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IB106-340
User Manual
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Emerson Process Management IB106-340 User Manual

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Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
Oxygen Transmitter
http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative 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 mainte-
nance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate In- struction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s per­formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-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 Universal HART® Communicator is used with this unit, the software within the Model 275 may require modification. If a software modification is required, please contact your local Fisher-Rosemount Service Group or National Response Center at 1-800-654-7768.
Emerson Process Management
Rosemount Analytical Inc. Process Analytic Division
1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com

HIGHLIGHTS OF CHANGES

Effective May, 1998 Rev. 2.0
Page Summary
— Modified existing manual to accommodate integrally mounted SPS 4000
Single Probe Autocalibration Sequencer information.
— Added locks for the electronic housing covers throughout the manual.
— Changed test gas to calibration gas throughout the manual.
— Changed reference gas to reference air throughout the manual.
Page P-1 Added symbols.
Page 1-1 Added product matrix information.
Page 1-4 Indicated that heater thermocouple and diffusion element are field re-
placeable (paragraph 1-2.d.4).
Page 1-4 Added paragraph 1-2.d.9(c) to indicate a third method to calibrate and
troubleshoot an Oxymitter 4000.
Page 1-10 Added 0 to 40% O
range via HART. Added manual to calibration types.
2
Updated signal specifications.
Pages 1-12 and 1-13 Added product matrix (Table 1-1).
Page 1-13 and 1-14 Added Tables 1-2, 1-3, 1-4.
Page 2-1 Deleted adapter plate disassembly recommendation from paragraph
2-1b2.
Page 2-8 Changed horizontal to vertical in paragraph 2-1.b.5.
Page 2-9 Added CE compliance NOTE.
Page 3-2 Added 0 to 40% O
range to paragraphs 3-1.c.2 and 3-1.e.2.
2
Page 3-4 Expanded paragraphs 3-2, 3-2.a, and 3-2.b to further describe logic I/O.
Changed 1 Kohm to 330 ohm in paragraph 3-2.a.
Page 5-3 Added NOTE concerning HART Communicator warmup period.
Page 5-4 Identified logic I/O defaults in Table 5-1.
Pages 5-5, 5-6, and
Modified HART menu tree (Figure 5-3).
5-7
Page 5-8 Added WARNING about removing the Oxymitter 4000 from any auto-
matic control loops prior to performing a calibration.
Page 5-9 Added paragraph 5-8 to explain the procedure to enter a timed calibra-
tion via HART.
Page 6-1 Added overview paragraph 6-1. Expanded calibration paragraph (new
paragraph 6-2) to include test gas checks and calibration types. Ex­panded calibration paragraph (new paragraph 6-2) to include calibration types.
HIGHLIGHTS OF CHANGES (CONTINUED)
Effective May, 1998 Rev. 2.0 (Continued)
Page Summary
Page 6-4 Updated Figure 6-3 to include last calibration failed alarm.
Page 6-6 Added fault 14 to Table 6-1.
Page 6-14 Added NOTE to determine when to replace the diffusion element.
Page 7-1 Added general troubleshooting information to paragraph 7-1. Added 4-20
mA line output information to paragraph 7-3 and Table 7-1. Added fault 14 to Table 7-1.
Page 7-8 Modified the case temperature in paragraph 7-3.f.1.
Page 7-15 Added new paragraph 7-3.n and Figure 7-14 to explain a last calibration
failed indication and troubleshooting instructions.
Page 8-1 Updated European address.
Pages 10-1 through 10-4
Page Summary
Page P-3 through P-9 Added Material Safety Data Sheets.
Page 1-5 Changed source of instrument air from required to optional.
Page 2-9 Added CAUTION concerning uninsulated stacks and ambient
Page 2-10 Added paragraph 2-2.c.3 concerning alarm contacts without
Page 2-11 Modified paragraph 2.3. Added paragraphs 2-3.a and b concerning
Page 3-5 Added paragraph 3-3 concerning recommended configurations. Subse-
Page 6-10 through 6-11
Page 6-15 Added paragraph 6-9 Ceramic Diffusion Element Replacement. Subse-
Added Section 10, Optional Accessories.
Effective Oct., 1998 Rev. 2.1
temperatures.
autocalibration.
autocalibration and alarms contacts.
quent paragraphs renumbered.
Deleted references in paragraphs 6-5.b, c, and d to remove and install oxymitter from stack. Procedures 6-5.b, c, and d renumbered.
quent paragraphs renumbered.
Page 7-1 Modified paragraph 7-2 to explain alarm indications will be available via
HART. Added paragraph 7-3 concerning alarm contacts and autocalibra­tion. Subsequent paragraphs renumbered.
Page 7-3 Modified Table 7-1 Diagnostic/Unit Alarm Fault Definitions.
Page 9-1 Changed Figure and Index No., Part Numbers, and Descriptions.
HIGHLIGHTS OF CHANGES (CONTINUED)
Effective Oct., 1998 Rev. 2.1 (Continued)
Page Summary
Page 9-2 Changed Figure and Index No.
Page 9-3 Changed Figure and Index No. and Description. Added Abrasive Shield
Assemblies to parts list.
Page 9-5 through 9-7 Changed Figure and Index No. and Part Numbers.
Effective Feb., 1999 Rev. 2.2
Page Summary
Pages 1-12 and 1-13 Modified the product matrix in Table 1-1. Removed the disposable gas
bottles and flow regulators from the matrix and created Table 1-2 to dis­tinguish these components as separate order items because the calibra­tion gas bottles cannot be shipped via airfreight.
Page 1-14 Updated the numbering of subsequent tables in Section 1.
Page 2-10 Added references to step 2 to direct users to the information explaining
the contacts and additional alarm contacts associated with the IMPS
4000.
Page 2-11 Removed the IMPS 4000 information from paragraph 2-3.
Page 7-11 Removed step 2 explaining that a 204 mV to 1 volt DC value indicated
high combustibles.
Pages 9-1 through 9-6 Updated part numbers.
Page 9-7 Updated part numbers and added Table 9-4 to list calibration gas bottles
and flow regulators as replacement parts.
HIGHLIGHTS OF CHANGES (CONTINUED)
Effective Nov., 1999 Rev. 2.3
Page Summary
Pages P-11 thru P-15 Added new Quick Start Guide.
Page 1-10 Added information on electronics operating temperatures and parts for
mounting.
Page 1-14 Removed Table 1-4, renumbered subsequent tables in Section 1.
Page 3-3 Changed default values for SW2 to 3.8 mA and 22 mA in Figure 3-2.
Page 3-5 Updated default 4-20 mA signal values in paragraph 3-3.a.
Page 6-6 Updated Table 6-1 to include new Fault 4, A/D Comm Error.
Page 6-8 Added Note to paragraph 6-5.
Page 7-3 Updated Table 7-1 to include new Heater T/C fault 4, A/D Comm Error.
Page 7-7 Added new Figure 5-7 and paragraph d for Fault 4, A/D Comm Error.
Pages 7-8 thru 7-22 Updated subsequent figures and paragraphs in Section 5.
Effective April, 2001 Rev. 2.4
Page Summary
Page 7-3 Table 7-1; changed Heater Fault 6 Self-Clearing column data to “NO”
and Fault 8 Self Clearing column data to “YES”.
Oxymitter 4000
PREFACE........................................................................................................................ P-1
Definitions ........................................................................................................................P-1
Safety Instructions .......................................................................................................... P-2
What You Need to Know ........................................................................................... P-10
Quick Start Guide ........................................................................................................ P-11
1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1
1-1 Component Checklist of Typical System (Package Contents) .................................. 1-1
1-2 System Overview............................................................................................................ 1-1
1-3 IMPS 4000 (Optional) ...................................................................................................... 1-7
1-4 SPS 4000 (Optional)........................................................................................................ 1-7
1-5 Model 751 Remote Powered Loop LCD Display........................................................ 1-9
1-6 Specifications................................................................................................................. 1-10
2-0 INSTALLATION .............................................................................................................. 2-1
2-1 Mechanical Installation ................................................................................................... 2-1
2-2 Electrical Installation (for Oxymitter 4000 without SPS 4000) ................................. 2-9
2-3 Electrical Installation (for Oxymitter 4000 with SPS 4000) ..................................... 2-11
2-4 Pneumatic Installation (for Oxymitter 4000 without SPS 4000) ............................. 2-14
2-5 Pneumatic Installation (for Oxymitter 4000 with SPS 4000) .................................. 2-15
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001

