Emerson Rosemount Oxymitter 4000 Instruction Manual

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Instruction Manual

IM-106-340, Rev 4.3 July 2017

Rosemount

Oxymitter 4000

Oxygen Transmitter

HIGHLIGHTS OF CHANGES

Effective May 31, 2006 Rev. 4.0

Page Summary

General Reformatted entire manual from a two column layout. Removed all references to JIS

specifications. Replaced SPS 4000 information with SPS 4001B information. Cover Updated photo, revision number and date. viii Removed Figure 3. Oxymitter 4000 with SPS 4000 Wiring Diagram from Quick Start

Guide. 1-2 Revised Figure 1-1 to show SPS 4001B and updated IMPS 4000. 1-5 Revised Figure 1-2 to show SPS 4001B. 1-8 Added step 11 and Figure 1-6. 1-10, 1-11 Revised Figure 1-8 and Figure 1-9 to show SPS 4001B. 1-12 Removed Components paragraph. 1-13 Removed Figure 1-9. SPS 4000. 1-15

Updated Figure 1-14. Abrasive Shield Assembly. 1-16

, 1-17 Revised Specifications. 1-18, 1-19 Revised Product Matrix table. 2-1 Added two additional warnings. 2-5 Removed Figure 2-3. Oxymitter 4000 Installation (with SPS 4000). 2-12, 2-15 Revised Figure 2-9 and Figure 2-10 to show grounding locations. 2-16 Revised Install Interconnecting Cable paragraph. Removed Electrical Installation (For

Oxymitter 4000 with SPS 400). 2-18 Added SPS 4001B Connections. 3-1, 4-1 Revised Terminal Block Wiring text. 5-2 Added Reference Air information. 7-9 Added D/A Trim Procedure. 8-3 Revised Alarm Indications to include signal alarm levels. 8-23 Removed SPS 4000 Troubleshooting. 9-8, 9-9 Revised Figure 9-3 and Figure 9-4. 9-11, 9-13 Revised Figure 9-6 and Figure 9-7 with updated circuit board. 9-17 Revised Figure 9-10. 9-20 Removed SPS 4000 Maintenance and Component Replacement. 10-3

, 10-4 Updated part numbers for the Cell Replacement Kit, ANSI 15’ and 18’.

10-4

Updated part numbers for the Contact and Thermocouple Replacement Assembly, 15’ and

18’.

HIGHLIGHTS OF CHANGES (CONTINUED)

Effective May 31, 2006 Rev. 4.0 (Continued)

Page Summary

10-5

Removed Ceramic Diffuser Hub Assy. Changed part numbers 4851B89G04 and

4851B90G04 to 10 microns.

10-6

Revised Table 10-2. Removed Replacement Parts for SPS 4000 table.

11-4 Revised Figure 11-4 to show the SPS 4001B. 11-6

Added Figure 11-7 and explanation of the Oxybalance Display and Averaging System.

A-21 Added General Precautions for Handling and Storing High Pressure Gas Cylinders.

Effective January 2007 Rev. 4.1

Page Summary

General Revised reference air specifications to read 1 l/min (2 scfh) throughout the manual. Page 8-22 Added the paragraph and procedural steps after 'Heater Not Open, but Unable to Reach

736°C Setpoint. '

Page A-2 thru A-24 Added note 11 to the safety data section. Added new language translations. Page B-1 Updated the return of materials address. Back cover Updated the address blocks.

Effective July 2008 Rev. 4.2

Page Summary

Page 6-4 Added note regarding cleaning the LOI screen before use.

Effective July 2017 Rev. 4.3

Page Summary

Title page Added “Rosemount” to manual title. Replaced Emerson Process Management logo with Emerson logo. General Replaced all instances of “Rosemount Analytical” with “Rosemount”. Replaced all instances of “Emerson Process Management” with “Emerson”. Back cover Added URL to main website. Added social media icons and URLs. Updated address blocks.

Replaced Rosemount Analytical and Emerson Process Management logos with

Rosemount and Emerson logos.

