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Instruction Manual

IB-106-340Rev. 3.0

December 2003

Oxymitter 4000

Oxygen Transmitter

http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical 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 instructionsMUST 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. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY.Look-alikesubstitutions 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 localFisher-RosemountService Group or National Response Center at1-800-654-7768.

Emerson Process Management

Rosemount Analytical Inc.

Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901T (330)682-9010

F (330) 684-4434

e-mail:gas.csc@EmersonProcess.com http://www.processanalytic.com

 

HIGHLIGHTS OF CHANGES

 

Effective December, 2003 Rev. 3.0

 

 

Page

Summary

 

 

Cover

Updated photo, revision number, and date.

P-3throughP-14

Added foreign language versions of ‘Safety Instructions for the Wiring

 

and Installation of this Apparatus’.

P-22

Revised Figure 1 to include remote electronics versions.

1-1

Revised para. 1-2a to include Local operator Interface (LOI) and Model

 

375 communicator. All IB references to HART Model 275 changed to

 

read ‘HART Model 275/375’.

1-2

Revised Figure 1-1 to include Oxymitter 4000 with remote electronics.

1-3

Revised para. 1-2c to include reference to remote electronics version.

1-4

Revised para. 1-2d to include differences between units with LOI versus

 

membrane keypad and to include new Figure 1-3and Figure1-4views.

1-6

Revised NOTE to include LOI operating temperature data.

1-7

Revised Figure 1-7 to include remote electronics versions.

1-14, 1-15

Revised para. 1-7 Specifications to include LOI data, update electronic

 

noise data, temperature range data, and certification references.

1-16, 1-17

Revised Table 1-1 Product Matrix to update Communication Options and

 

Calibration Accessories, and to include Probe-to-ElectronicsCables.

2-1

Revised para. 2-1a to reference remote electronics version and LOI.

2-4

Revised Figure 2-3 to indicate the integral electronics version is shown.

2-9

Added para. 2-1c to discuss mounting of remote electronics version.

2-12

Added new para. 2-3 for installing remote electronics version.

3-1

Revised section heading to denote configuration instructions applicable

 

to membrane keypad version only.

3-2

Revised para. 3-1e.4 to define new voltage selection parameters.

3-3

Revised Figure 3-2 to update default parameter settings.

3-5,3-6

Revised para. 3-3a to correct mA signal level values. Moved power up

 

procedure to Section 5.

4-1 through4-6

Added new Section 4 to discuss unit configuration with the LOI. Previous

 

Section 4 is now Section 5.

5-1

Revised section heading to apply to membrane keypad version only.

6-1 through6-6

Added new Section 6 to discuss Operation with the LOI. Previous

 

Sections 5 through 11 are now Sections 7 through 13.

8-1

Added new Figure 8-1 and related overview discussion.

8-3

Revised para. 8-5 to include reference to LOI error indications.

8-4

Corrected mA signal level values in notes for Table 8-1.AddedTable 8-2

 

to identify to LOI fault/alarm messages.

HIGHLIGHTS OF CHANGES (CONTINUED)

 

Effective December, 2003 Rev. 3.0 (Continued)

 

 

Page

Summary

 

 

8-5 through8-19

Revised Figure 8-3 throughFigure 8-17 and related text to include LOI

 

fault/alarm messages and corrective actions.

9-0

Moved Calibration Record forward for faster access.

9-2

Added new procedural step, para. 9-2b.2(b) for use with LOI.

9-3 through9-7

Denoted procedure to be for use with membrane keypad. Referenced

 

new para. 9-3 for calibration with LOI.

8-4

Revised Table 8-1 for fit in 2 column format. Added new para.8-6 and

 

Table 8-2 to discuss fault/alarm indications for units with the LOI.

9-6

Added new para. 9-4 to designate start of Oxymitter 4000 repair proce-

 

dures. New para. includes previous para. 9-5through9-10,renumbered.

9-7

Previous Figure 9-1 is nowFigure 9-3 for proximity to related text.

9-8

Added new Figure 9-4 to illustrate remote electronic system parts.

9-18

Added new para. 9-4k to identify terminal housing wiring connections.

 

Renumbered para. 9-5.

11-1 through11-5

Updated Figure number references in Table 11-1.

11-6

Revised Table 11-2 to include remote electronics and LOI components.

12-3

Added Catalyst Regeneration equipment Optional Accessories.

 

 

Oxymitter 4000

Instruction Manual

IB-106-340Rev. 3.0

December 2003

 

 

TABLE OF CONTENTS

 

 

PREFACE........................................................................................................................

 

 

 

P-1

Definitions .....................................................................................................................................

 

 

 

P-1

Safety

Instructions .......................................................................................................................

 

 

 

P-2

What You Need to Know ........................................................................................................