TABLE OF CONTENTS

3-0 STARTUP........................................................................................................................ 3-1
3-1 General ............................................................................................................................ 3-1
3-2 Logic I/O ......................................................................................................................... 3-4
3-3 Recommended Configuration......................................................................................... 3-5
3-4 Power Up........................................................................................................................ 3-6
3-5 Start Up Oxymitter 4000 Calibration............................................................................ 3-6
3-6 IMPS 4000 Connections ................................................................................................ 3-6
4-0 OPERATION ...................................................................................................................4-1
4-1 General ............................................................................................................................ 4-1
5-0 HART/AMS...................................................................................................................... 5-1
5-1 Overview.......................................................................................................................... 5-1
5-2 HART Communicator Signal Line Connections .......................................................... 5-1
5-3 Hart Communicator PC Connections .......................................................................... 5-3
5-4 Off-Line and On-Line Operations ................................................................................. 5-3
5-5 Logic I/O Conifgurations .................................................................................................. 5-3
5-6 Menu Tree for HART Communicator/Oxymitter 4000 Applications........................... 5-3
5-7 HART Communicator Manual O
5-8 Defining a Timed Calibration Via HART ..................................................................... 5-9
Cal Method ........................................................... 5-8
2
Rosemount Analytical Inc. A Division of Emerson Process Management i
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
6-0 MAINTENANCE AND SERVICE .................................................................................. 6-1
6-1 Overview.......................................................................................................................... 6-1
6-2 Calibration........................................................................................................................ 6-1
6-3 LED Status Indicators .................................................................................................... 6-5
6-4 Oxymitter 4000 Removal/Replacement........................................................................ 6-7
6-5 Electronics Replacement................................................................................................ 6-8
6-6 Entire Probe Replacement (Excluding Electronics) .................................................. 6-11
6-7 Heater Strut Replacement ........................................................................................... 6-12
6-8 Cell Replacement ......................................................................................................... 6-13
6-9 Ceramic Diffusion Element Replacement................................................................... 6-15
6-10 SPS 4000 Maintenance and Component Replacement........................................... 6-16
7-0 TROUBLESHOOTING .................................................................................................... 7-1
7-1 General ............................................................................................................................ 7-1
7-2 Alarm Indications ............................................................................................................ 7-1
7-3 Alarm Contacts ............................................................................................................... 7-1
7-4 Identifying and Correcting Alarm Indications............................................................... 7-2
7-5 SPS 4000 Troubleshooting.......................................................................................... 7-19
8-0 RETURN OF MATERIAL ................................................................................................ 8-1
Oxymitter 4000
9-0 REPLACEMENT PARTS ................................................................................................ 9-1
10-0 OPTIONAL ACCESSORIES........................................................................................ 10-1
11-0 INDEX............................................................................................................................ 11-1
ii Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
Figure 1-1. Typical System Package ....................................................................................... 1-2
Figure 1-2. Oxymitter 4000 Autocalibration System Options .................................................. 1-3
Figure 1-3. Oxymitter 4000 HART Communications and AMS Application ............................. 1-5
Figure 1-4. Typical System Installation .................................................................................... 1-6
Figure 1-5. SPS 4000............................................................................................................... 1-8
Figure 1-6. Model 751 Remote Powered Loop LCD Display .................................................. 1-9
Figure 2-1. Oxymitter 4000 Installation .................................................................................... 2-2
Figure 2-2. Oxymitter 4000 Installation (with SPS 4000) ......................................................... 2-3
Figure 2-3. Oxymitter 4000 with Abrasive Shield ..................................................................... 2-4
Figure 2-4. Oxymitter 4000 Adapter Plate Dimensions............................................................ 2-5
Figure 2-5. Oxymitter 4000 Adapter Plate Installation ............................................................. 2-6
Figure 2-6. Oxymitter 4000 Bracing Installation ....................................................................... 2-7
Figure 2-7. Orienting the Optional Vee Deflector ..................................................................... 2-8
Figure 2-8. Installation with Drip Loop and Insulation Removal ............................................... 2-8
Figure 2-9. Terminal Block .....................................................................................................2-10
Figure 2-10. SPS 4000 Electrical Connections ........................................................................ 2-13
Figure 2-11. Air Set, Plant Air Connection ............................................................................... 2-14
Figure 2-12. Oxymitter 4000 Gas Connections Calibration Gas Connections......................... 2-15
Figure 3-1. Integral Electronics ................................................................................................ 3-1
Figure 3-2. Oxymitter 4000 Defaults ........................................................................................ 3-3
Figure 3-3. Startup and Normal Operation............................................................................... 3-5
Figure 3-4. Calibration Keys..................................................................................................... 3-6
Figure 4-1. Normal Operation...................................................................................................4-2
Figure 5-1. Signal Line Connections, ≥ 250 Ohms Lead Resistance ...................................... 5-2
Figure 5-2. Signal Line Connections, < 250 Ohms Lead Resistance ...................................... 5-2
Figure 5-3. Menu Tree for HART/AMS on the Oxymitter 4000 ................................................ 5-5
Figure 6-1. Oxymitter 4000 Exploded View.............................................................................. 6-2
Figure 6-2. Membrane Keypad................................................................................................. 6-3
Figure 6-3. Inside Right Cover .................................................................................................6-4
Figure 6-4. Terminal Block ....................................................................................................... 6-6
Figure 6-5. Electronic Assembly............................................................................................... 6-9
Figure 6-6. J8 Connector.......................................................................................................... 6-9
Figure 6-7. Fuse Location ......................................................................................................6-11
Figure 6-8. Heater Strut Assembly......................................................................................... 6-12
Figure 6-9. Cell Replacement Kit ........................................................................................... 6-13
Figure 6-10. Ceramic Diffusion Element Replacement ............................................................ 6-15
Figure 6-11. SPS 4000 Manifold Assembly ............................................................................. 6-17
Figure 6-12. Power Supply Board and Interface Board Connections ...................................... 6-19
Figure 6-13. Calibration Gas and Reference Air Components ................................................ 6-23
Figure 7-1. Fault 1, Open Thermocouple ................................................................................. 7-4
Figure 7-2. Fault 2, Shorted Thermocouple ............................................................................. 7-5
Figure 7-3. Fault 3, Reversed Thermocouple .......................................................................... 7-6
Figure 7-4. Fault 4, A/D Comm Error ....................................................................................... 7-7
Figure 7-5. Fault 5, Open Heater ............................................................................................. 7-8
Figure 7-6. Fault 6, High High Heater Temp ............................................................................ 7-9
Figure 7-7. Fault 7, High Case Temp..................................................................................... 7-10
Figure 7-8. Fault 8, Low Heater Temp ................................................................................... 7-11
Figure 7-9. Fault 9, High Heater Temp .................................................................................. 7-12
Figure 7-10. Fault 10, High Cell mV......................................................................................... 7-13
Figure 7-11. Fault 11, Bad Cell ................................................................................................7-14
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001

