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SPS 4001B
User Manual
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Emerson SPS 4001B User Manual

Instruction Manual
IM-106-340AC-1, Rev 1.0 April 2005
SPS 4001B Single Probe Autocalibration Sequencer
http://www.raihome.com
Instruction Manual
IM-106-340AC-1, Rev. 1.0 April 2005
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1 Description and Specifications
SECTION 2 Installation
SECTION 3 Operation
SECTION 4 Maintenance and Service
Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Calibration Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Reference Air Flow Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Calibration Gas Flow Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Automatic Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Semi-automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Remove/Install Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Pressure Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pressure Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Flow Meter Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
SECTION 5 Troubleshooting
SECTION 6 Replacement Parts
APPENDIX A Safety Data
APPENDIX B Return of Materials
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SPS 4001B Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SPS 4001B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Calibration Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
TOC-1
Instruction Manual
IM-106-340AC-1, Rev. 1.0
April 2005
TOC-2
Instruction Manual
IM-106-340AC-1, Rev. 1.0 April 2005
SPS 4001B Single Probe Autocalibration Sequencer

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
specifications. The following instructions MUST be adhered to 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
product.
• If you do not understand any of the instructions, contact your
Rosemount Analytical representative
• Follow all warnings, cautions, and instructions
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 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-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.
to ensure they continue to operate within their normal
and integrated
prior to installing, operating, and servicing the
for clarification.
marked on and
.
to install,
.
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The information contained in this document is subject to change without notice.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
Instruction Manual
IM-106-340AC-1, Rev. 1.0
April 2005

PREFACE

DEFINITIONS

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the SPS 4001B Single Probe Autocalibration Sequencer.
Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

SYMBOLS

NOTE
Highlights an essential operating procedure, condition, or statement.
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.
ii
Instruction Manual
IM-106-340AC-1, Rev. 1.0 April 2005

Section 1 Description and Specifications

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-2

COMPONENT CHECKLIST

Figure 1-1. SPS 4001B Package
A typical SPS 4001B Single Probe Autocalibration Sequencer should contain the items shown in Figure 1-1. Record the part number, serial number, and order number for the SPS 4001B on the back cover of this manual.
NOTE
The SPS 4001B operates exactly the same with either the Oxymitter 4000 Oxygen Transmitter or the Oxymitter 5000 Oxygen Transmitter with FOUNDATION fieldbus communications. Any references to the Oxymitter 4000 throughout this instruction manual also apply to the Oxymitter 5000.
1
2
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OVERVIEW

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1. SPS 4001B
37470004
2. Instruction Manual
The SPS 4001B provides the capability of performing automatic, timed or on demand, calibrations of a single Oxymitter 4000 without sending a technician to the probe site.
The SPS 4001B replaces the SPS 4000, a similar unit with exposed analog devices mounted to a stainless steel support bracket. The operating parameters of the SPS 4000 and SPS 4001B are identical. All SPS units require additional calibration system components. These components, available from Rosemount Analytical, are listed in Table 1-1.