Instruction Manual

IM-106-340, Rev 4.3 July 2017

Oxymitter 4000

TOC-1

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 Configuration of Oxymitter 4000 with Membrane Keypad

Verify Installation .................................................................................. 2-1

Mechanical Installation .................................................................... 2-1

Terminal Block Wiring ..................................................................... 2-1

Oxymitter 4000 Configuration ......................................................... 2-2

Logic I/O ............................................................................................... 2-5

Recommended Configuration ......................................................... 2-6

SECTION 3 Installation

Mechanical Installation ......................................................................... 3-2

Selecting Location ........................................................................... 3-2

Probe Installation ............................................................................. 3-2

Remote Electronics Installation ....................................................... 3-9

Electrical Installation (with Integral Electronics) ................................. 3-10

Electrical Installation (with Remote Electronics)................................. 3-13

Install Interconnecting Cable ......................................................... 3-16

Pneumatic Installation ........................................................................ 3-16

IMPS 4000 Connections ..................................................................... 3-18

SPS 4001B Connections .................................................................... 3-18

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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

Heater Not Open, but Unable to Reach 736°C Setpoint ..................... 8-22

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

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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

OxyBalance Display and Averaging System ...................................... 11-6

APPENDIX A Safety Data

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . A-24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30

APPENDIX B Return of Material

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

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Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

ESSENTIAL INSTRUCTIONS

Oxymitter Oxygen Transmitters

READ THIS PAGE BEFORE PROCEEDING!

Emerson designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety

program when installing, using, and maintaining Emerson’s Rosemount

products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

•

Read all instructions prior to installing, operating, and servicing the product.

•

If you do not understand any of the instructions, contact your Emerson representative for clarification.

•

Follow all warnings, cautions, and instructions marked on and supplied with the product.

•

Inform and educate your personnel in the proper installation, operation, and maintenance of the product.

•

Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and

pressure sources.

•

To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.

•

When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson. 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 Emerson Service Group or National Response Center at 1-800433-6076 or 1-888-433-6829.

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

Section i 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

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

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.

SYMBOLS

NOTE

Highlights an essential operating procedure, condition, or statement.

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.

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.

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Oxymitter 4000

IMPS

4000

SPS

4001B

WHAT YOU NEED TO KNOW

BEFORE INSTALLING AND WIRING A ROSEMOUNT 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

LOGIC I/O

Cal. Gas Ref. Air

Line Voltage Cal. Gas 1

Cal. Gas 2

Instr. Air (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)

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.

38890001

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July 2017

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

Calibration Gas Reference Air Cal. Gas 2

Cal. Gas 1

Instr. Air

IMPS

4000

38890049

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Oxymitter 4000

vii

CAN YOU USE THE QUICK START GUIDE?

Use this Quick Start Guide if...

Your system requires an Oxymitter 4000 with or without the SPS 4001B OPTION. Installation options for the Oxymitter 4000 are shown in Figure 1.

Your system does NOT require an IMPS 4000 OPTION installation.

Your system does NOT use a Remote Electronics as shown in Figure 2.

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 3: Installation, in this Instruction Manual.

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viii

QUICK START GUIDE FOR OXYMITTER 4000 SYSTEMS

Before using the Quick Start Guide, please read "WHAT YOU NEED TO KNOW BEFORE INSTALLING AND WIRING A ROSEMOUNT OXYMITTER 4000 OXYGEN TRANSMITTER" on the preceding page.

Install the Oxymitter 4000 in an appropriate location on the stack or duct. Refer to "Selecting Location" in Section 3: Installation, for information on selecting a location for the Oxymitter 4000.

If using an SPS 4001B, connect the calibration gasses to the appropriate fittings on the SPS 4001B manifold.

Connect reference air to the Oxymitter 4000 or SPS 4001B, as applicable.

If using an SPS 4001B, make the wiring connections as shown in the SPS 4001B Single Probe Autocalibration Sequencer Instruction Manual.

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.

Verify the Oxymitter 4000 switch configuration is as desired. Refer to "Oxymitter 4000 Configuration", "SW1 Setting", and "SW2 Setting" all in Section 2: 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.