LIST OF ILLUSTRATIONS

Rosemount Analytical Inc. A Division of Emerson Process Management iii
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Figure 7-12. Fault 12, EEPROM Corrupt ................................................................................. 7-15
Figure 7-13. Fault 13, Invalid Slope ......................................................................................... 7-16
Figure 7-14. Fault 14, Invalid Constant .................................................................................... 7-17
Figure 7-15. Fault 15, Last Calibration Failed .......................................................................... 7-18
Figure 7-16. SPS 4000 Troubleshooting Flowchart ................................................................. 7-21
Figure 9-1. Cell Replacement Kit ............................................................................................. 9-2
Figure 9-2. Probe Disassembly Kit........................................................................................... 9-4
Table 1-1. Product Matrix ......................................................................................................1-12
Table 1-2. Calibration Components ...................................................................................... 1-13
Table 1-3. Intelligent Multiprobe Test Gas Sequencer Versions ............................................ 1-14
Table 1-4. Single Probe Autocalibration Sequencer Coding .................................................. 1-14
Table 3-1. Logic I/O Configuration .......................................................................................... 3-4
Table 5-1. Logic I/O Configuration .......................................................................................... 5-4
Table 6-1. Diagnostic/Unit Alarms .......................................................................................... 6-6
Table 7-1. Diagnostic/Unit Alarm Fault Definitions ................................................................. 7-3
Table 7-2. SPS 4000 Fault Finding ....................................................................................... 7-20
Table 9-1. Replacement Parts for Probe ................................................................................ 9-1
Table 9-2. Replacement Parts for Electronics ........................................................................ 9-5
Table 9-3. Replacement Parts for SPS 4000........................................................................... 9-7
Table 9-4. Replacement Parts for Calibration Components ................................................... 9-7
Oxymitter 4000

LIST OF TABLES

iv Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
The purpose of this manual is to provide information concerning the components, func­tions, installation and maintenance of the Oxymitter 4000.
Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001

