU

VE ATM OS I O PL WA RN I NG - SPH EX -

AL

-

E ER

IT

Figure 11-2. By-Pass Mounting

P

T

IN

26170024

CAL. GAS

EE

The specially designed Rosemount Analytical By-Pass Package for oxygen analyzers has proven to withstand the high temperatures in process heaters while providing the same advantages offered by the in situ sensor. Inconel or Kanthal steel tubes provide effective resistance to corrosion, and the package uses no moving parts, air pumps, or other components common to other sampling systems. For more information, call Emerson Process Management at 1-800-433-6076.

11-2

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

IMPS 4000 INTELLIGENT MULTIPROBE TEST GAS SEQUENCER

26170006

Figure 11-3. IMPS 4000

The IMPS 4000 Intelligent Multiprobe Test Gas Sequencer is housed within an IP56 (NEMA 4X) enclosure and has the intelligence to provide calibration gas sequencing of up to four Oxymitter 4000 units to accommodate automatic and semi-automatic calibration routines. This sequencer works in conjunction with the Oxymitter 4000 CALIBRATION RECOMMENDED feature, eliminating out-of-calibration occurrences and the need to send a technician to the installation site. In addition, the SPS 4001B provides a remote contact input to initiate a calibration from a remote location and relay outputs to alert when a calibration is in progress, an Oxymitter 4000 is out of calibration, calibration gases are on, and calibration gas pressure is low. For more information, call Emerson Process Management at 1-800-433-6076.

11-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 SPS 4001B SINGLE PROBE AUTOCALIBRATION SEQUENCER Figure 11-4. SPS 4001B

OXYMITTER 4000

26170007

SPS 4001B

Rosemount Analytical specifically designed the SPS 4001B Single Probe Autocalibration Sequencer to provide the capability to perform automatic or on-demand Oxymitter 4000 calibrations. The SPS 4001B is fully enclosed in a NEMA cabinet suited for wall-mounting. This cabinet provides added protection against dust and minor impacts. The SPS 4001B works in conjunction with the Oxymitter 4000's CALIBRATION RECOMMENDED feature, eliminating out-of-calibration occurrences and the need to send a technician to the installation site. In addition, the SPS 4001B provides a remote contact input to initiate a calibration from a remote location and relay outputs to indicate when a calibration is in progress or the Oxymitter 4000 is out of calibration. For more information, call Emerson Process Management at 1-800-433-6076.

11-4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

O2 CALIBRATION GAS

26170021

Figure 11-5. Calibration Gas Bottles

Rosemount Analytical's O2 Calibration Gas and Service Kits have been carefully designed to provide a more convenient and fully portable means of testing, calibrating, and servicing. Rosemount Analytical's oxygen analyzers. These lightweight, disposable gas cylinders eliminate the need to rent gas bottles. For more information, call Emerson Process Management at 1-800-433-6076.

11-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 CATALYST REGENERATION Figure 11-6. Catalyst Regeneration Oxymitter 4000 Probe in Retracted Position

Isolation Valving System

37260042

Integral Pressure Balancing Assembly

Measure O2 in regenerators at pressures up to 50 psi. In-situ design resists plugging due to catalyst fines Class I, Div. I, Group B, C, and D. Optional pressure balancing arrangement. Optional isolation valving system permits installation and withdrawal while the process is running. Specified by UOP. See Application Data Sheet ADS 106-300F.A01, Isolation Valving System.

OXYBALANCE DISPLAY AND AVERAGING SYSTEM Figure 11-7. OxyBalance

An

aly

tic

38370012

al

11-6

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Appendix A

Oxymitter 4000

Safety Data Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-2 Safety Data Sheet for Ceramic Fiber Products . . . . . . . . page A-15

http://www.processanalytic.com

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 SAFETY INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards. 1. Adequate earth connections should be made to all earthing points, internal and external, where provided. 2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times. 3. Mains supply cords should comply with the requirements of IEC227 or IEC245. 4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C. 5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage. 6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards. 7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment - and then only by trained service personnel. 8. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch. 9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions. 10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

A-2

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 BELANGRIJK Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel. De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften. 1. Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten, intern en extern. 2. Na installatie of controle moeten alle veiligheidsdeksels en -aardingen terug geplaatst worden. Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven. 3. Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften. 4. Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen, hoger dan 75°C. 5. Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd is. 6. Om de veilige werking van dit toestel te verzekeren, moet de voeding door een stroomonderbreker gevoerd worden (min 10A) welke alle draden van de voeding moet onderbreken. De stroomonderbreker mag een mechanische schakelaar bevatten. Zoniet moet een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten onderworpen zijn aan een erkende standaard zoals IEC947. 7. Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning aanwezig. Deze deksels mogen enkel verwijderd worden nadat de voedingsspanning werd afgelegd en enkel door getraind onderhoudspersoneel. 8. Waar toestellen of deksels aangegeven staan met het symbool is er gevaar voor hete oppervlakken. Deze deksels mogen enkel verwijderd worden door getraind onderhoudspersoneel nadat de voedingsspanning verwijderd werd. Sommige oppper-vlakken kunnen 45 minuten later nog steeds heet aanvoelen. 9. Waar toestellen of deksels aangegeven staan met het symbool gelieve het handboek te raadplegen. 10. Alle grafische symbolen gebruikt in dit produkt, zijn afkomstig uit een of meer van devolgende standaards: EN61010-1, IEC417 en ISO3864.