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.

If using an SPS 4001B, initiate a semi-automatic calibration.

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.

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Oxymitter 4000

Figure 3. Oxymitter 4000 without SPS 4001B Wiring Diagram

QUICK REFERENCE GUIDE MANUAL CALIBRATION INSTRUCTIONS

Performing a Manual Calibration with a Membrane Keypad

Place the control loop in manual.

Press the CAL key. The CAL LED will light solid.

Apply the first calibration gas.

Press the CAL key. When the unit has taken the readings using the first calibration gas, the CAL LED will flash continuously.

Remove the first calibration gas and apply the second calibration gas.

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.

Remove the second calibration gas and cap off the calibration gas port.

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.

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.

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July 2017

Oxymitter 4000

HART COMMUNICATOR FAST KEY SEQUENCES

Perform Calibration

2 3 1 1

Trim Analog Output

Toggle Analog Output Tracking

Upper Range Value

3 2 1

Analog Output Lower Range Value

3 2 2

View O2 Value

View Analog Output

1 2 1

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’s field service throughout the U.S. and abroad.

Phone: 1-800-654-RSMT (1-800-654-7768) Emerson may also be reached via the Internet through e-mail and the World

Wide Web: e-mail: GAS.CSC@emersonprocess.com World Wide Web: www.raihome.com

2 3 1 2 1 1 1

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Oxymitter 4000

Section 1 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 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 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.

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1-2

Figure 1-1. Typical System Package

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 and Cable (Optional)

Reference Air Set (used if SPS 4001B without reference air option or IMPS 4000 supplied)

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1-3

System Description 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:

P2 is the partial pressure of the oxygen in the measured gas on one side of the cell.

P1 is the partial pressure of the oxygen in the reference air on the opposite side of the cell.

T is the absolute temperature.

C is the cell constant.

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.

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System Configuration 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.

The cell output voltage and sensitivity increase as the oxygen concentration decreases.

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1-5

Figure 1-2. Oxymitter 4000 AutoCalibration System Options

)

Membrane keypad, Figure 1-3, and HART communication are standard. To use the HART capability, you must have either:

HART Model 275/375 Communicator.

Asset Management Solutions (AMS) software for the PC.

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1-6

Figure 1-3. Membrane Keypad

DIAGNOSTIC

ALARMS

HEATER T/C

HEATER

02 CELL

CALIBRATION

CALIBRATION RECOMMENDED

02 CELL mV +

TEST

POINTS

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

INC INC

HIGH

GAS

LOW GAS

DEC DEC

TEST GAS +

PROCESS -

% 02

MEMBRANE

KEYPAD

An optional Local Operator Interface, Figure 1-4, allows continuous O

display and full interface capability.

Figure 1-4. Local Operator Interface (LOI)

Field replaceable cell, heater, thermocouple, and diffusion element.

The Oxymitter 4000 is constructed of rugged 316 L stainless steel for all wetted parts.

The electronics are adaptable for line voltages from 90-250 VAC; therefore, no configuration is necessary.

CAL

38890004 38890003

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1-7

The Oxymitter 4000 membrane keypad is available in five languages:

English French German Italian Spanish

An operator can calibrate and diagnostically troubleshoot the Oxymitter 4000 in one of four ways:

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.

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.

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:

Rosemount 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 Emerson 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 Emerson.

iii.

Selected Distributed Control Systems - The use of distributed control systems requires input/output (I/O) hardware and AMS software which permit HART communications.

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.

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Figure 1-5. Model 751 LCD Display Panel

Figure 1-6. OxyBalance Display Displaying Outputs

Handling the Oxymitter 4000

10.

The optional Rosemount 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.

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.

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

Hazardous Area Oxymitter 4000

with Integral Electronics

4-20 mA Output

(Twisted Pairs)

HART

Model 275/375

Handheld

Interface

2 Calibration Gas Lines

by Customer

[300 ft (90 m) max]

Line Voltage

Termination in Control Room

Asset Management Solutions

System Considerations 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 degr ade 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.

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

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

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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 The SPS 4001B works in conjunction with the Oxymitter 4000's CALIBRA-

TION 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.