PREFACE

DEFINITIONS
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 essential operating procedure, condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
NOTE TO USERS
Highlights an operation or maintenance procedure, practice, condition, state­ment, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
The number in the lower right corner of each illustration in this publication is a manual illus­tration number. It is not a part number, and is not related to the illustration in any technical manner.
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
FOR THE WIRING AND INSTALLATION
The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non­EU states should also comply with the following unless superseded by local or National Standards.
1. Adequate earth connections should be made to all earthing points, internal and external,
where provided.
2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.
The integrity of all earth terminals must be maintained at all times.
3. Mains supply cords should comply with the requirements of IEC227 or IEC245.
Oxymitter 4000
IMPORTANT
SAFETY INSTRUCTIONS
OF THIS APPARATUS
4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.
5. All cable glands used should be of such internal dimensions as to provide adequate cable
anchorage.
6. To ensure safe operation of this equipment, connection to the mains supply should only be
made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.
7. Where equipment or covers are marked with the symbol to the right, hazard-
ous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then only by trained service personnel.
8. Where equipment or covers are marked with the symbol to the right, there is a
danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Cer­tain surfaces may remain hot to the touch.
9. Where equipment or covers are marked with the symbol to the right, refer to
the Operator Manual for instructions.
10. All graphical symbols used in this product are from one or more of the follow-
ing standards: EN61010-1, IEC417, and ISO3864.
P-2 Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
CERAMIC FIBER PRODUCTS
MATERIAL SAFETY DATA SHEET
JULY 1, 1996
SECTION I. IDENTIFICATION
PRODUCT NAME
Ceramic Fiber Heaters, Molded Insulation Modules and Ceramic Fiber Radiant Heater Panels.
CHEMICAL FAMILY
Vitreous Aluminosilicate Fibers with Silicon Dioxide.
CHEMICAL NAME
N.A.
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
CHEMICAL FORMULA
N.A.
MANUFACTURER’S NAME AND ADDRESS
Watlow Columbia 573-474-9402 2101 Pennsylvania Drive 573-814-1300, ext. 5170 Columbia, MO 65202
HEALTH HAZARD SUMMARY
WARNING
• Possible cancer hazard based on tests with laboratory animals.
• May be irritating to skin, eyes and respiratory tract.
• May be harmful if inhaled.
• Cristobalite (crystalline silica) formed at high temperatures (above 1800ºF) can cause severe respiratory
disease.
Rosemount Analytical Inc. A Division of Emerson Process Management P-3
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
SECTION II. PHYSICAL DATA
APPEARANCE AND ODOR
Cream to white colored fiber shapes. With or without optional white to gray granular surface coating and/or optional black surface coating.
SPECIFIC WEIGHT: 12-25 LB./CUBIC FOOT BOILING POINT: N.A.
VOLATILES (% BY WT.): N.A. WATER SOLUBILITY: N.A.
SECTION III. HAZARDOUS INGREDIENTS
MATERIAL, QUANTITY, AND THRESHOLD/EXPOSURE LIMIT VALUES
Aluminosilicate (vitreous) 99+ % 1 fiber/cc TWA CAS. No. 142844-00-06 10 fibers/cc CL Zirconium Silicate 0-10% 5 mg/cubic meter (TLV) Black Surface Coating** 0 - 1% 5 mg/cubic meter (TLV) Armorphous Silica/Silicon Dioxide 0-10% 20 mppcf (6 mg/cubic meter)
PEL (OSHA 1978) 3 gm cubic meter (Respirable dust): 10 mg/cubic meter, Intended TLV (ACGIH 1984-85)
**Composition is a trade secret.
SECTION IV. FIRE AND EXPLOSION DATA
FLASH POINT: NONE FLAMMABILITY LIMITS: N.A.
EXTINGUISHING MEDIA
Use extinguishing agent suitable for type of surrounding fire.
UNUSUAL FIRE AND EXPLOSION HAZARDS / SPECIAL FIRE FIGHTING PROCEDURES
N.A.
P-4 Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
IB-106-340 Rev. 2.4
Oxymitter 4000
SECTION V. HEALTH HAZARD DATA
THRESHOLD LIMIT VALUE
(See Section III)
EFFECTS OF OVER EXPOSURE
EYE
Avoid contact with eyes. Slightly to moderately irritating. Abrasive action may cause damage to outer surface of eye.
INHALATION
May cause respiratory tract irritation. Repeated or prolonged breathing of particles of respirable size may cause inflam­mation of the lung leading to chest pain, difficult breathing, coughing and possible fibrotic change in the lung (Pneumo­coniosis). Pre-existing medical conditions may be aggravated by exposure: specifically, bronchial hyper-reactivity and chronic bronchial or lung disease.
April, 2001
INGESTION
May cause gastrointestinal disturbances. Symptoms may include irritation and nausea, vomiting and diarrhea.
SKIN
Slightly to moderate irritating. May cause irritation and inflammation due to mechanical reaction to sharp, broken ends of fibers.
EXPOSURE TO USED CERAMIC FIBER PRODUCT
Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) may undergo partial conversion to cristobalite, a form of crystalline silica which can cause severe respiratory disease (Pneumoconiosis). The amount of cristobalite present will depend on the temperature and length of time in service. (See Section IX for permissible expo­sure levels).
SPECIAL TOXIC EFFECTS
The existing toxicology and epidemiology data bases for RCF’s are still preliminary. Information will be updated as studies are completed and reviewed. The following is a review of the results to date:
EPIDEMIOLOGY
At this time there are no known published reports demonstrating negative health outcomes of workers exposed to re­fractory ceramic fiber (RCF). Epidemiologic investigations of RCF production workers are ongoing.
1) There is no evidence of any fibrotic lung disease (interstitial fibrosis) whatsoever on x-ray.
2) There is no evidence of any lung disease among those employees exposed to RCF that had never smoked.
3) A statistical “trend” was observed in the exposed population between the duration of exposure to RCF and a de-
crease in some measures of pulmonary function. These observations are clinically insignificant. In other words, if these observations were made on an individual employee, the results would be interpreted as being within the nor­mal range.
Rosemount Analytical Inc. A Division of Emerson Process Management P-5
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
4) Pleural plaques (thickening along the chest wall) have been observed in a small number of employees who had a
long duration of employment. There are several occupational and non-occupational causes for pleural plaque. It should be noted that plaques are not “pre-cancer” nor are they associated with any measurable effect on lung function.
TOXICOLOGY
A number of studies on the health effects of inhalation exposure of rats and hamsters are available. Rats were exposed to RCF in a series of life-time nose-only inhalation studies. The animals were exposed to 30, 16, 9, and 3 mg/m corresponds with approximately 200, 150, 75, and 25 fibers/cc.
Animals exposed to 30 and 16 mg/m posed to 9 mg/m the response typically observed any time a material is inhaled into the deep lung. While a statistically significant in­crease in lung tumors was observed following exposure to the highest dose, there was no excess lung cancers at the other doses. Two rats exposed to 30 mg/m
The International Agency for Research on Cancer (IARC) reviewed the carcinogenicity data on man-made vitreous fi­bers (including ceramic fiber, glasswool, rockwool, and slagwool) in 1987. IARC classified ceramic fiber, fibrous glasswool and mineral wool (rockwool and slagwool) as possible human carcinogens (Group 2B).
3
had developed a mild parenchymal fibrosis; animals exposed to the lowest dose were found to have
3
were observed to have developed a pleural and parenchymal fibroses; animals ex-
3
and one rat exposed to 9 mg/m3 developed masotheliomas.
Oxymitter 4000
EMERGENCY FIRST AID PROCEDURES
3
, which
EYE CONTACT
Flush eyes immediately with large amounts of water for approximately 15 minutes. Eye lids should be held away from the eyeball to insure thorough rinsing. Do not rub eyes. Get medical attention if irritation persists.
INHALATION
Remove person from source of exposure and move to fresh air. Some people may be sensitive to fiber induced irritation of the respiratory tract. If symptoms such as shortness of breath, coughing, wheezing or chest pain develop, seek medi­cal attention. If person experiences continued breathing difficulties, administer oxygen until medical assistance can be rendered.
INGESTION
Do not induce vomiting. Get medical attention if irritation persists.
SKIN CONTACT
Do not rub or scratch exposed skin. Wash area of contact thoroughly with soap and water. Using a skin cream or lotion after washing may be helpful. Get medical attention if irritation persists.
SECTION VI. REACTIVITY DATA
STABILITY/CONDITIONS TO AVOID
Stable under normal conditions of use.
HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID
N.A.
P-6 Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
IB-106-340 Rev. 2.4
Oxymitter 4000
INCOMPATIBILITY/MATERIALS TO AVOID
Incompatible with hydrofluoric acid and concentrated alkali.
HAZARDOUS DECOMPOSITION PRODUCTS
N.A.
SECTION VII. SPILL OR LEAK PROCEDURES
STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED
Where possible, use vacuum suction with HEPA filters to clean up spilled material. Use dust suppressant where sweep­ing if necessary. Avoid clean up procedure which may result in water pollution. (Observe Special Protection Informa­tion Section VIII.)
WASTE DISPOSAL METHODS
The transportation, treatment, and disposal of this waste material must be conducted in compliance with all applicable Federal, State, and Local regulations.
April, 2001
SECTION VIII. SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION
Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. NIOSH/MSHA approved breathing equipment may be required for non-routine and emergency use. (See Section IX for suitable equipment).
Pending the results of long term health effects studies, engineering control of airborne fibers to the lowest levels attain­able is advised.