A-3

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr. Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bør også følges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder. 1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse forefindes. 2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og jordforbindelser reetableres. 3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245. 4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur højere end 75°C. 5. Alle benyttede kabelforskruninger skal have en intern dimension, så passende kabelaflastning kan etableres. 6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse mod indirekte berøring gennem afbryder (min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsitua-tion. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og mærkes som sådan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947. 7. Hvor udstyr eller dæksler er mærket med dette symbol, er farlige spændinger normalt forekom-mende bagved. Disse dæksler bør kun afmonteres, når forsyningsspændingen er frakoblet - og da kun af instrueret servicepersonale. 8. Hvor udstyr eller dæksler er mærket med dette symbol, forefindes meget varme overflader bagved. Disse dæksler bør kun afmonteres af instrueret servicepersonale, når forsyningsspænding er frakoblet. Visse overflader vil stadig være for varme at berøre i op til 45 minutter efter frakobling. 9. Hvor udstyr eller dæksler er mærket med dette symbol, se da i betjeningsmanual for instruktion. 10. Alle benyttede grafiske symboler i dette udstyr findes i én eller flere af følgende standarder:- EN61010-1, IEC417 & ISO3864.

A-4

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 BELANGRIJK Veiligheidsinstructies voor de bedrading en installatie van dit apparaat. Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving anders voorschrijft. 1. Alle voorziene interne- en externe aardaansluitingen dienen op adequate wijze aangesloten te worden. 2. Na installatie, onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels /kappen en aardingen om reden van veiligheid weer aangebracht te worden. 3. Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of IEC 245. 4. Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven 75°C. 5. Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankering van de kabel wordt verkregen. 6. Om een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats te vinden via een meerpolige automatische zekering (min.10A) die alle spanningvoerende geleiders verbreekt indien een foutconditie optreedt. Deze automatische zekering mag ook voorzien zijn van een mechanisch bediende schakelaar. Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars dienen te voldoen aan een erkende standaard zoals IEC 947. 7. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder spanning voerende delen bevinden die gevaar op kunnen leveren. Deze beschermdeksels/ kappen mogen uitsluitend verwijderd worden door getraind personeel als de spanning is afgeschakeld. 8. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder hete oppervlakken of onderdelen bevinden. Bepaalde delen kunnen mogelijk na 45 min. nog te heet zijn om aan te raken. 9. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, dient men de bedieningshandleiding te raadplegen. 10. Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende standaarden: EN 61010-1, IEC 417 & ISO 3864.

A-5

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 TÄRKEÄÄ

Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa. Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive) yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta, elleivät kansalliset standardit estä sitä. 1. Riittävät maadoituskytkennät on tehtävä kaikkiin maadoituspisteisiin, sisäisiin ja ulkoisiin. 2. Asennuksen ja vianetsinnän jälkeen on kaikki suojat ja suojamaat asennettava takaisin pai-koilleen. Maadoitusliittimen kunnollinen toiminta täytyy aina ylläpitää. 3. Jännitesyöttöjohtimien täytyy täyttää IEC227 ja IEC245 vaatimukset. 4. Kaikkien johdotuksien tulee toimia >75°C lämpötiloissa. 5. Kaikkien läpivientiholkkien sisähalkaisijan täytyy olla sellainen että kaapeli lukkiutuu kun-nolla kiinni. 6. Turvallisen toiminnan varmistamiseksi täytyy jännitesyöttö varustaa turvakytkimellä (min 10A), joka kytkee irti kaikki jännitesyöttöjohtimet vikatilanteessa. Suojaan täytyy myös sisältyä mekaaninen erotuskytkin. Jos ei, niin jännitesyöttö on pystyttävä katkaisemaan muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi. Turvakytkimien tai kat-kaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä. 7. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla hengenvaarallisen suuruinen jännite. Suojaa ei saa poistaa jänniteen ollessa kytkettynä laitteeseen ja poistamisen saa suorittaa vain alan asian-tuntija. 8. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla kuuma pinta. Suojan saa poistaa vain alan asiantuntija kun jännite-syöttö on katkaistu. Tällainen pinta voi säilyä kosketuskuumana jopa 45 mi-nuuttia. 9. Mikäli laite tai kosketussuoja on merkitty tällä merkillä katso lisäohjeita käyt-töohjekirjasta. 10. Kaikki tässä tuotteessa käytetyt graafiset symbolit ovat yhdestä tai useammasta seuraavis-ta standardeista: EN61010-1, IEC417 & ISO3864.