 

 

P-22

Quick

Start Guide? ...................................................................................................................

 

 

P-24

1-0

DESCRIPTION AND SPECIFICATIONS........................................................................

1-1

1-1

Component Checklist of Typical System (Package Contents)..................................

1-1

1-2

System Overview............................................................................................................

 

 

1-1

1-3

IMPS 4000 (Optional) ......................................................................................................

 

 

1-9

1-4

SPS 4000 (Optional)........................................................................................................

 

 

1-9

1-5

Model 751 Remote Powered Loop LCD Display......................................................

1-11

1-6

Probe Options................................................................................................................

 

 

1-11

1-7

Specifications.................................................................................................................

 

 

1-14

2-0

INSTALLATION ..............................................................................................................

 

 

2-1

2-1

Mechanical

Installation ...................................................................................................

 

 

2-1

2-2

Electrical Installation (for Oxymitter 4000 with Integral Electronics,

 

 

without SPS 4000).......................................................................................................

 

 

2-10

2-3

Electrical Installation (for Oxymitter 4000 with Remote Electronics,

 

 

without SPS 4000).......................................................................................................

 

 

2-12

2-4

Electrical Installation (for

Oxymitter 4000 with SPS 4000)....................................

2-15

2-5

Pneumatic

Installation

(for

Oxymitter 4000 without SPS 4000) ............................

2-17

2-6

Pneumatic

Installation

(for

Oxymitter 4000 with SPS 4000) .................................

2-19

2-7

IMPS 4000 Connections................................................................................................

 

2-19

3-0

CONFIGURATION OF OXYMITTER 4000 WITH MEMBRANE KEYPAD ...................

3-1

3-1

General ............................................................................................................................

 

 

 

3-1

3-2

Logic I/O .........................................................................................................................

 

 

 

3-4

3-3

Recommended Configuration.........................................................................................

3-5

4-0

CONFIGURATION OF OXYMITTER 4000 WITH LOI....................................................

4-1

4-1

General ............................................................................................................................

 

 

 

4-1

4-2

Logic I/O .........................................................................................................................

 

 

 

4-4

4-3

Recommended Configuration.........................................................................................

4-5

5-0

STARTUP AND OPERATION OF OXYMITTER 4000 WITH MEMBRANE KEYPAD . 5-1

5-1

Power Up ........................................................................................................................

 

 

 

5-1

5-2

General operation...........................................................................................................

 

 

5-1

Rosemount Analytical Inc. A Division of Emerson Process Management

i

Instruction Manual

IB-106-340Rev. 3.0

December 2003

Oxymitter 4000

6-0

STARTUP AND OPERATION OF OXYMITTER 4000 WITH LOI.................................

6-1

6-1

Power Up ........................................................................................................................

6-1

6-2

Start Up Oxymitter 4000 Calibration............................................................................

6-1

6-3

Navigating the Local Operator Interface......................................................................

6-2

6-4

LOI Key Designations....................................................................................................

6-2

6-5

LOI Menu Tree...............................................................................................................

6-3

6-6

Oxymitter 4000 Setup at the LOI................................................................................

6-4

6-7

LOI Installation................................................................................................................

6-6

6-8

Oxymitter 4000 Test Points ..........................................................................................

6-7

6-9

Model 751 Remote Powered Loop LCD Display (Optional)......................................

6-7

7-0

HART/AMS......................................................................................................................

 

 

7-1

7-1

Overview..........................................................................................................................

 

 

7-1

7-2

HART Communicator Signal Line Connections ..........................................................

7-1

7-3

Hart Communicator PC Connections ...........................................................................

7-2

7-4

Off-Line and On-Line Operations .................................................................................

 

7-2

7-5

Logic I/O Configurations ................................................................................................

 

 

7-2

7-6

Menu Tree for HART Communicator/Oxymitter 4000 Applications...........................

7-2

7-7

HART Communicator Manual

O2

Cal Method...........................................................

7-6

7-8

Defining a Timed Calibration

Via

HART .....................................................................

7-7

8-0

TROUBLESHOOTING ....................................................................................................

8-1

8-1

Overview..........................................................................................................................

8-1

8-2

General ............................................................................................................................

8-2

8-3

Alarm

Indications ............................................................................................................

8-2

8-4

Alarm

Contacts ...............................................................................................................

8-3

8-5

Identifying and Correcting Alarm Indications with Membrane Keypad.....................

8-3

8-6

Oxymitter 4000 Passes Calibration, but Still Reads Incorrectly ....................................

8-20

8-7

SPS 4000 Troubleshooting..........................................................................................

8-21

9-0

MAINTENANCE AND SERVICE ..................................................................................

9-1

9-1

Overview..........................................................................................................................

9-1

9-2

Calibration – Oxymitter 4000 with a Membrane Keypad.................................................