VENTILATION
Ventilation should be used whenever possible to control or reduce airborne concentrations of fiber and dust. Carbon monoxide, carbon dioxide, oxides of nitrogen, reactive hydrocarbons and a small amount of formaldehyde may accom­pany binder burn-off during first heat. Use adequate ventilation or other precautions to eliminate vapors resulting from binder burn-off. Exposure to burn-off fumes may cause respiratory tract irritation, bronchial hyper-reactivity and asth­matic response.
SKIN PROTECTION
Wear gloves, hats and full body clothing to prevent skin contact. Use separate lockers for work clothes to prevent fiber transfer to street clothes. Wash work clothes separately from other clothing and rinse washing machine thoroughly after use.
EYE PROTECTION
Wear safety glasses or chemical worker’s goggles to prevent eye contact. Do not wear contact lenses when working with this substance. Have eye baths readily available where eye contact can occur.
Rosemount Analytical Inc. A Division of Emerson Process Management P-7
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
SECTION IX. SPECIAL PRECAUTIONS
PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING
General cleanliness should be followed. The Toxicology data indicate that ceramic fiber should be handled with caution. The handling practices described in this
MSDS must be strictly followed. In particular, when handling refractory ceramic fiber in any application, special cau­tion should be taken to avoid unnecessary cutting and tearing of the material to minimize generation of airborne dust.
It is recommended that full body clothing be worn to reduce the potential for skin irritation. Washable or disposable clothing may be used. Do not take unwashed work clothing home. Work clothes should be washed separately from other clothing. Rinse washing machine thoroughly after use. If clothing is to be laundered by someone else, inform launderer of proper procedure. Work clothes and street clothes should be kept separate to prevent contamination.
Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) may undergo partial conversion to cristobalite, a form of crystalline silica. This reaction occurs at the furnace lining hot face. As a consequence, this material becomes more friable; special caution must be taken to minimize generation of airborne dust. The amount of cristobalite present will depend on the temperature and length in service.
IARC has recently reviewed the animal, human, and other relevant experimental data on silica in order to critically evaluate and classify the cancer causing potential. Based on its review, IARC classified crystalline silica as a group 2A carcinogen (probable human carcinogen).
The OSHA permissible exposure limit (PEL for cristobalite is 0.05 mg/m value (TLV) for cristobalite is 0.05 mg/m ment when airborne exposure limits may be exceeded. The minimum respiratory protection recommended for given air­borne fiber or cristobalite concentrations are:
3
(respirable dust) (ACGIH 1991-92). Use NIOSH or MSHA approved equip-
3
(respirable dust). The ACGIH threshold limit
CONCENTRATION
0-1 fiber/cc or 0-0.05 mg/m3 cristobalite Optional disposable dust respirator (e.g. 3M 9970 (the OSHA PEL) or equivalent).
Up to 5 fibers/cc or up to 10 times the Half face, air-purifying respirator equipped with high OSHA PEL for cristobalite efficiency particulate air (HEPA) filter cartridges
(e.g. 3M 6000 series with 2040 filter or equivalent).
Up to 25 fibers/cc or 50 times the OSHA Full face, air-purifying respirator with high efficiency PEL for cristobalite (2.5 mg/m
Greater than 25 fibers/cc or 50 times the Full face, positive pressure supplied air respirator OSHA PEL for cristobalite (2.5 mg/m
If airborne fiber or cristobalite concentrations are not known, as minimum protection, use NIOSH/MSHA approved half face, air-purifying respirator with HEPA filter cartridges.
3
) particulate air (HEPA) filter cartridges (e.g. 3M 7800S
with 7255 filters or equivalent) or powered air -purifying respirator (PARR) equipped with HEPA filter cartridges (e.g. 3M W3265S with W3267 filters or equivalent).
3
) (e.g. 3M 7800S with W9435 hose & W3196 low
pressure regulator kit connected to clean air supply or equivalent).
P-8 Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
IB-106-340 Rev. 2.4
Oxymitter 4000
Insulation surface should be lightly sprayed with water before removal to suppress airborne dust. As water evaporates during removal, additional water should be sprayed on surfaces as needed. Only enough water should be sprayed to suppress dust so that water does not run onto the floor of the work area. To aid the wetting process, a surfactant can be used.
After RCF removal is completed, dust-suppressing cleaning methods, such as wet sweeping or vacuuming, should be used to clean the work area. If dry vacuuming is used, the vacuum must be equipped with HEPA filter. Air blowing or dry sweeping should not be used. Dust-suppressing components can be used to clean up light dust.
Product packaging may contain product residue. Do not reuse except to reship or return Ceramic Fiber products to the factory.
April, 2001
Rosemount Analytical Inc. A Division of Emerson Process Management P-9
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
BEFORE INSTALLING AND WIRING A ROSEMOUNT
1. What type of installation does your system require?
Use the following drawing, Figure 1, to identify which type of installation is required for your Oxymitter 4000 system.
Oxymitter 4000
WHAT YOU NEED TO KNOW
OXYMITTER 4000 OXYGEN TRANSMITTER
STANDARD
REFERENCE AIR CALIBRATION GAS
OXYMITTER 4000
INTEGRAL SPS 4000 OPTION
OXYMITTER 4000
(WITH INTEGRAL SPS 4000)
IMPS 4000 OPTION
LINE VOLTAGE
4-20 mA SIGNAL
LINE VOLTAGE
4-20 mA SIGNAL
CALIBRATION GAS 1 CALIBRATION GAS 2 REFERENCE AIR
LINE VOLTAGE 4-20 mA SIGNAL
OXYMITTER 4000
LOGIC I/0
CAL GAS
REFERENCE AIR
IMPS
4000
INSTR. AIR SUPPLY
CALIBRATION GAS 1
CALIBRATION GAS 2
LINE VOLTAGE
29770001
Figure 1. Oxymitter 4000 Installation Options
P-10 Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
Use this Quick Start Guide if ...
1. Your system requires a STANDARD or INTEGRAL SPS 4000 OPTION installation. Installa-
tion options for the Oxymitter 4000 are shown in Figure 1.
2. Your system does NOT require an IMPS 4000 OPTION installation.
3. You are familiar with the installation requirements for the Oxymitter 4000 Oxygen Transmit-
ter. You are familiar with the installation requirements for the Oxymitter 4000 Oxygen Transmitter with an integral SPS 4000.
If you cannot use the Quick Start Guide, turn to Section 2, Installation, in this Instruction Bulletin.
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
CAN YOU USE THE FOLLOWING
QUICK START GUIDE?
Rosemount Analytical Inc. A Division of Emerson Process Management P-11
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
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.
1. Install the Oxymitter 4000 in an appropriate location on the stack or duct. Refer to Section 2,
paragraph 2-1.a for information on selecting a location for the Oxymitter 4000.
2. If using an SPS 4000, connect the calibration gasses to the appropriate fittings on the SPS
4000 manifold.
3. Connect reference air to the Oxymitter 4000 or SPS 4000, as applicable.
4. If using an SPS 4000, make the following wire connections as shown in Figure 2: line volt-
age, cal initiate-remote contact input, relay output, and 4-20 mA.
Oxymitter 4000
QUICK START GUIDE
FOR OXYMITTER 4000 SYSTEMS
5. If NOT using an SPS 4000, make the following wire connections as shown in Figure 3: line
voltage, 4-20 mA, and logic I/O.
6. Verify the Oxymitter 4000 switch configuration is as desired. Refer to Section 3, paragraphs
3-1.c, 3-1.d, and 3-1.e.
7. Apply power to the Oxymitter 4000; the cell heater will turn on. Allow approximately one half
hour for the cell to heat to operating temperature. Once the ramp cycle has completed and the Oxymitter 4000 is at normal operation, proceed with step 8.
8. If using an SPS 4000, initiate a semi-automatic calibration.
9. If NOT using an SPS 4000, perform a manual calibration. Refer to the QUICK REFERENCE
GUIDE manual calibration instructions on the following pages, or Section 6, paragraph 6-2, Calibration, in this instruction bulletin.
P-12 Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
+
CAL INITIATE 5 VDC SELF POWERED TO REMOTE CONTACT
-
INPUT CONNECTION
+
4-20 mA CONNECTION
-
TERMINALS 5 AND 6 NOT USED
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
FAC TORY
WIRED
(85 TO 264 VAC)
+
CAL FAI L
-
+
IN CAL
-
LINE GROUND NEUTRAL
Figure 2. Oxymitter 4000 with SPS 4000 Wiring Diagram
AC TERMINAL
COVER
LINE VOLTAGE
TERMINAL
BLOCK
AC L1
AC N
AC LINE
VOLTAGE PORT
5-3O VDC TO RELAY OUTPUT CONNECTION
90-250 VAC 50/60 Hz LINE VOLTAGE
29770002
GROUND LUGS
LOGIC I/O
4-20 mA SIGNAL
4-20
+
-
+
-
SIGNAL
LEFT SIDE OF
OXYMITTER 4000
PORT
29770003
Figure 3. Oxymitter 4000 without SPS 4000 Wiring Diagram
Rosemount Analytical Inc. A Division of Emerson Process Management P-13
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
OXYMITTER 4000 OXYGEN TRANSMITTER
Performing a Manual Calibration
1. Place the control loop in manual.
2. Press the CAL key. The CAL LED will light solid.
3. Apply the first calibration gas.
4. Press the CAL key. When the unit has taken the readings using the first calibration gas, the
CAL LED will flash continuously.
5. Remove the first calibration gas and apply the second calibration gas.
6. Push the CAL key. The CAL LED will light solid. When the unit has taken the readings using
the second calibration gas, the CAL LED will flash a two-pattern flash or a three-pattern flash. A two-pattern flash equals a valid calibration, three-pattern flash equals an invalid cali­bration.
Oxymitter 4000
QUICK REFERENCE GUIDE
7. Remove the second calibration gas and cap off the calibration gas port.
8. Press the CAL key. The CAL LED will be lit solid as the unit purges. When the purge is
complete, the CAL LED will turn off.
9. If the calibration was valid, the DIAGNOSTIC ALARMS LEDs indicate normal operation. If
the new calibration values are not within the parameters, the DIAGNOSTIC ALARMS LEDs will indicate an alarm.
10. Place the control loop in automatic.
P-14 Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000