A-6

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 IMPORTANT Consignes de sécurité concernant le raccordement et l'installation de cet appareil. Les consignes de sécurité ci-dessous s'adressent particulièrement à tous les états membres de la communauté européenne. Elles doivent être strictement appliquées afin de satisfaire aux directives concernant la basse tension. Les états non membres de la communauté européenne doivent également appliquer ces consignes sauf si elles sont en contradiction avec les standards locaux ou nationaux. 1. Un raccordement adéquat à la terre doit être effectuée à chaque borne de mise à la terre, interne et externe. 2. Après installation ou dépannage, tous les capots de protection et toutes les prises de terre doivent être remis en place, toutes les prises de terre doivent être respectées en permanence. 3. Les câbles d'alimentation électrique doivent être conformes aux normes IEC227 ou IEC245. 4. Tous les raccordements doivent pouvoir supporter une température ambiante supérieure à 75°C. 5. Tous les presse-étoupes utilisés doivent avoir un diamètre interne en rapport avec les câbles afin d'assurer un serrage correct sur ces derniers. 6. Afin de garantir la sécurité du fonctionnement de cet appareil, le raccordement à l'alimentation électrique doit être réalisé exclusivement au travers d'un disjoncteur (minimum 10A.) isolant tous les conducteurs en cas d'anomalie. Ce disjoncteur doit également pouvoir être actionné manuellement, de façon mécanique. Dans le cas contraire, un autre système doit être mis en place afin de pouvoir isoler l'appareil et doit être signalisé comme tel. Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telle IEC947. 7. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des tensions dangereuses sont présentes. Ces capots ne doivent être démontés que lorsque l'alimentation est coupée, et uniquement par un personnel compétent. 8. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des surfaces dangereusement chaudes sont présentes. Ces capots ne doivent être démontés que lorsque l'alimentation est coupée, et uniquement par un personnel compétent. Certaines surfaces peuvent rester chaudes jusqu'à 45 mn. 9. Lorsque les équipements ou les capots affichent le symbole suivant, se reporter au manuel d'instructions. 10. Tous les symboles graphiques utilisés dans ce produit sont conformes à un ou plusieurs des standards suivants: EN61010-1, IEC417 & ISO3864.

A-7

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 WICHTIG

Sicherheitshinweise für den Anschluß und die Installation dieser Geräte. Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der Niederspannungsrichtlinie zu genügen. Nichtmitgliedsstaaten der europäischen Gemeinschaft sollten die national gültigen Normen und Richtlinien einhalten. 1. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden. 2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerät müssen alle Sicherheitsabdeckungen und Erdungen wieder installiert werden. Die Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gestört sein. 3. Die Netzspannungsversorgung muß den Anforderungen der IEC227 oder IEC245 genügen. 4. Alle Verdrahtungen sollten mindestens bis 75°C ihre Funktion dauerhaft erfüllen. 5. Alle Kabeldurchführungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so gewählt werden, daß diese eine sichere Verkabelung des Gerätes ermöglichen. 6. Um eine sichere Funktion des Gerätes zu gewährleisten, muß die Spannungsversorgung über mindestens 10 A abgesichert sein. Im Fehlerfall muß dadurch gewährleistet sein, daß die Spannungsversorgung zum Gerät bzw. zu den Geräten unterbrochen wird. Ein mechanischer Schutzschalter kann in dieses System integriert werden. Falls eine derartige Vorrichtung nicht vorhanden ist, muß eine andere Möglichkeit zur Unterbrechung der Spannungszufuhr gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden. Ein solcher Mechanismus zur Spannungsunterbrechung muß mit den Normen und Richtlinien für die allgemeine Installation von Elektrogeräten, wie zum Beispiel der IEC947, übereinstimmen. 7. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, die eine gefährliche (Netzspannung) Spannung führen. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen. 8. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, in bzw. unter denen heiße Teile vorhanden sind. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen. Bis 45 Minuten nach dem Unterbrechen der Netzzufuhr können derartig Teile noch über eine erhöhte Temperatur verfügen. 9. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, bei denen vor dem Eingriff die entsprechenden Kapitel im Handbuch sorgfältig durchgelesen werden müssen. 10. Alle in diesem Gerät verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgend aufgeführten Standards: EN61010-1, IEC417 & ISO3864.

A-8

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 IMPORTANTE Norme di sicurezza per il cablaggio e l'installazione dello strumento. Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell'Unione Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all'Unione Europea, salvo quanto disposto dalle vigenti normative locali o nazionali. 1. Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra interni ed esterni, dove previsti. 2. Dopo l'installazione o la localizzazione dei guasti, assicurarsi che tutti i coperchi di protezione siano stati collocati e le messa a terra siano collegate. L'integrità di ciscun morsetto di terra deve essere costantemente garantita. 3. I cavi di alimentazione della rete devono essere secondo disposizioni IEC227 o IEC245. 4. L'intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore a 75°C. 5. Le dimensioni di tutti i connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggio al cavo. 6. Per garantire un sicuro funzionamento dello strumento il collegamento alla rete di alimentazione principale dovrà essere eseguita tramite interruttore automatico (min.10A), in grado di disattivare tutti i conduttori di circuito in caso di guasto. Tale interruttore dovrà inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione dell'alimentazione, chiaramente identificabile. Gli interruttori dovranno essere conformi agli standard riconosciuti, quali IEC947. 7. Il simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza di elevati voltaggi. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento. 8. Il simbolo riportato sullo strumento o sui coperchi di protezione indica rischio di contatto con superfici ad alta temperatura. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento. Alcune superfici possono mantenere temperature elevate per oltre 45 minuti. 9. Se lo strumento o il coperchio di protezione riportano il simbolo, fare riferimento alle istruzioni del manuale Operatore. 10. Tutti i simboli grafici utilizzati in questo prodotto sono previsti da uno o più dei seguenti standard: EN61010-1, IEC417 e ISO3864.