SPECIFICATIONS

Instruction Manual
IM-106-340AC-1, Rev. 1.0
April 2005
The SPS 4001B is fully enclosed in a NEMA cabinet suited for wall-mounting. The enclosure provides added protection against corrosive atmospheres and incidental impact damage.
Rosemount Analytical has offered multiprobe autocalibration sequencer systems for many years. These autocalibration systems are most cost effective for boilers and other combustion processes that utilize many probes. Users with only one probe per combustion process can take advantage of Rosemount Analytical's autocalibration capability with the SPS 4001B.
Specifications
SPS 4001B Assembly
Part Number Mounting Wall mount Materials of Construction:
Enclosure Fiberglass Manifold Aluminum with 1/4 in. NPT ports Pneumatic tubing - Low
Pressure Pneumatic tubing - High
Pressure
Assembly hardware Galvanized and stainless steel Humidity range 5 - 95% relative humidity, non condensing Ambient temperature range -40° to 149°F (-40° to 65°C) with optional heater
Enclosure protection NEMA 4 (IP66) Hazardous area option Electrical entries 1/2 in. NPT (0.875 in. with gland) Input power 90 to 250 VAC ±10%, 50/60 Hz Power consumption 5VA maximum External electrical noise EN 61326-1 class A Handshake signal to/from
Oxymitter 4000
(self-powered) Cal initiate input from control
room: In-Cal Relay Contact Cal Failed Relay Contact Cabling distance between SPS
4001B and Oxymitter 4000 Piping distance between
SPS 4001B and
Oxymitter 4000 Approximate shipping weight 10 lbs (4.5 kg) Pollution degree 2 Overvoltage Category II Certification General Purpose
(1)
(4)(5)
(4)(5)
(2) (3)
6A00175G01
Buna N with overbraid
Impolene
-25° to 149°F (-5° to 65°C)
Z-purge (by owner)
5V (5mA maximum)
Internally 5V powered
5 to 30 VDC, 100 mA, Form A (SPST) 5 to 30 VDC, 100 mA, Form A (SPST) Maximum 1000 ft (303 m)
Maximum 300 ft (91 m)
1-2
CUS
NOTES (1) Hazardous area option requires the addition of a Z-purging system by the owner. (2) Reference air is recommended with 9 ft (2.74 m) and 12 ft (3.66 m) long probes. Reference air is also
recommended when ambient air may not contain the normal 20.95% O
mounted into a positive pressure duct with leaks or where there is a process unit nearby with leaks. (3) Customer to provide piping from remote SPS 4001B to probe. (4) External current limiting device must be provided by customer. (5) If contacts are used to drive relay coils, a reverse blocking (flyback) diode must be installed on the input
to the relay coil. Relay and diode to be provided by customer.
APPROVED
, such as when the probe is
2
Instruction Manual
IM-106-340AC-1, Rev. 1.0 April 2005
Table 1-1. Calibration Components
PART NUMBER DESCRIPTION
1A99119G01
1A99119G02 Two flow regulators for calibration gas bottles
1A99119G03 Bottle rack
NOTES (1) Calibration gas bottles cannot be shipped via airfreight. (2) When the bottles are used with "CALIBRATION RECOMMENDED" features, the bottles should provide
2 to 3 years of calibrations in normal service.
Two disposable calibration gas bottles - 0.4% and 8% O nitrogen - 550 liters each
(1) (2)
, balance
2

PHYSICAL DESCRIPTION

Figure 1-2. SPS 4001B Components
The main components of the SPS 4001B are illustrated in Figure 1-2.
Manifold
The manifold provides porting to and from the calibration solenoids. The manifold ports are accessible from outside the enclosure for making piping connections. The Oxymitter 4000 calibration gases are piped into and sequenced through the calibration gas solenoids mounted on the manifold.
CALIBRATION GAS
FLOW METER
REFERENCE AIR
FLOW METER
CIRCUIT
BOARD
OUT
REFERENCE
AIR PRESSURE
REGULATOR
MANIFOLD
CALIBRATION GAS 1
(LOW CAL GAS)
CALIBRATION GAS 2
(HIGH CAL GAS)
SOLENOID
PRESSURE
SWITCH
SOLENOID
37740002
1-3
Instruction Manual
IM-106-340AC-1, Rev. 1.0
April 2005
Calibration Gas Solenoids
The solenoids sequence the calibration gases. One solenoid controls calibration gas 1 (high calibration gas), and the other controls calibration gas 2 (low calibration gas). The solenoids activate and deactivate to allow the calibration gases to flow between the sequencer and Oxymitter 4000.
Pressure Switch
The pressure switch detects if the pressure of a calibration gas is low, which can be caused by an empty gas bottle, a disconnected gas line, etc. Calibration is prohibited when calibration gas pressure is low.
Circuit Board
The circuit board converts the incoming line voltage from AC to DC for use by the solenoids, terminations, and the programmable logic device. The power circuit is protected by a 1.6 A, 250 V, fast acting fuse.
The board contains a programmable logic device (PLD) that has the electronics to energize and deenergize the solenoids based on a signal from the Oxymitter 4000.
A terminal strip provides convenient access for all signal and power user connections.
Calibration Gas Flow Meter
The calibration gas flow meter indicates the flow rate of calibration gas flowing to the Oxymitter 4000.
Reference Air Flow Meter
The reference air flow meter indicates the amount of reference air continuously flowing to the Oxymitter 4000.
Pressure Regulator
The 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.
1-4
Instruction Manual
IM-106-340AC-1, Rev. 1.0 April 2005