HART COMMUNICATOR FAST KEY SEQUENCES

Perform Calibration O2 Upper Range Value
Trim Analog Output Analog Output Lower Range Value
Toggle Analog Output Tracking View O2 Value
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
2311 321
24 322
2312 111
View Analog Output
121
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
In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Rosemount’s field service throughout the U.S. and abroad.
Phone: 1-800-654-RSMT (1-800-654-7768)
Rosemount may also be reached via the Internet through e-mail and the World Wide Web:
e-mail: GAS.CSC@frco.com
World Wide Web: www.processanalytic.com
Rosemount Analytical Inc. A Division of Emerson Process Management P-15
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
P-16 Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
1
DESCRIPTION AND SPECIFICATIONS
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
SECTION 1
1-1 COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
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.

1-2 SYSTEM OVERVIEW

a. Scope
This Instruction Bulletin is designed to supply details needed to install, start up, operate, and maintain the Oxymitter 4000. Integral signal conditioning electronics outputs a 4­20 mA signal representing an O provides a membrane keypad for setup, cali­bration, and diagnostics. This same informa­tion, plus additional details, can be accessed with the HART Model 275 handheld commu­nicator or Asset Management Solutions (AMS) software.
b. System Description
The Oxymitter 4000 is designed to measure the net concentration of oxygen in an indus­trial 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
value and
2
proper temperature, the millivolt output volt­age of the cell is given by the following Nernst equation:
EMF = KT log
Where:
1. P
is the partial pressure of the
2
oxygen in the measured gas on one side of the cell.
2. P
is the partial pressure of the
1
oxygen in the reference air on the opposite side of the cell.
3. T is the absolute temperature.
4. C is the cell constant.
5. K is an arithmetic constant.
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.
10(P1/P2
NOTE
) + C
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
HART
MAN4275A00
October1994
Communicator
o
FISHER-ROSEMOUNT
1
2
7
English
TM
3
6
5
4
26170008
1. Instruction Bulletin
2. IMPS 4000 Intelligent Multiprobe Test Gas Sequencer (Optional)
3. Oxymitter 4000 with Integral Electronics
4. SPS 4000 Single Probe Autocalibration Sequencer (Optional) — (Shown with reference air option)
5. Adapter Plate with Mounting Hardware and Gasket
6. HART
®
Communicator Package (Optional)
7. Reference Air Set (used if SPS 4000 without reference air option or IMPS 4000 not supplied)
Figure 1-1. Typical System Package
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
1
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
c. System Configuration
Oxymitter 4000 units are available in five 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), or 12 ft (3.66 m).
The integral 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 50/60 Hz; therefore, no setup procedures are required. The oxygen sensing cell is maintained at a constant temperature by modulating the duty cycle of the probe heater portion of the integral electronics. The integral electronics accepts millivolt signals generated by the sensing cell and produces the outputs to be used by re­motely connected devices. The output is an isolated 4-20 mA linearized current.
Two calibration gas sequencers are avail­able to the Oxymitter 4000: the IMPS 4000 and the SPS 4000 (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.
d. System Features
1. The CALIBRATION RECOMMENDED feature detects when the sensing cell is likely out of limits. This may eliminate the need to calibrate on a “time since last cal” basis.
2. The cell output voltage and sensitivity increase as the oxygen concentration decreases.
OXYMITTER 4000
INTEGRALLY
MOUNTED
SPS 4000
(1 PROBE)
INTEGRAL OR
REMOTE
For systems with one or two Oxymitter 4000 units per combustion process, an optional SPS 4000 Single Probe Autocalibration Se­quencer can be used with each Oxymitter 4000 to provide automatic calibration gas sequencing. The SPS 4000 can be mounted directly to the Oxymitter 4000 or in a remote location if space is limited. The sequencer performs autocalibrations based on the CALIBRATION RECOMMENDED
IMPS 4000
(1 TO 4 PROBES)
REMOTE MOUNTED
SPS 4000
(1 PROBE)
(EXPLO VERSIONS MUST
BE REMOTE MOUNTED)
26170002
signal from the Oxymitter 4000, a timed in­terval set up in HART, or whenever a cali­bration request is initiated.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Figure 1-2. Oxymitter 4000 Autocalibration
System Options
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
3. Membrane keypad and HART commu­nication are standard. To use the HART capability, you must have either:
(a) HART Model 275 Communicator.
(b) Asset Management Solutions
(AMS) software for the PC.
4. Field replaceable cell, heater, thermo­couple, and diffusion element.
5. The Oxymitter 4000 is constructed of rugged 316 L stainless steel for all wetted parts.
6. Integral electronics eliminates tradi­tional wiring between probe and elec­tronics.
7. The integral electronics are adaptable for line voltages from 90-250 VAC; therefore, no configuration is necessary.
8. The Oxymitter 4000 membrane keypad is available in five languages:
English French German Italian Spanish
9. An operator can calibrate and diagnos­tically troubleshoot the Oxymitter 4000 in one of three ways:
(a) Membrane Keypad. The mem-
brane keypad, housed within the right side of the electronics hous­ing, provides fault indication by way of flashing LEDs. Calibration can be performed from the mem­brane keypad.
(b) 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:
1 Rosemount Model 275 Hand-
held Communicator - The handheld communicator re­quires Device Description (DD) software specific to the Oxymitter 4000. The DD soft­ware will be supplied with many Model 275 units but can also be programmed into ex­isting units at most Fisher­Rosemount service offices. See Section 5, HART/ AMS, for additional information.
2 Personal Computer (PC) -
The use of a personal com­puter requires AMS software available from Fisher­Rosemount.
3 Selected Distributed Control
Systems - The use of distrib­uted control systems re­quires input/output (I/O) hardware and AMS soft­ware which permit HART communications.
(c) Optional IMPS 4000. The Pro-
grammable 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 Bulletin for more information.
10. The optional Rosemount 751 remote­mounted LCD display panel is loop­driven by the 4-20 mA output signal representing the O
percentage.
2
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
1
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
e. Handling the Oxymitter 4000
It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to pre­vent possible equipment damage.
The Oxymitter 4000 is designed for in­dustrial applications. Treat each com­ponent of the system with care to avoid physical damage. Some probe components are made from ceramics, which are susceptible to shock when mishandled.
f. 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 1-3 shows a typical system wiring. A
typical system installation is illustrated in Figure 1-4.
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 tanks 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 4000.
NOTE
The integral electronics is rated NEMA 4X (IP66) and is capable of operation at temperatures up to 149°F (65°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.
HART MODEL 275
HAND HELD
INTERFACE
4-20 MA OUTPUT (TWISTED PAIR)
OXYMITTER 4000
WITH INTEGRAL ELECTRONICS
2 CALIBRATION GAS LINES
BY CUSTOMER
[300 FT (90 M) MAX]
LINE VOLTAGE
TERMINATION IN
CONTROL ROOM
ASSET MANAGEMENT SOLUTIONS
26170032
Figure 1-3. Oxymitter 4000 HART Communications and AMS Application
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
GASES
STACK
OXYMITTER
4000
LINE
VOLTAGE
LOGIC I/O
4TO20mA
SIGNAL
STANDARD
DUCT
FLOWMETER
CALIBRATION GAS
ADAPTER PLATE
SPS 4000 OPTION
(WITH REFERENCE AIR OPTION)
GASES
(REFERENCE AIR)
PRESSURE
REGULATOR
ADAPTER
PLATE
OXYMITTER
LINE
VOLTAGE
4TO20mA
SIGNAL
INSTRUMENT
AIR SUPPLY
GASES
STACK
4000
LOGIC I/O
IMPS 4000 OPTION
DUCT
CALIBRATION GAS
CALIBRATION G
C
ALIBRATIO
REFERENCE
AIR
INST. AIR
N
G
SUPPLY
AS
AS
1
2
OXYMITTER
INSTRUMENT
AIR SUPPLY
STACK
4000
VOLTAGE
LINE
DUCT
ADAPTER PLATE
CALIBRATION GAS 1 (HIGH GAS)CALIBRATION
CALIBRATION
CALIBRATION
(LOW GAS)
4-20 mA SIGNAL, RELAY OUTPUTS, AND REMOTE CONTACT INPUT
GAS 2
IMPS 4000
35830001
Figure 1-4. Typical System Installation
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
1
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001

1-3 IMPS 4000 (Optional)

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

1-4 SPS 4000 (Optional)