A-9

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 VIKTIG

Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret. Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder. 1. Passende jordforbindelser må tilkobles alle jordingspunkter, interne og eksterne hvor disse forefinnes. 2. Etter installasjon eller feilsøking skal alle sikkerhetsdeksler og jordforbindelser reetableres. Jordingsforbindelsene må alltid holdes i god stand. 3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245. 4. Alle ledningsforbindelser skal være konstruert for en omgivelsestemperatur høyere en 750°C. 5. Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnåes. 6. For å oppnå sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom en strømbryter (minimum 10A) som vil bryte spenningsforsyningen til alle elektriske kretser ved en feilsituasjon. Strømbryteren kan også inneholde en mekanisk operert bryter for å isolere instrumentet fra spenningsforsyningen. Dersom det ikke er en mekanisk operert bryter installert, må det være en annen måte å isolere utstyret fra spenningsforsyningen, og denne måten må være tydelig merket. Kretsbrytere eller kontakter skal oppfylle kravene i en annerkjent standard av typen IEC947 eller tilsvarende. 7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. 8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. Noen overflater kan være for varme til å berøres i opp til 45 minutter etter spenningsforsyning frakoblet. 9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til instruksjonsmanualen for instrukser. 10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av følgende standarder: EN61010-1, IEC417 & ISO3864.

A-10

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 IMPORTANTE Instruções de segurança para ligação e instalação deste aparelho. As seguintes instruções de segurança aplicam-se especificamente a todos os estados membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tensão. Relativamente aos estados que não pertençam à UE, deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação local a tiver substituído. 1. Devem ser feitas ligações de terra apropriadas a todos os pontos de terra, internos ou externos. 2. Após a instalação ou eventual reparação, devem ser recolocadas todas as tampas de segurança e terras de protecção. Deve manter-se sempre a integridade de todos os terminais de terra. 3. Os cabos de alimentação eléctrica devem obedecer às exigências das normas IEC227 ou IEC245. 4. Os cabos e fios utilizados nas ligações eléctricas devem ser adequados para utilização a uma temperatura ambiente até 75ºC. 5. As dimensões internas dos bucins dos cabos devem ser adequadas a uma boa fixação dos cabos. 6. Para assegurar um funcionamento seguro deste equipamento, a ligação ao cabo de alimentação eléctrica deve ser feita através de um disjuntor (min. 10A) que desligará todos os condutores de circuitos durante uma avaria. O disjuntor poderá também conter um interruptor de isolamento accionado manualmente. Caso contrário, deverá ser instalado qualquer outro meio para desligar o equipamento da energia eléctrica, devendo ser assinalado convenientemente. Os disjuntores ou interruptores devem obedecer a uma norma reconhecida, tipo IEC947. 7. Sempre que o equipamento ou as tampas contiverem o símbolo, é provável a existência de tensões perigosas. Estas tampas só devem ser retiradas quando a energia eléctrica tiver sido desligada e por Pessoal da Assistência devidamente treinado. 8. Sempre que o equipamento ou as tampas contiverem o símbolo, há perigo de existência de superfícies quentes. Estas tampas só devem ser retiradas por Pessoal da Assistência devidamente treinado e depois de a energia eléctrica ter sido desligada. Algumas superfícies permanecem quentes até 45 minutos depois. 9. Sempre que o equipamento ou as tampas contiverem o símbolo, o Manual de Funcionamento deve ser consultado para obtenção das necessárias instruções. 10. Todos os símbolos gráficos utilizados neste produto baseiam-se em uma ou mais das seguintes normas: EN61010-1, IEC417 e ISO3864.

A-11

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 IMPORTANTE

Instrucciones de seguridad para el montaje y cableado de este aparato. Las siguientes instrucciones de seguridad, son de aplicacion especifica a todos los miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension. 1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en aquellos terminales previstos al efecto. 2. Una vez finalizada las operaciones de mantenimiento del equipo, se deben volver a colocar las cubiertas de seguridad aasi como los terminales de tierra. Se debe comprobar la integridad de cada terminal. 3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245. 4. Todo el cableado sera adecuado para una temperatura ambiental de 75ºC. 5. Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables. 6. Para un manejo seguro del equipo, la alimentacion electrica se realizara a traves de un interruptor magnetotermico ( min 10 A ), el cual desconectara la alimentacion electrica al equipo en todas sus fases durante un fallo. Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio. 7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa, dicho alojamiento solamente se abrira una vez que se haya interrumpido la alimentacion electrica al equipo asimismo la intervencion sera llevada a cabo por personal entrenado para estas labores. 8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con alta temperatura, por tanto se abrira una vez que se haya interrumpido la alimentacion electrica al equipo por personal entrenado para estas labores, y al menos se esperara unos 45 minutos para enfriar las superficies calientes. 9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el manual de instrucciones. 10. Todos los simbolos graficos usados en esta hoja, estan de acuerdo a las siguientes normas EN61010-1, IEC417 & ISO 3864.