THEORY OF OPERATION

The Oxymitter 4000 is one of the few instruments found in industry that permit the permanent piping of a calibration standard into the probe. Most instruments measuring pressure, flow, or temperature, require that a calibration standard be brought to the instrument or that the instrument be taken to the calibration source in the instrument shop.
The permanent calibration gas connections allow for autocalibrations to occur without operator intervention. The following paragraphs describe how an Oxymitter 4000 is autocalibrated when used with the SPS 4001B.
In addition to the calibration methods available via the Oxymitter 4000 keypad, HART communicator, AMS software, or a remote contact, the SPS 4001B works in conjunction with the Oxymitter 4000's CAL RECOMMENDED feature to perform an autocalibration.
This feature automatically performs an impedance check every hour on the Oxymitter 4000. If a calibration is recommended and its contact output signal is set for "handshaking" with the SPS 4001B sequencer, the Oxymitter 4000 sends a signal to the sequencer. The sequencer automatically performs a calibration upon receiving the signal. Therefore, no human interface is required for the automatic calibration to take place.
See Figure 1-3. When a calibration is required, the Oxymitter 4000 sends a signal to the programmable logic device (PLD) on the interface board of the sequencer. The PLD energizes the calibration gas 1 (high O Calibration gas 1 then flows through the sequencer to the Oxymitter 4000. The Oxymitter 4000 measures the oxygen content of calibration gas 1 and sends a signal to the sequencer indicating that it received the gas. When the sequencer receives the signal, the PLD deenergizes the calibration gas 1 solenoid.
) solenoid.
2
Next, the PLD energizes the calibration gas 2 (low O calibration gas 2 then flows through the sequencer to the Oxymitter 4000. The Oxymitter 4000 measures the oxygen content of calibration gas 2 and sends a signal to the sequencer indicating that it received the gas. After measuring the two calibration gases, the Oxymitter 4000 automatically makes an internal calibration adjustment and sends the signal to the sequencer. When the sequencer receives the signal, the PLD deenergizes the calibration gas 2 solenoid.
) solenoid, and
2
1-5
Figure 1-3. SPS 4001B Calibration Setup
Instruction Manual
IM-106-340AC-1, Rev. 1.0
April 2005
OXYMITTER 4000 LOGIC I/O
CHECK VALVE
(SEE NOTE 1)
SPS
4001B
CALIBRATION GAS
OXYMITTER 4000
(BOTTOM VIEW)
INSTRUMENT
AIR IN
(SEE NOTE 2)
NOTES:
A CHECK VALVE IS REQUIRED AT THE
1. OXYMITTER 4000 (BETWEEN THE CALIBRATION GAS FITTING AND THE GAS LINE) TO PREVENT THE MIGRATION OF PROCESS GASES DOWN THE CALIBRATION GAS LINE.
CLEAN, DRY INSTRUMENT AIR IS
2. RECOMMENDED FOR REFERENCE AIR. NO REFERENCE AIR IS REQUIRED IF AMBIENT AIR CONDITIONS CONTAIN
20.95% OXYGEN.
REFERENCE AIR (SEE NOTE 2)
CALIBRATION
GAS 1
(HIGH O )
2
CALIBRATION
(LOW O )
37740005
GAS 2
2
1-6
Instruction Manual
IM-106-340AC-1, Rev. 1.0 April 2005

Section 2 Installation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-4

OVERVIEW

MECHANICAL INSTALLATION

This section describes SPS 4001B installation.
Before starting to install this equipment, read the "Safety instructions for the wiring and installation of this apparatus" in Section A: Safety Data. Failure to follow the safety instructions could result in serious injury or death.
Secure equipment cover and ground leads after installation. Failure to secure covers and ground leads could result in serious injury or death.
The outline drawing in Figure 2-1 shows mounting centers and clearances of the SPS 4001B. The unit is designed to mount on a wall, bulkhead, or pipe. Ensure the unit is installed according to the following specifications.
1. Install the unit no further than 300 ft (91 m) from the Oxymitter 4000 and no further than 1000 ft (303 m) from the electronics package or any customer-supplied remote input or relay output in the control room.
2. Locate the unit where the ambient temperature is between -25° and 149°F (-5° and 65°C) or -40° and 149°F (-40° and 65°C) with optional heater.
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Instruction Manual
IM-106-340AC-1, Rev. 1.0
April 2005