9-1

9-3

Calibration – Oxymitter 4000 with a Local Operator Interface (LOI) ...............................

9-5

9-4

Oxymitter 4000 Repair...................................................................................................

9-6

9-5

SPS 4000 Maintenance and Component Replacement...........................................

9-18

10-0

RETURN OF MATERIAL ..............................................................................................

10-1

11-0

REPLACEMENT PARTS ..............................................................................................

11-1

12-0

OPTIONAL ACCESSORIES........................................................................................

12-1

13-0

INDEX............................................................................................................................

13-1

ii

Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 4000

Instruction Manual

IB-106-340Rev. 3.0

December 2003

LIST OF ILLUSTRATIONS

Figure 1-1.

Typical System Package .......................................................................................

1-2

Figure 1-2.

Oxymitter 4000 Autocalibration System Options ..................................................

1-3

Figure 1-3.

Membrane Keypad.................................................................................................

1-4

Figure 1-4.

Local Operator Interface (LOI)...............................................................................

1-4

Figure 1-5.

Model 751 LCD Display Panel...............................................................................

1-5

Figure 1-6.

Oxymitter 4000 HART Communications and AMS Application .............................

1-6

Figure 1-7.

Typical System Installation – Oxymitter 4000 with Integral Electronics ................

1-7

Figure 1-8.

Typical System Installation – Oxymitter 4000 with Remote Electronics................

1-8

Figure 1-9.

SPS 4000.............................................................................................................

1-10

Figure 1-10.

Model 751 Remote Powered Loop LCD Display................................................

1-11

Figure 1-11.

Ceramic Diffusion Assembly................................................................................

1-11

Figure 1-12. Snubber Diffusion Assembly................................................................................

1-11

Figure 1-13.

Hastelloy Cup-Type Diffusion Assembly.............................................................

1-12

Figure 1-14.

Abrasive Shield Assembly ...................................................................................

1-13

Figure 2-1.

Oxymitter 4000 Probe Installation..........................................................................

2-2

Figure 2-2.

Oxymitter 4000 Remote Electronics Installation....................................................

2-3

Figure 2-3.

Oxymitter 4000 Installation (with SPS 4000) .........................................................

2-4

Figure 2-4.

Oxymitter 4000 with Abrasive Shield.....................................................................

2-5

Figure 2-5.

Oxymitter 4000 Adapter Plate Dimensions............................................................

2-6

Figure 2-6.

Oxymitter 4000 Adapter Plate Installation .............................................................

2-7

Figure 2-7.

Oxymitter 4000 Abrasive Shield Bracing Installation.............................................

2-8

Figure 2-8.

Orienting the Optional Vee Deflector.....................................................................

2-9

Figure 2-9.

Installation with Drip Loop and Insulation Removal...............................................

2-9

Figure 2-10.

Electrical Installation – Oxymitter 4000 with Integral Electronics ........................

2-11

Figure 2-11.

Electrical Installation – Oxymitter 4000 with Remote Electronics........................

2-13

Figure 2-12. SPS 4000 Electrical Connections ........................................................................

2-16

Figure 2-13.

Air Set, Plant Air Connection ...............................................................................

2-18

Figure 2-14.

Oxymitter 4000 Gas Connections Calibration Gas Connections.........................

2-18

Figure 3-1.

Electronics Housing Terminals and Membrane Keypad........................................

3-1

Figure 3-2.

Defaults – Oxymitter 4000 with Membrane Keypad ..............................................

3-3

Figure 4-1.

Electronics Housing Terminals and LOI ................................................................

4-1

Figure 4-2.

Defaults – Oxymitter 4000 with LOI .......................................................................

4-3

Figure 5-1.

Startup and Normal Operation...............................................................................

5-1

Figure 5-2.

Calibration Keys.....................................................................................................

5-2

Figure 6-1.

Startup Display.......................................................................................................

6-1

Figure 6-2.

O2 Concentration Display.......................................................................................

6-1

Figure 6-3.

LOI Features .........................................................................................................

6-2

Figure 6-4.

Menu Tree for Local Operator Interface on the Oxymitter 4000............................

6-3

Figure 6-5.

LOI Module Connectors.........................................................................................

6-6

Figure 6-6.

Oxymitter 4000-Test Points ...................................................................................

6-7

Figure 7-1.

Signal Line Connections, 250 Ohms Load Resistance ......................................

7-0

Figure 7-2.

Signal Line Connections, < 250 Ohms Load Resistance ......................................

7-0

Figure 7-3.

Menu Tree for HART/AMS on the Oxymitter 4000 ................................................

7-3

Figure 8-1.

O2 Sensor mV Reading vs. % O2 at 736ºC (Reference Air, 20.9% O2).................