A-12

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 VIKTIGT Säkerhetsföreskrifter för kablage och installation av denna apparat. Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varje avseende för att överensstämma med Lågspännings direktivet. Icke EU medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala eller nationella föreskrifter. 1. Tillämplig jordkontakt skall utföras till alla jordade punkter, såväl internt som externt där så erfordras. 2. Efter installation eller felsökning skall samtliga säkerhetshöljen och säkerhetsjord återplaceras. Samtliga jordterminaler måste hållas obrutna hela tiden. 3. Matningsspänningens kabel måste överensstämma med föreskrifterna i IEC227 eller IEC245. 4. Allt kablage skall vara lämpligt för användning i en omgivningstemperatur högre än 75ºC. 5. Alla kabelförskruvningar som används skall ha inre dimensioner som motsvarar adekvat kabelförankring. 6. För att säkerställa säker drift av denna utrustning skall anslutning till huvudströmmen endast göras genom en säkring (min 10A) som skall frånkoppla alla strömförande kretsar när något fel uppstår. Säkringen kan även ha en mekanisk frånskiljare. Om så inte är fallet, måste ett annat förfarande för att frånskilja utrustningen från strömförsörjning tillhandahållas och klart framgå genom markering. Säkring eller omkopplare måste överensstämma med en gällande standard såsom t ex IEC947. 7. Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för livsfarlig spänning i närheten. Dessa höljen får endast avlägsnas när strömmen ej är ansluten till utrustningen - och då endast av utbildad servicepersonal. 8. När utrustning eller hölje är markerad med vidstående symbol föreligger risk för brännskada vid kontakt med uppvärmd yta. Dessa höljen får endast avlägsnas av utbildad servicepersonal, när strömmen kopplats från utrustningen. Vissa ytor kan vara mycket varma att vidröra även upp till 45 minuter efter avstängning av strömmen. 9. När utrustning eller hölje markerats med vidstående symbol bör instruktionsmanualen studeras för information. 10. Samtliga grafiska symboler som förekommer i denna produkt finns angivna i en eller flera av följande föreskrifter:- EN61010-1, IEC417 & ISO3864.

A-13

Instruction Manual

Oxymitter 4000

A-14

IM-106-340, Rev. 4.0 February 2006

Instruction Manual IM-106-340, Rev. 4.0 February 2006

SAFETY DATA SHEET FOR CERAMIC FIBER PRODUCTS

Oxymitter 4000 JULY 1, 1996 SECTION I. IDENTIFICATION PRODUCT NAME Ceramic Fiber Heaters, Molded Insulation Modules and Ceramic Fiber Radiant Heater Panels. CHEMICAL FAMILY Vitreous Aluminosilicate Fibers with Silicon Dioxide. CHEMICAL NAME N.A. CHEMICAL FORMULA N.A. MANUFACTURER'S NAME AND ADDRESS Watlow Columbia 2101 Pennsylvania Drive Columbia, MO 65202 573-814-1300, ext. 5170 573-474-9402 HEALTH HAZARD SUMMARY WARNING •

Possible cancer hazard based on tests with laboratory animals.



May be irritating to skin, eyes and respiratory tract.



May be harmful if inhaled.



Cristobalite (crystalline silica) formed at high temperatures (above 1800ºF) can cause severe respiratory disease.

SECTION II. PHYSICAL DATA APPEARANCE AND ODOR Cream to white colored fiber shapes. With or without optional white to gray granular surface coating and/or optional black surface coating. SPECIFIC WEIGHT: 12-25 LB./CUBIC FOOT BOILING POINT: N.A. VOLATILES (% BY WT.): N.A. WATER SOLUBILITY: N.A.

A-15

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 SECTION III. HAZARDOUS INGREDIENTS

MATERIAL, QUANTITY, AND THRESHOLD/EXPOSURE LIMIT VALUES Aluminosilicate (vitreous) 99+ % 1 fiber/cc TWA CAS. No. 142844-00-0610 fibers/cc CL Zirconium Silicate0-10% 5 mg/cubic meter (TLV) Black Surface Coating**0 - 1% 5 mg/cubic meter (TLV) Armorphous Silica/Silicon Dioxide0-10% 20 mppcf (6 mg/cubic meter) PEL (OSHA 1978) 3 gm cubic meter (Respirable dust): 10 mg/cubic meter, Intended TLV (ACGIH 1984-85) **Composition is a trade secret.

SECTION IV. FIRE AND EXPLOSION DATA FLASH POINT: None FLAMMABILITY LIMITS: N.A. EXTINGUISHING MEDIA Use extinguishing agent suitable for type of surrounding fire. UNUSUAL FIRE AND EXPLOSION HAZARDS / SPECIAL FIRE FIGHTING PROCEDURES N.A.

SECTION V. HEALTH HAZARD DATA THRESHOLD LIMIT VALUE (See Section III) EFFECTS OF OVER EXPOSURE

A-16



EYE - Avoid contact with eyes. Slightly to moderately irritating. Abrasive action may cause damage to outer surface of eye.



INHALATION - May cause respiratory tract irritation. Repeated or prolonged breathing of particles of respirable size may cause inflammation of the lung leading to chest pain, difficult breathing, coughing and possible fibrotic change in the lung (Pneumoconiosis). Pre-existing medical conditions may be aggravated by exposure: specifically, bronchial hyper-reactivity and chronic bronchial or lung disease.