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MODEL 751 REMOTE POWERED LOOP LCD DISPLAY

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

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.

Figure 1-11. Ceramic Diffusion Assembly

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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.

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 10 or 40 micron, sintered, Hastelloy element.

This element is also available with a dust seal for use with an abrasive shield.

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.

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Figure 1-14. Abrasive Shield Assembly

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.

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SPECIFICATIONS

Oxymitter Specifications

O2 Range

Standard 0 to 10% O2, 0 to 25% O2, 0 to 40% O2 (via HART) Accuracy ±0.75% of reading or 0.05% O2, whichever is greater System Response to Calibration Gas

Temperature Limits

Initial – less than 3 seconds, T90 – less than 8 seconds

Process 32°to 1300°F (0° to 704°C) up to 2400°F (1300°C)

with optional accessories Electronics Housing -40° to 158°F (-40°to 70°C) amb ient Electronics Package -40° to 185°F (-40°to 85°C) [Operating temperature

of electronics inside of instrument housing, as

measured by a HART communicator, Rosemount

Asset Management Solutions software.] Local Operator Interface -40°to 158°F (-40°to 70° C), [above 158°F (70°C) the

infrared keypad will cease to function, but the

Oxymitter 4000 will continue to operate properly.]

Probe Lengths 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)

Mounting and Mounting Position Vertical or horizontal;

a spool piece, (P/N 3D39761G02), is available to

offset transmitter housing from hot ductwork.

Materials

Probe Wetted or welded parts - 316L stainless steel (SS)

Non-wetted parts - 304 SS, low-copper aluminum Electronics Enclosure Low-copper aluminum

Calibration Manual, semi-automatic, or automatic Calibration Gas Mixtures

Recommended

0.4% O2, Balance N

8% O2, Balance N

Calibration Gas Flow 2.5 l/min (5 scfh) Reference Air 1 l/min (2 scfh), clean, dry, instrument-quality air

(20.95% O2), regulated to 34 kPa (5 psi)

Electronics NEMA 4X, IP66 with fitting and pipe on reference

exhaust port to clear dry atmosphere

Electric Noise EN 61326-1, Class A Certifications General Purpose

Line Voltage

90-250 VAC, 48/62 Hz. No configuration necessary. 3/4 in. -14 NPT conduit port

Table continued on next page

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Signals

Oxymitter Specifications

Analog Output/HART 4-20 mA isolated from power supply, 950 ohms

maximum load Logic I/O 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)

Power Requirements:

Probe Heater 175 W nominal Electronics 10 W nominal Maximum 500 W

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Table 1-1. Product Matrix

OXT4A

Oxymitter 4000 In Situ Oxygen Transmitter

Oxygen Transmitter - Instruction Book

Code

Sensing Probe Type

1 ANSI (N. American Std.) Probe with Ceramic Diffuser

2 ANSI Probe with Flame Arrestor and Ceramic Diffuser

3 ANSI Probe with Snubber Diffuser

4 DIN (European Std.) Probe with Ceramic Diffuser

5 DIN Probe with Flame Arrestor and Snubber Diffuser

6 DIN Probe with Snubber Diffuser

Code

Probe Assembly

0 18 in. (457 mm) Probe

18 in. (457 mm) Probe with Abrasive Shield

(1)

2 3 ft (0,91 m) Probe

3 3 ft (0,91 m) Probe with Abrasive Shield

(1)

4 6 ft (1,83 m) Probe

5 6 ft (1,83 m) Probe with Abrasive Shield

(1)

6 9 ft (2,74 m) Probe

9 ft (2,74 m) Probe with Abrasive Shield

(1)

8 12 ft (3,66 m) Probe

9 12 ft (3,66 m) Probe with Abrasive Shield

(1)

A 15 ft (4,57 m) Probe with Abrasive Shield

(1)

B 18 ft (5,49 m) Probe with Abrasive Shield

(1)