The SPS 4000 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.
a. Mounting
The SPS 4000 can be mounted either di­rectly to an Oxymitter 4000 or at a remote location if space is limited. In addition, the integrally mounted SPS 4000 can be con­figured for a horizontally or vertically mounted Oxymitter 4000 (Figure 2-2). The information in this instruction bulletin will cover the integrally mounted units only. For information on remote mounted units, refer to the SPS 4000 Single Probe Autocalibra­tion Sequencer Instruction Bulletin.
b. Components (Figure 1-5)
The SPS 4000 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 4000 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.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
CALIBRATION GAS
FLOWMETER
FRONT VIEW
REFERENCE GAS
FLOWMETER
REAR VIEW (OF MANIFOLD ONLY)
CALIBRATION GAS 1
INTERFACE
BOARD
(HIGH CALIBRATION GAS)
SOLENOID
REFERENCE AIR PRESSURE REGULATOR (OPTIONAL)
NOTE:
MANIFOLD COVER IS REMOVED TO SHOW INTERNAL COMPONENTS.
ALSO, BOARD COMPONENTS ARE NOT SHOWN FOR CLARITY.
Oxymitter 4000
TERMINAL
COVER
POWER
SUPPLY BOARD
PRESSURE SWITCH
MANIFOLD
CALIBRATION GAS 2
(LOW CALIBRATION GAS)
SOLENOID
Figure 1-5. SPS 4000
26170001
1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
1
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
c. Operation
The SPS 4000 works in conjunction with the Oxymitter 4000’s CALIBRATION RECOM­MENDED feature to perform an autocalibra­tion. This feature automatically performs a gasless calibration check every hour on the Oxymitter 4000. If a calibration is recom­mended and its contact output signal is set for “handshaking” with the sequencer, the Oxymitter 4000 sends a signal to the se­quencer. The sequencer automatically per­forms a calibration upon receiving the signal. Thus, no human interface is required for the automatic calibration to take place.
1-5 MODEL 751 REMOTE POWERED LOOP
LCD DISPLAY
The display 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 (Figure 1-6).
Refer to Model 751 remote powered loop LCD manual for calibration and wiring.
++
%
++
22220059
Figure 1-6. Model 751 Remote Powered Loop
LCD Display
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
1-6 SPECIFICATIONS
Oxymitter 4000
O
Range:
2
Standard .................................................. 0 to 10% O
0 to 25% O
2
2
0 to 40% O2 (via HART)
Oxymitter 4000
Accuracy ............................................................. ±0.75% of reading or 0.05% O
, whichever is greater
2
System Response to Calibration Gas ................ Initial response in less than 3 seconds T90 in less than
8 seconds
Temperature Limits:
Process .................................................... 32° to 1300°F (0° to 704°C) up to 2400°F (1300°C)
with optional accessories
Electronics ............................................... -40° to 185°F (-40° to 85°C)
Operating temperature of electronics inside of instru­ment housing, as measured by a HART communicator or Rosemount Asset Management Solutions software.
Probe Lengths .................................................... 18 in. (457 mm)
3 ft (0.91 m) 6 ft (1.83 m) 9 ft (2.74 m) 12 ft (3.66 m)
Mounting and Mounting Position ........................ Vertical or horizontal
Spool pieces are available, P/N 3D39761G02, to offset transmitter housing from hot ductwork.
Materials:
Probe ....................................................... Wetted or welded parts - 316L stainless steel
Non-wetted parts - 304 stainless steel, low-copper aluminum
Electronics Enclosure .............................. Low-copper aluminum
Calibration .......................................................... Manual, semi-automatic, or automatic
Calibration Gas Mixtures Recommended .......... 0.4% O
8% O2, Balance N
, Balance N
2
2
2
Calibration Gas Flow .......................................... 5 scfh (2.5 l/m)
Reference Air ..................................................... 2 scfh (1 l/m), clean, dry, instrument-quality air
(20.95% O
), regulated to 5 psi (34 kPa)
2
Electronics .......................................................... NEMA 4X, IP66 with fitting and pipe on reference ex-
haust port to clear dry atmosphere
Electronic Noise ................................................. Meets EN 50082-2 Generic Immunity Std. Part II.
Includes EN 61000-4-2 for Electrostatic Discharge
4 KV contact, 8 KV in air
Includes IEC 801-4 for fast transients; 2 KV on power
supply and control lines
Line Voltage ....................................................... 90-250 VAC, 50/60 Hz. No configuration necessary
3/4 in. - 14 NPT conduit port
1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
1
Signals:
Analog Output/HART ............................... 4-20 mA isolated from power supply, 950 ohms maxi-
mum load
Logic I/O .................................................. Two-terminal logic contact configurable as either an
alarm output or as a bi-directional calibration hand-
shake signal to IMPS 4000 or SPS 4000 Self-powered (+5 V), in series with 340 ohms Conduit ports — 3/4 in.-14 NPT (one threaded hole for
both analog output and logic I/O)
Power Requirements:
Probe Heater ........................................... 175 W nominal
Electronics ............................................... 10 W nominal
Maximum ................................................. 500 W
SPS 4000
Mounting ............................................................. Integral to Oxymitter 4000
Remote from Oxymitter 4000
Materials of Construction:
Manifold/Electronics Enclosure ............... Aluminum
Mounting Brackets ................................... 316 stainless steel (SS)
Pneumatic Fittings ................................... 1/8 in. brass NPT (SS optional)
Pneumatic Tubing .................................... 1/4 in. Teflon (SS optional)
Assembly Hardware ................................ Galvanized and stainless steel
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
Humidity Range .................................................. 100% relative humidity
Ambient Temperature Range ............................. -40° to 149°F (-40° to 65°C)
Electrical Classification ....................................... NEMA 4X (IP56)
Explosion-Proof Option (both pending) .............. CENELEC EExd IIB + H2
(Class 1, Div. 1, Group B,C,D)
Electrical Feedthroughs ..................................... 1/2 in. NPT
Input Power ........................................................ 90 to 250 VAC, 50/60 Hz
Power Consumption ........................................... 5 VA maximum
External Electrical Noise .................................... EN 50 082-2, includes 4 KV electrostatic discharge
Handshake Signal to/from
Oxymitter 4000 (self-powered) ................ 5 V (5 mA maximum)
Cal Initiate Contact Input from Control Room .... 5 VDC (self-powered)
Relay Outputs to Control Room ......................... 5 to 30 VDC, Form A (SPST)
(one “In-Cal”, one “Cal Failed”)
Cabling Distance between
SPS 4000 and Oxymitter 4000 ................ Maximum 1000 ft (303 m)
Piping Distance between
SPS 4000 and Oxymitter 4000 ................ Maximum 300 ft (91 m)
Approximate Shipping Weight ............................ 10 lbs (4.5 kg)
Fisher-Rosemount has satisfied all obligations coming from the European legislation to harmonize the product requirements in Europe.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-11
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
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 7 JIS (Japanese Std.) Probe with Ceramic Diffuser 8 JIS Probe with Flame Arrestor and Ceramic Diffuser 9 JIS Probe with Snubber Diffuser
Code Probe Assembly
0 18 in. (457 mm) Probe 1 18 in. (457 mm) Probe with Abrasive Shield 2 3 ft (0.91 m) Probe 3 3 ft (0.91 m) Probe with Abrasive Shield 4 6 ft (1.83 m) Probe 5 6 ft (1.83 m) Probe with Abrasive Shield 6 9 ft (2.74 m) Probe 7 9 ft (2.74 m) Probe with Abrasive Shield 8 12 ft (3.66 m) Probe 9 12 ft (3.66 m) Probe with Abrasive Shield