INGESTION - May cause gastrointestinal disturbances. Symptoms may include irritation and nausea, vomiting and diarrhea.



SKIN - Slightly to moderate irritating. May cause irritation and inflammation due to mechanical reaction to sharp, broken ends of fibers.

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 EXPOSURE TO USED CERAMIC FIBER PRODUCT Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) may undergo partial conversion to cristobalite, a form of crystalline silica which can cause severe respiratory disease (Pneumoconiosis). The amount of cristobalite present will depend on the temperature and length of time in service. (See Section IX for permissible exposure levels). SPECIAL TOXIC EFFECTS The existing toxicology and epidemiology data bases for RCF's are still preliminary. Information will be updated as studies are completed and reviewed. The following is a review of the results to date: EPIDEMIOLOGY At this time there are no known published reports demonstrating negative health outcomes of workers exposed to refractory ceramic fiber (RCF). Epidemiologic investigations of RCF production workers are ongoing. 1. There is no evidence of any fibrotic lung disease (interstitial fibrosis) whatsoever on x-ray. 2. There is no evidence of any lung disease among those employees exposed to RCF that had never smoked. 3. A statistical "trend" was observed in the exposed population between the duration of exposure to RCF and a decrease in some measures of pulmonary function. These observations are clinically insignificant. In other words, if these observations were made on an individual employee, the results would be interpreted as being within the normal range. 4. Pleural plaques (thickening along the chest wall) have been observed in a small number of employees who had a long duration of employment. There are several occupational and non-occupational causes for pleural plaque. It should be noted that plaques are not "pre-cancer" nor are they associated with any measurable effect on lung function. TOXICOLOGY A number of studies on the health effects of inhalation exposure of rats and hamsters are available. Rats were exposed to RCF in a series of life-time nose-only inhalation studies. The animals were exposed to 30, 16, 9, and 3 mg/m3, which corresponds with approximately 200, 150, 75, and 25 fibers/cc. Animals exposed to 30 and 16 mg/m3 were observed to have developed a pleural and parenchymal fibroses; animals exposed to 9 mg/m3 had developed a mild parenchymal fibrosis; animals exposed to the lowest dose were found to have the response typically observed any time a material is inhaled into the deep lung. While a statistically significant increase in lung tumors was observed following exposure to the highest dose, there was no excess lung cancers at the other doses. Two rats exposed to 30 mg/m3 and one rat exposed to 9 mg/m3 developed masotheliomas.

A-17

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

The International Agency for Research on Cancer (IARC) reviewed the carcinogenicity data on man-made vitreous fibers (including ceramic fiber, glasswool, rockwool, and slagwool) in 1987. IARC classified ceramic fiber, fibrous glasswool and mineral wool (rockwool and slagwool) as possible human carcinogens (Group 2B). EMERGENCY FIRST AID PROCEDURES •

EYE CONTACT - Flush eyes immediately with large amounts of water for approximately 15 minutes. Eye lids should be held away from the eyeball to insure thorough rinsing. Do not rub eyes. Get medical attention if irritation persists.



INHALATION - Remove person from source of exposure and move to fresh air. Some people may be sensitive to fiber induced irritation of the respiratory tract. If symptoms such as shortness of breath, coughing, wheezing or chest pain develop, seek medical attention. If person experiences continued breathing difficulties, administer oxygen until medical assistance can be rendered.



INGESTION - Do not induce vomiting. Get medical attention if irritation persists.



SKIN CONTACT - Do not rub or scratch exposed skin. Wash area of contact thoroughly with soap and water. Using a skin cream or lotion after washing may be helpful. Get medical attention if irritation persists.

SECTION VI. REACTIVITY DATA STABILITY/CONDITIONS TO AVOID Stable under normal conditions of use. HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID N.A. INCOMPATIBILITY/MATERIALS TO AVOID Incompatible with hydrofluoric acid and concentrated alkali. HAZARDOUS DECOMPOSITION PRODUCTS N.A.

SECTION VII. SPILL OR LEAK PROCEDURES STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED Where possible, use vacuum suction with HEPA filters to clean up spilled material. Use dust suppressant where sweeping if necessary. Avoid clean up procedure which may result in water pollution. (Observe Special Protection Information Section VIII.) WASTE DISPOSAL METHODS The transportation, treatment, and disposal of this waste material must be conducted in compliance with all applicable Federal, State, and Local regulations.

A-18

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 SECTION VIII. SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. NIOSH/MSHA approved breathing equipment may be required for non-routine and emergency use. (See Section IX for suitable equipment). Pending the results of long term health effects studies, engineering control of airborne fibers to the lowest levels attainable is advised. VENTILATION Ventilation should be used whenever possible to control or reduce airborne concentrations of fiber and dust. Carbon monoxide, carbon dioxide, oxides of nitrogen, reactive hydrocarbons and a small amount of formaldehyde may accompany binder burn off during first heat. Use adequate ventilation or other precautions to eliminate vapors resulting from binder burn off. Exposure to burn off fumes may cause respiratory tract irritation, bronchial hyper-reactivity and asthmatic response. SKIN PROTECTION Wear gloves, hats and full body clothing to prevent skin contact. Use separate lockers for work clothes to prevent fiber transfer to street clothes. Wash work clothes separately from other clothing and rinse washing machine thoroughly after use. EYE PROTECTION Wear safety glasses or chemical worker's goggles to prevent eye contact. Do not wear contact lenses when working with this substance. Have eye baths readily available where eye contact can occur.