Code

Mounting Hardware- Stack Side

0 No Mounting Hardware ("0" must be chosen under "Mounting Hardware - Probe Side" below)

1 New Installation - Square weld plate with studs

2 Mounting to Model 218 Mounting Plate (with Model 218 Shield Removed)

3 Mounting to Existing Model 218 Support Shield

4 Mounting to Other Mounting

(2)

5 Mounting to Model 132 Adapter Plate

Code

Mounting Hardware- Probe Side

0 No Mounting Hardware

1 Probe Only (ANSI) (N. American Std.)

2 New Bypass or New Abrasive Shield (ANSI)

4 Probe Only (DIN)

5 New Bypass or New Abrasive Shield (DIN)

Code

Electronic Housing & Filtered Customer Termination - NEMA 4X, IP66

HART Integral Electronics, Transient Protected Filtered Termination, ATEX Certification

Remote Electronics with Transient Protected Filtered Termination (requires cable)

OXT4C 3 3 1 1

Example

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Cont’d

Code

Operator Interface

(3)

1 HART with Membrane Keypad - blind cover

2 HART with Membrane Keypad - window cover

3 HART with Local Operation Interface, window cover, English only

Code

Language

1 English 2

German

3 French

4 Spanish 5

Italian

Code

Termination Filtering

Specified as part of Electronic Housing

Code

Calibration Accessories

No Hardware

Calibration Gas Flowmeter and Reference Air Set

Intelligent Multiprobe Sequencer (Refer to Table 1-3)

Code

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

Cont’d 1 3

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

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

Plate without studs

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

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Part Number Description

Table 1-2. Calibration Components

1A99119G01 Two disposable calibration gas bottles - 0.4% and 8% O2, balance

nitrogen - 550 liters each* 1A99119G02 Two flow regulators for calibration gas bottles 1A99119G03 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 Description Number of Oxymitters

3D39695G01

IMPS

3D39695G02

IMPS

3D39695G03

IMPS

3D39695G04

IMPS

3D39695G05

IMPS w/115 V Heater

3D39695G06

IMPS w/115 V Heater

3D39695G07

IMPS w/115 V Heater

3D39695G08

IMPS w/115 V Heater

3D39695G09

IMPS w/220V Heater

3D39695G10

IMPS w/220V Heater

3D39695G11

IMPS w/220V Heater

3D39695G12

IMPS w/220V Heater

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Oxymitter 4000

Section 2 Configuration of Oxymitter 4000

with Membrane Keypad

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1

Logic I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-5

VERIFY INSTALLATION

Mechanical Installation Ensure the Oxymitter 4000 is installed correctly. See Section 3: Installation.

Terminal Block Wiring 1. Remove cover (27) to expose terminal block (25).

Check the terminal block wiring (Figure 2-1). 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.

Install housing cover (27, Figure 9-3 or Figure 9-4) on terminal block (25).

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.

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Figure 2-1. Electronics Housing Terminals and Membrane Keypad

Oxymitter 4000 Configuration

Located on the microprocessor board, the top board, are two switches that configure outputs for the Oxymitter 4000 (Figure 2-2). SW1 determines if the 4-20 mA signal is internally or externally powered. SW2 determines:

Oxymitter 4000 status, HART or LOCAL.

Oxygen range, 0 to 10% O2 or 0 to 25% O2. (0 to 40% O2 is also configurable only through HART/AMS.)

The 4-20 mA signal, at fault or power up, 3.5 mA or 21.6 mA.

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.

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

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SW2 Setting

The factory sets this switch as follows:

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.

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.

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.

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).

Typically, the probe's sensing cell, in direct contact with the process gases, is heated to approximately 1357°F (736°C). The external temperat ure 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.

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

Read O2 Concentration

Once the cell is up to operating temperature, the O2 percentage can be read:

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.

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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

HART/AMS.

Model 751. The loop-driven LCD display.

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 2-1.

Table 2-1. Logic I/O Configuration (as set at HART/AMS or LOI)

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.

5* 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.

8** The unit is configured for a calibration handshake with IMPS 4000 or SPS 4001B.

CALIBRATION RECOMMENDED will initiate the calibration cycle.