8-1

Figure 8-2.

Diagnostic LEDs ....................................................................................................

8-2

Figure 8-3.

Fault 1, Open Thermocouple .................................................................................

8-5

Figure 8-4.

Fault 2, Shorted Thermocouple .............................................................................

8-6

Figure 8-5.

Fault 3, Reversed Thermocouple ..........................................................................

8-7

Figure 8-6.

Fault 4, A/D Comm Error .......................................................................................

8-8

Figure 8-7.

Fault 5, Open Heater .............................................................................................

8-9

Rosemount Analytical Inc. A Division of Emerson Process Management

iii

Instruction Manual

IB-106-340Rev. 3.0

December 2003

Oxymitter 4000

Figure 8-8.

Fault 6, High High Heater Temp..........................................................................

8-10

Figure 8-9.

Fault 7, High Case Temp.....................................................................................

8-11

Figure 8-10.

Fault 8, Low Heater Temp ...................................................................................

8-12

Figure 8-11.

Fault 9, High Heater Temp ..................................................................................

8-13

Figure 8-12.

Fault 10, High Cell mV.........................................................................................

8-14

Figure 8-13.

Fault 11, Bad Cell ................................................................................................

8-15

Figure 8-14.

Fault 12, EEPROM Corrupt .................................................................................

8-16

Figure 8-15.

Fault 13, Invalid Slope .........................................................................................

8-17

Figure 8-16.

Fault 14, Invalid Constant ....................................................................................

8-18

Figure 8-17.

Fault 15, Last Calibration Failed..........................................................................

8-19

Figure 8-18.

Probe Leakage Paths ..........................................................................................

8-20

Figure 8-19.

SPS 4000 Troubleshooting Flowchart .................................................................

8-23

Figure 9-1.

Membrane Keypad.................................................................................................

9-2

Figure 9-2.

Inside Right Cover .................................................................................................

9-3

Figure 9-3.

Oxymitter 4000 with Integral Electronics, Exploded View .....................................

9-7

Figure 9-4.

Oxymitter 4000 with Remote Electronics, Exploded View.....................................

9-8

Figure 9-5.

Electronic Assembly.............................................................................................

9-10

Figure 9-6.

J8 Connector........................................................................................................

9-10

Figure 9-7.

Fuse Location ......................................................................................................

9-11

Figure 9-8.

Heater Strut Assembly.........................................................................................

9-13

Figure 9-9.

Probe to Probe Head Assembly – Remote Electronics Only...............................

9-14

Figure 9-10.

Cell Replacement Kit ...........................................................................................

9-14

Figure 9-11.

Ceramic Diffusion Element Replacement............................................................

9-16

Figure 9-12.

Termination Housing Connections for Remote Electronics Probe Head.............

9-18

Figure 9-13.

SPS 4000 Manifold Assembly .............................................................................

9-20

Figure 9-14.

Power Supply Board and Interface Board Connections ......................................

9-22

Figure 9-15.

Calibration Gas and Reference Air Components ................................................

9-25

Figure 11-1.

Cell Replacement Kit ...........................................................................................

11-3

Figure 11-2.

Probe Disassembly Kit.........................................................................................

11-5

LIST OF TABLES

Table 1-1.

Product Matrix ......................................................................................................

1-16

Table 1-2.

Calibration Components ......................................................................................

1-17

Table 1-3.

Intelligent Multiprobe Test Gas Sequencer Versions ............................................

1-18

Table 3-1.

Logic I/O Configuration (as set at HART/AMS or LOI) ..........................................

3-4

Table 4-1.

Logic I/O Configuration (as set at HART/AMS or LOI) ..........................................

4-4

Table 7-1.

Logic I/O Configuration ..........................................................................................

7-2

Table 8-1.

Diagnostic/Unit Alarm Fault Definitions – Membrane Keypad Only ......................

8-4

Table 8-2.

Diagnostic/Unit Alarm Fault Definitions – LOI .......................................................

8-4

Table 8-3.

SPS 4000 Fault Finding.......................................................................................

8-22

Table 11-1.

Replacement Parts for Probe ..............................................................................

11-1

Table 11-2.

Replacement Parts for Electronics ......................................................................

11-6

Table 11-3.

Replacement Parts for SPS 4000.........................................................................

11-7

Table 11-4.

Replacement Parts for Calibration Components .................................................

11-7

iv

Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 4000

Instruction Manual

IB-106-340Rev. 3.0

December 2003

PREFACE

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

Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-termhealth 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.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL : RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

Rosemount Analytical Inc. A Division of Emerson Process Management

P-1

Instruction Manual

IB-106-340Rev. 3.0

December 2003

Oxymitter 4000

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. NonEU 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.

P-2

Rosemount Analytical Inc. A Division of Emerson Process Management