SECTION IX. SPECIAL PRECAUTIONS PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING General cleanliness should be followed. The Toxicology data indicate that ceramic fiber should be handled with caution. The handling practices described in this MSDS must be strictly followed. In particular, when handling refractory ceramic fiber in any application, special caution should be taken to avoid unnecessary cutting and tearing of the material to minimize generation of airborne dust. It is recommended that full body clothing be worn to reduce the potential for skin irritation. Washable or disposable clothing may be used. Do not take unwashed work clothing home. Work clothes should be washed separately from other clothing. Rinse washing machine thoroughly after use. If clothing is to be laundered by someone else, inform launderer of proper procedure. Work clothes and street clothes should be kept separate to prevent contamination. Product which has been in service at elevated temperatures (greater than 1800°F/982°C) may undergo partial conversion to cristobalite, a form of crystalline silica. This reaction occurs at the furnace lining hot face. As a consequence, this material becomes more friable; special caution must be taken to minimize generation of air-borne dust. The amount of cristobalite present will depend on the temperature and length in service.

A-19

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

IARC has recently reviewed the animal, human, and other relevant experimental data on silica in order to critically evaluate and classify the cancer causing potential. Based on its review, IARC classified crystalline silica as a group 2A carcinogen (probable human carcinogen). The OSHA permissible exposure limit (PEL for cristobalite is 0.05 mg/m3 (respirable dust). The ACGIH threshold limit value (TLV) for cristobalite is 0.05 mg/m3 (respirable dust) (ACGIH 1991-92). Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. The minimum respiratory protection recommended for given airborne fiber or cristobalite concentrations are:

CONCENTRATION Concentration

Personal Protective Equipment

0-1 fiber/cc or 0-0.05 mg/m3 cristobalite (the OSHA PEL) Up to 5 fibers/cc or up to 10 times the OSHA PEL for cristobalite

Optional disposable dust respirator (e.g. 3M 9970 or equivalent). Half face, air purifying respirator equipped with high efficiency particulate air (HEPA)filter cartridges (e.g. 3M 6000 series with 2040 filter or equivalent). Full face, air purifying respirator with high efficiency particulate air (HEPA) filter cartridges (e.g. 3M 7800S with 7255 filters or equivalent) or powered air purifying respirator (PARR) equipped with HEPA filter cartridges (e.g. 3M W3265S with W3267 filters or equivalent). Full face, positive pressure supplied air respirator (e.g. 3M 7800S with W9435 hose & W3196 low pressure regulator kit connected to clean air supply or equivalent).

Up to 25 fibers/cc or 50 times the OSHA PEL for cristobalite (2.5 mg/m3)

Greater than 25 fibers/cc or 50 times the OSHA PEL for cristobalite (2.5 mg/m3)

If airborne fiber or cristobalite concentrations are not known, as minimum protection, use NIOSH/MSHA approved half face, air purifying respirator with HEPA filter cartridges. Insulation surface should be lightly sprayed with water before removal to suppress airborne dust. As water evaporates during removal, additional water should be sprayed on surfaces as needed. Only enough water should be sprayed to suppress dust so that water does not run onto the floor of the work area. To aid the wetting process, a surfactant can be used. After RCF removal is completed, dust suppressing cleaning methods, such as wet sweeping or vacuuming, should be used to clean the work area. If dry vacuuming is used, the vacuum must be equipped with HEPA filter. Air blowing or dry sweeping should not be used. Dust suppressing components can be used to clean up light dust. Product packaging may contain product residue. Do not reuse except to reship or return Ceramic Fiber products to the factory.

A-20

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000 GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed Gases" published in 1981 Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202 Used by Permission

1. Never drop cylinders or permit them to strike each other violently. 2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent. 3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in a cylinder stand, and is ready to be used. 4. Avoid dragging, rolling, or sliding cylinders, even for short distance; they should be moved by using a suitable handtruck. 5. Never tamper with safety devices in valves or cylinders. 6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is attached to a pressurized system. 7. No part of cylinder should be subjected to a temperature higher than 52°C (125°F). A flame should never be permitted to come in contact with any part of a compressed gas cylinder. 8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions must be taken to prevent striking an arc against the cylinder.