9 The unit is configured for a calibration handshake. CALIBRATION

RECOMMENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4001B.

*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 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 2-1, 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.

Mode Configuration

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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 2-1, 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

Emerson 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 O

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

Emerson 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.

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.

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 O

signal is being utilized in an automatic control loop, this contact should be utilized to place the control loop into manual during calibration.

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.

4-20 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.

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Oxymitter 4000

Section 3 Installation

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-2

Electrical Installation (with Integral Electronics) . . . . . . . page 3-10

Electrical Installation (with Remote Electronics) . . . . . . . page 3-13

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-16

IMPS 4000 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-18

SPS 4001B Connections . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-18

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.

The Oxymitter 4000 (OXT4A) can be installed in general purpose areas only. Do not install the OXT4A in hazardous areas. For hazardous areas use the OXT4C.

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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 3-1 through Figure 3-8 provide mechanical installation references. The ambient temperature of the integral electronics housing must not exceed 185°F (85°C). F or higher ambient temperatures, we recommend the remote mounted electronics option.

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.

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.

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.

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 3-6.

Weld or bolt adapter plate (Figure 3-5) onto the duct.

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 3-7). This may be done by loosening the setscrews and rotating the vee deflector to the desired position. Retighten the setscrews

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

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

3-3

Figure 3-1. Oxymitter 4000 Probe Installation

HART

800-

433-

6076

Cal

Gas

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

3-4

(84,6)

Figure 3-2. 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

5.52

(140,2)

2.62

(66,5)

2.68 (68,1)

Note:

Dimensions are in inches with millimeters in parentheses.

PIPE MOUNT

CONFIGUR

ATION

ALL

MOUNT

CONFIGUR

ATION

38890046

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

3-5

Figure 3-3. Oxymitter 4000 with Abrasive Shield

Dim

"B"

Removal

Envelope

Dim

"A"

3.9

(99)

Snubber/Dust

Seal

Assembly

0.2

(5)

7.00

(178) 12.50

(318)

3.6

(91)

Dia

Nominal

CAL.

GAS

Diffuser/Dust Seal

Assy

Deflector

Assy

3/4

NPT

Electrical

Connection

Cal Gas*

Ref

Air

ANSI

1/4

in.

Tube

DIN 6

Tube

*Add

check

valve

Cal

Gas

line

38890070

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

3-6

Figure 3-4. Oxymitter 4000 Adapter Plate Dimensions

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

3-7

Figure 3-5. Oxymitter 4000 Adapter Plate Installation

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

3-8

Figure 3-6. Oxymitter 4000 Abrasive Shield Bracing Installation

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 3-8).

If the system has an abrasive shield, check the dust seal gaskets. The joints in the two gaskets must be staggered 180°. A lso, make sure the gaskets are in the hub grooves as the Oxymitter 4000 slides into the 15° forcing cone in the abrasive shield.

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 3-6).

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 reco mmend the remote mounted electronics option.

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

3-9

Figure 3-7. Orienting the Optional Vee Deflector

Remote Electronics Installation

8. If insulation is being removed to access the duct work for Oxymitter 4000 mounting, make sure the insulation is replaced afterward (Figure 3-8).

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 3-2.

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

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

3-10

Figure 3-8. Installation with Drip Loop and Insulation Removal

ELECTRICAL INSTALLATION (WITH INTEGRAL ELECTRONICS)

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.

38890075

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Oxymitter 4000

3-11

NOTE

To maintain proper earth grounding, ensure a positive connection exists between the sensor housing, the electronics housing, and earth. The connecting ground wire must be 14 AWG minimum. Refer to Figure 3-9.

NOTE

Line voltage, signal, and relay wiring must be rated for at least 221°F (105°C).

Remove cover (27).

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 3-9). The Oxymitter 4000 automatically will configure itself for 90-250 VAC line voltage and 50/60 Hz. The power supply requires no setup.

Connect 4-20 mA Signal and Calibration Handshake/Logic I/O Leads. Use individual shielded twisted wire pairs. Terminate the shield only at the electronics housing.

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.

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.

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 2-1 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.