GAS CONNECTIONS

Use the following procedures to connect the reference air and the calibration gases.
Reference Air (Figure 2-1)
The Oxymitter 4000 requires a source of reference air that is constantly
20.95% O
. Clean and dry instrument air provides the most stable source of
2
reference air. If instrument air is unavailable, the reference air port of the probe can be left open, permitting ambient air to passively diffuse into the probe.
1. Connect the instrument air supply to the INST AIR IN port of the manifold.
2. The pressure regulator is factory set at 20 psi (138 kPa). If necessary, readjust by turning the knob on the top of the regulator until the desired pressure is obtained.
3. Next, connect the reference air from the REF GAS OUT port of the manifold to the REF GAS port on the Oxymitter 4000.
Calibration Gas (Figure 2-1)
1. Connect O
calibration gas 1 (high calibration gas) to the HI GAS IN
2
port on the manifold. Ensure the calibration gas pressure is set at 20 psi (138 kPa).
Instrument air is not recommended for the high calibration gas. Do not use 100% nitrogen as a low gas (zero gas). It is suggested that the low (zero) gas be between 0.4% and 2.0%
. Do not use gases with hydrocarbon concentrations of more than 40 parts per million.
O
2
Failure to use proper gases will result in erroneous readings.
2. Connect O
calibration gas 2 (low calibration gas) to the LOW GAS IN
2
port on the manifold. Ensure the calibration gas pressure is set at 20 psi (138 kPa).
3. Connect the calibration gas from the CAL GAS OUT manifold fitting to the check valve connected to the CAL GAS port on the Oxymitter 4000.
2-2
Instruction Manual
IM-106-340AC-1, Rev. 1.0 April 2005
Figure 2-1. Installation
5-15/16
(151)
SPS 4001B
REPLACEABLE
MOUNTING FOOT
(4 PLACES)
11
(279)
SIGNAL
CABLE IN
3/8 IN. (9,5 MM)
POWER
CABLE IN
Analytical
CONDENSATE
DISCHARGE TUBE
(FROM AIR PRESSURE
REGULATOR/FILTER)
TEST GAS
OUT
CABLE GRIPS
NOTE: DIMENSIONS ARE IN INCHES WITH
MILLIMETERS IN PARENTHESES.
REF GAS
OUT
LOW GAS
IN
INST AIR
IN
MANIFOLD
HI GAS
IN
6-1/2 (165)
37470007
2-3
Instruction Manual
IM-106-340AC-1, Rev. 1.0
April 2005

ELECTRICAL CONNECTIONS

All wiring must conform to local and national codes. Use the following procedure to connect an SPS 4001B to an Oxymitter 4000.
Disconnect and lock out power before connecting the unit to the power supply.
NOTE
Ensure the Oxymitter 4000 is set up to handshake with the sequencer by configuring the logic I/O to mode 8. Refer to the Oxymitter 4000 Oxygen Transmitter Instruction Manual for more information.
NOTE
To maintain proper earth grounding, ensure a positive connection exists between the ground lug and earth.
1. Loosen the SPS 4001B cover screws and open the cover.
2. Route the line voltage cable into the enclosure through the rear cable grip. Ensure adequate wire length to connect the line voltage leads per Figure 2-2, then tighten the cable grip nut.
3. Connect the incoming 90 to 250 VAC ±10%, 50/60 Hz line voltage leads to the terminal strip and ground lug as indicated in Figure 2-2.
4. Route the signal wiring cable through the front cable grip. Ensure adequate wire length to connect all signal wires per Figure 2-2, then tighten the cable grip nut. Use shielded twisted pair wiring. Terminate the shield at the SPS 4001B.
5. Connect the 5V (5 mA maximum) logic I/O leads from the Oxymitter 4000 to the terminal strip as indicated in Figure 2-2. Use shielded twisted pair wiring. Terminate the shield at the Oxymitter 4000.
6. To set up the SPS 4001B to initiate a calibration from a remote location, connect the 5 VDC input leads to the terminal strip as shown in Figure 2-2.
7. Relay output connections are available on the unit to signal when the Oxymitter 4000 is in calibration or when calibration failed. Relay outputs can be connected to either indicator lights or a computer interface. The relay contacts are capable of handling a 5 to 30 VDC maximum power source. The cabling requirement is 1000 ft (303 m) maximum. Connect the relay output wires to the terminal strip as shown in Figure 2-2. Use shielded twisted pair wiring. Terminate the shield at the SPS 4001B.
8. Once all connections are made, close the enclosure cover and tighten the cover screws.
2-4
Instruction Manual
IM-106-340AC-1, Rev. 1.0 April 2005
Figure 2-2. Electrical Connections
90 - 250 VAC,
50/60 HZ LINE
VOLTAGE INPUT
L1
N
GROUND
5 VDC (SELF-POWERED) O REMOTE
CLOSURE
INPUT CONNECTION
5 VDC (5 mA MAXIMUM)
OPTIONAL
MOMENTARY
CONTACT
LOGIC I/O CONNECTION TO OXYMITTER 4000
OPTIONAL
5-30VDCTO
RELAY OUTPUT
CONNECTIONS
EARTH GROUND
CABLE SHIELDS
GROUND
LUG
GND
NC
} }
CAL INIT
HANDSHAKE
CAL FAIL
IN CAL
37740003
2-5
Instruction Manual
IM-106-340AC-1, Rev. 1.0
April 2005
2-6
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