A-21

Instruction Manual

Oxymitter 4000

A-22

IM-106-340, Rev. 4.0 February 2006

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Appendix B

Return of Material

RETURNING MATERIAL

If factory repair of defective equipment is required, proceed as follows: 1. Secure a return authorization number from a Rosemount Analytical Sales Office or representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount Analytical instructions or it will not be accepted. In no event will Rosemount Analytical be responsible for equipment returned without proper authorization and identification. 2. Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to ensure that no additional damage will occur during shipping. 3. In a cover letter, describe completely: a. The symptoms from which it was determined that the equipment is faulty. b. The environment in which the equipment has been operating (housing, weather, vibration, dust, etc.). c. Site from which equipment was removed. d. Whether warranty or nonwarranty service is requested. e. Complete shipping instructions for return of equipment. f. Reference the return authorization number. 4. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Rosemount Analytical Return Authorization, prepaid, to: Rosemount Analytical Inc. RMR Department 6565P Davis Industrial Parkway Solon, Ohio 44139 If warranty service is requested, the defective unit will be carefully inspected and tested at the factory. If failure was due to conditions listed in the standard Rosemount Analytical warranty, the defective unit will be repaired or replaced at Rosemount Analytical's option, and an operating unit will be returned to the customer in accordance with shipping instructions furnished in the cover letter. For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.

http://www.processanalytic.com

Instruction Manual

Oxymitter 4000

B-2

IM-106-340, Rev. 4.0 February 2006

Instruction Manual IM-106-340, Rev 4.0 February 2006

Oxymitter 4000

Index A

L

Alarm Contacts . . . . . . . . . . . 8-4 Alarm Indications . . . . . . . . . . 8-3 Alarms, Corrective Actions . . . 8-5

Local Operator Interface Logic I/O Mode . . . . . . LOI Menu Tree . . . . . . LOI, Lockout . . . . . . . .

.... ..... ..... .....

6-1 4-5 6-4 6-3

B By-Pass Packages . . . . . . . . 11-2

C Calibration . . . . . . . . 3-6, 4-6, 6-3 Calibration Gas Bottles 1-20, 11-5,

11-6 Calibration Handshake Cell Replacement Kit . Configuration . . . . . . . HART . . . . . . . . . Recommended . .

. . . . . . 4-5 . . . . . 10-3 . . . . . . 3-2 . . 3-2, 4-2 . . 3-6, 4-6

D Display, Error . . . . . . . . 5-2, 6-1 Display, Operating . . . . . 5-1, 6-1 Display, Startup . . . . . . . 5-1, 6-1

E Electrical Noise . . . . . . . . . . . 8-3 Electrostatic Discharge . . . . . . 8-3 Essential Instructions . . . . . . . . i-i

H HART Communications . . . . . 7-1 HART Handheld Communicator 11-1

I IMPS 4000 . . . . . . . . . . . . . 11-3 Installation Mechanical . . . . . . . . . . . 2-2

K Kit Cell Replacement . . . . . 10-3 Probe Disassembly . . . . 10-5

http://www.raihome.com

M Maintenance . . . . . . . . . . Material Safety Data Sheet Membrane Keypad . . . . . Menu Tree HART . . . . . . . . . . . LOI . . . . . . . . . . . . . Menu Tree, LOI . . . . . . . .

. . . 9-1 . . A-15 . . . 5-2 . . . 7-5 . . . 6-4 . . . 6-4

P Parts, Replacement . . . . . . . 10-1 Power Up . . . . . . . . . . . . . . . 5-1 Product Matrix . . . . . . . . . . . 1-18

R Reference Air . . . . . . . . . . . . 5-2 Replacement Parts . . . . . . . 10-1 Returning Material . . . . . . . . . B-1

S Service . . . . . . . . . . . Specifications . . . . . . SPS 4001B . . . . . . . . System Configuration System Description . . System Features . . . .

. . . . . . 9-1 . . . . . 1-16 . . . . . 11-4 . . . . . . 1-4 . . . . . . 1-3 . . . . . . 1-6

T Troubleshooting . . . . . . . . . . 8-1

Instruction Manual

Oxymitter 4000

Index-2

IM-106-340, Rev 4.0 February 2006

WARRANTY Rosemount Analytical warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount Analytical shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount Analytical with respect to the quality of the equipment. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE). The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure of Rosemount Analytical to comply with the warranty provisions, whether claims by the purchaser are based in contract or in tort (including negligence). Rosemount Analytical does not warrant equipment against normal deterioration due to environment. Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the warranty period. Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be subject to the same warranty as is extended to Rosemount Analytical by the original manufacturer. At the time of installation it is important that the required services are supplied to the system and that the electronic controller is set up at least to the point where it is controlling the sensor heater. This will ensure, that should there be a delay between installation and full commissioning that the sensor being supplied with ac power and reference air will not be subjected to component deterioration.

3833 2/06

Instruction Manual IM-106-340, Rev. 4.0 February 2006

Oxymitter 4000

Oxymitter 4000

Part no.____________ Serial no.____________ Order no.____________

Rosemount Analytical and the Rosemount Analytical logotype are registered trademarks of Rosemount Analytical Inc. HART is a registered trademark of the HART Communications Foundation. All other marks are the property of their respective owners. Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 6565P Davis Industrial Parkway Solon, OH 44139 T (440) 914 1261 F (440) 914 1271 E [email protected]

Fisher-Rosemount GmbH & Co. Industriestrasse 1 63594 Hasselroth Germany T +49 (0) 6055 884-0 F +49 (0) 6055 884-209 E [email protected]

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd. Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount Av. das Americas Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

http://www.raihome.com © 2006 Rosemount Analytical Inc. All rights reserved.

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd. 1 Pandan Crescent Singapore 128461 Republic of Singapore T +65 6777-8211 F +65 6777-0947 E [email protected]