Install cover (27, Figure 9-3).

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

3-12

Figure 3-9. Electrical Installation - Oxymitter 4000 with Integral Electronics

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

3-13

ELECTRICAL INSTALLATION (WITH REMOTE ELECTRONICS)

For Oxymitter 4000 with Remote Electronics

All wiring must conform to local and national codes.

NOTE

Line voltage, signal, and relay wiring must be rated for at least 221°F (105°C).

Remove cover (27) from remote electronics.

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 3-10). The Oxymitter 4000 automatically will configure itself for 90-250 VAC line voltage and 50/60 Hz. The power supply requires no setup.

Connect 4-20 mA Signal and Calibration Handshake/Logic I/O Leads (Figure 3-10). Use individual shielded twisted wire pairs. Terminate the shield only at the electronics housing.

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.

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July 2017

Oxymitter 4000

3-14

Install cover (27, Figure 9-4).

Install Interconnecting Cable. a.

Remove cover (3) from junction box (5). Connect the electronics end of the interconnecting cable to the "FROM PROBE" side of the terminal block (Figure 3-10).

Remove housing cover (27).

Connect the heater power leads, the thermocouple leads and the oxygen signal leads at the terminal block. The leads are tagged for polarity.

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

3-15

Figure 3-10. Electrical Installation - Oxymitter 4000 with Remote Electronics

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IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

3-16

Install Interconnecting Cable

NOTE

If interconnect cable was not purchased with the Oxymitter 4000, consult the factory for the proper wire type and gauge.

Remove cover (27, Figure 9-4) from junction box (5). Connect the electronics end of the interconnecting cable (9) to the "FROM PROBE" side of terminal block (Figure 3-10).

Remove cover (27).

See (Figure 3-10). 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.

Install covers (27, Figure 9-3 and Figure 9-4).

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 3-11.

Instrument Air (Reference Air): 10 psig (68.95 kPag) minimum, 225 psig (1551.38 kPag) maximum at 1 l/min (2 scfh) 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.

Calibration Gas

Two calibration gas concentrations are used with the Oxymitter 4000, Low Gas - 0.4% O2 and High Gas - 8% O2. See Figure 3-12 for the Oxymitter 4000 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.

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

3-17

Figure 3-11. Air Set, Plant Air Connection

Figure 3-12. Oxymitter 4000 Gas Connections Calibration Gas Connections

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

3-18

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.

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

Section 4 Configuration of Oxymitter 4000

with LOI

Verify installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1

Logic I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-4

VERIFY INSTALLATION

Mechanical Installation Ensure the Oxymitter 4000 is installed correctly. See Section 3: Installation. Terminal Block Wiring 1. Remove cover (27) to expose terminal block (25).

Check the terminal block wiring, Figure 4-1. Be sure the power, 4-20 mA signal, and logic outputs are properly connected and secure.

Install housing cover (27, Figure 9-3 or Figure 9-4) on terminal block (25).

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.

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

4-2

Figure 4-1. Electronics Housing Terminals with LOI

Oxymitter 4000 Configuration

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:

Range control, HART or LOCAL.

Oxygen range, 0 to 10% O2 or 0 to 25% O2. (0 to 40% O2 is also configurable only through HART/AMS.)

The 4-20 mA signal, at fault or power up, 3.5 mA or 21.6 mA.

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.

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

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

4-3

SW2 Setting

The factory sets this switch as follows:

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.

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.

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.

Read O2 Concentration

Once the cell is up to operating temperature, the O2 percentage can be read:

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

HART/AMS.

Model 751. The loop-driven LCD display.

Instruction Manual

IM-106-340, Rev. 4.3

July 2017

Oxymitter 4000

4-4

Figure 4-2. Defaults - Oxymitter 4000 with LOI

LOGIC I/O This two-terminal logic contact can be configured either as a solid-state

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, Emerson recommends connecting the output to a Potter & Brumfield 3.2 mA DC relay (P/N R10S-E1Y1-J1.0K).

Instruction Manual

IM-106-340, Rev. 4.3 July 2017

Oxymitter 4000

4-5

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)