(1)
Oxymitter 4000
Table 1-1. Product Matrix
(1)
(1)
(1)
(1)
(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 Abrasive Shield (ANSI) 4 Probe Only (DIN) (European Std.) 5 New Bypass or Abrasive Shield (DIN) 7 Probe Only (JIS) (Japanese Std.) 8 New Bypass or Abrasive Shield (JIS)
Code Electronics Housing & Filtered Customer Termination - NEMA 4X, IP66
11 Standard Filtered Termination 12 Transient Protected Filtered Termination
Code Communications
1 HART with Membrane Keypad
OXT4A3211111 (Cont’d) Example
1-12 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
1
IB-106-340 Rev. 2.4
Oxymitter 4000
Table 1-1. Product Matrix (Continued)
Cont'd Code Language
1 English 2German 3 French 4 Spanish 5 Italian
Code Filtered Customer Termination
00 Specified as Part of Electronics Housing
Code Calibration Accessories
00 No Hardware 01 Calibration Gas Flowmeter and Reference Air Set 02 Intelligent Multiprobe Sequencer (Refer to Table 1-3)
XX Single Probe Sequencer - mounted to Oxymitter 4000 (Refer to Table 1-4)
Cont’d 1 00 XX Example
NOTES:
(1)
Recommended usages: 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. Regardless of application, abrasive shields with support brackets are recommended for 9 ft (2.74 m) and 12 ft (3.66 m) probe installations, particularly horizontal installations.
(2)
Where possible, specify SPS number; otherwise, provide details of the existing mounting plate as follows:
Plate with studs Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate.
Plate without studs Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.
April, 2001
Table 1-2. Calibration Components
Part
Number Description
1A99119G01 Two disposable calibration gas bottles — 0.4%
and 8% O
, balance nitrogen — 550 liters each,
2
includes bottle rack*
1A99119G02 Two flow regulators for calibration gas bottles
*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.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-13
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
Table 1-3. Intelligent Multiprobe Test Gas Sequencer Versions
Number of
Part
Number Description
3D39695G01 IMPS 1
3D39695G02 IMPS 2
3D39695G03 IMPS 3
3D39695G04 IMPS 4
3D39695G05 IMPS w/115 V Heater 1
3D39695G06 IMPS w/115 V Heater 2
3D39695G07 IMPS w/115 V Heater 3
3D39695G08 IMPS w/115 V Heater 4
3D39695G09 IMPS w/220 V Heater 1
3D39695G10 IMPS w/220 V Heater 2
Oxymitter
4000 Units
3D39695G11 IMPS w/220 V Heater 3
3D39695G12 IMPS w/220 V Heater 4
Table 1-4. Single Probe Autocalibration Sequencer Coding
Oxymitter 4000
Ref Air Set Fittings/Tubings
Brass/
Code No Yes
03 X X X
04 X X X
05 X X X
06 X X X
07 X X X
08 X X X
09 X X X
10 X X X
Teflon ST Steel Hor Vert
Mounting
1-14 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
2
Before installing this equipment, read the “Safety instructions for the wiring and installation of this apparatus” at the front of this Instruction Bulletin. Failure to follow safety instructions could result in serious injury or death.
2-1 MECHANICAL INSTALLATION
a. Selecting Location
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
SECTION 2
INSTALLATION
either make the necessary repairs or install the Oxymitter 4000 upstream of any leakage.
3. Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance ac­cess to the membrane keypad. Allow adequate clearance for removal of the Oxymitter 4000 (Figure 2-1 or Figure 2-2).
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 O vary due to stratification. A point too near the wall of the duct, or the inside radius of a bend, may not provide a representative sample because of the very low flow conditions. The sensing point should be selected so the proc­ess gas temperature falls within a range of 32° to 1300°F (0° to 704°C). Figure 2-1 through Figure 2-6 provide mechanical installation references. The ambient temperature of the integral electronics housing must not exceed 149°F (65°C).
2. Check the flue or stack for holes and air leakage. The presence of this con­dition will substantially affect the accu­racy of the oxygen reading. Therefore,
can
2
Do not allow the temperature of the Oxymitter 4000 integral electronics to exceed 149°F (65°C) or damage to the unit may result.
b. Installation
1. Ensure all components are available to install the Oxymitter 4000. If equipped with the optional ceramic diffusion ele­ment, ensure it is not damaged.
2. The Oxymitter 4000 may be installed intact as it is received.
NOTE
An abrasive shield is recommended for high velocity particulates in the flue stream (such as those in coal­fired boilers, kilns, and recovery boil­ers). Vertical and horizontal brace clamps are provided for 9 ft and 12 ft (2.75 m and 3.66 m) probes to provide mechanical support for the Oxymitter
4000. Refer to Figure 2-6.
3. Weld or bolt adapter plate (Figure 2-5) onto the duct.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
85.8
49.8
31.8
(808)
16
(406)
18 IN.
34
3 FT
(1265)
70
(864)
1.55
6.52
(39)
12
TABLE 2. INSTALLATION/REMOVA L
(305)
DIM "B"
DIM "A"
PROBE
REF.
GAS
E
V
I
-
L
A
E
R
T
E
I
H
P
U
S
O
M
T
A
N
I
N
E
R
V
I
S
O
L
C
R
-
I
G
A
W
P
C
N
E
H
W
-
T
H
X
E
G
I
T
N
I
P
-
E
E
K
500VA
5 Amps
R
TM
HART
SMART FAMILY
800-433-6076
Rosemount Analytical Inc.
Orrville, OH 44667-0901
R
TM
4-20 mA
85-264VAC 48-62 Hz
OXYMITTER 4000
SERIAL NO.
VOLTS: WATTS:
TAG NO.
OUTPUT: LINE FUSE:
3/4 NPT
ELEC CONN
REF AIR
CAL GAS
DIN 6 mm TUBE
ANSI 1/4 (6.35) TUBE
6 mm TUBEJIS
(2179)
(1778)
6 FT
(166)
121.8
(3094)
106
(2692)
9 FT
2.89
(73)
157.8
(4008)
142
(3607)
12 FT
COVER REMOVAL & ACCESS
12
(305)
E
R
E
H
P
S
O
M
-
T
G
A
N
I
N
E
R
V
A
I
W
S
O
-
ALL DIMENSIONS ARE IN
INCHES WITH MILLIMETERS
IN PARENTHESES.
AMBIENT WEATHER CONDITIONS
NOTE:
INSULATE IF EXPOSED TO
3535B18H02
3535B46H01
3535B45H01
0.062 THK GASKET
ANSI
JIS
DIN
L
P
X
2.27 (58)
DIA MAX
E
E
V
I
-
L
A
T
I
U
C
R
I
C
N
E
H
W
T
H
G
I
T
N
I
P
-
E
E
K
CAL.
GAS
DIM "B"
12.50 (318)
REMOVAL ENVELOPE
BOTTOM VIEW
6.02 (153)
4.77 (121)
0.59
(15)
3.80(96)
ADD TO DIM “A”
DIM "A"
DIFFUSER
5.14(131)
FOR PROBE
WITH CERAMIC
WITH
SNUBBER
DIFFUSER
STANDARD
ARRESTOR
AND FLAME
ADD TO DIM “A”
FOR PROBE WITH
CERAMIC DIFFUSER
6.10
JIS
4512C18H01
DIN
7.28
4512C19H01
ANSI
6.00
TABLE 1. MOUNTING FLANGE
4512C17H01
FLANGE
(155)
(185)
(153)
DIA
0.71
(18)
0.75
(20)
DIA
HOLE
5.12
(130)
5.71
(145)
4.75
(121)
EQ SP
ON BC
(4) HOLES
PROCESS FLOW MUST BE IN
THIS DIRECTION WITH RESPECT
TO DEFLECTOR 3534B48G01
35830002
Figure 2-1. Oxymitter 4000 Installation
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
2
1/4 IN. TUBE
FITTING FOR
HIGH CAL
GAS IN
0.94
(23.88)
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
HORIZONTAL MOUNTED SPS 4000 A
1/4 IN. TUBE FITTING FOR
INSTRUMENT AIR IN (OPTIONAL)
11.00
(279.40)
NOMINAL
TERMINAL COVER
1/4 IN. TUBE
FITTING
TO CAL GAS
FLOWMETER
1/4 IN. TUBE
FITTING FOR
LOW CAL
GAS IN
0.94
(23.88)
2.00 (50.80)
1/2 NPT SIGNAL CONDUIT PORT
(CUSTOMER TO
SUPPLY FITTING)
14.00 (355.60) NOMINAL
12.00 (304.80) NOMINAL
VERTICAL MOUNTED SPS 4000 A
13.00
(330.20)
NOMINAL
1/2 IN. CONDUIT FITTING FOR LINE VOLTAGE
10 (254)
NOMINAL
2.00 (50.80) NOMINAL
CLEARANCE TO
REMOVE COVER
NOTE:
DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.
12.00 (304.80) NOMINAL
TO VIEW AND
OPERATE
OXYMITTER 4000
KEYPAD
2.00 (50.80) NOMINAL CLEARANCE TO REMOVE COVER
12.00 (304.80) NOMINAL
TO VIEW AND
OPERATE
OXYMITTER 4000
KEYPAD
26170003
FLOWMETER (OPTIONAL)
CALIBRATION GAS
FLOWMETER
(CALIBRATION GAS OUT
TO OXYMITTER 4000)
REFERENCE AIR
(REFERENCE AIR OUT
TO OXYMITTER 4000)
10 (254)
NOMINAL
Figure 2-2. Oxymitter 4000 Installation (with SPS 4000)
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
(318)
12.50
Oxymitter 4000
E
V
I
-
L
A
E
R
E
H
P
S
O
M
-
T
G
A
N
I
N
E
R
V
A
I
W
S
O
-
L
P
X
E
N
T
I
U
C
R
I
C
N
E
H
W
T
H
G
I
T
I
P
-
E
E
K
CAL.
GAS
CONNECTION
3/4 NPT ELECTRICAL
1/4 IN. TUBE
ANSI
CAL GAS*
REF AIR
6 mm TUBE
6 mm TUBE
ANSI
ANSI
*ADD CHECK VALVE IN CAL GAS LINE
DIM "B"
REMOVAL ENVELOPE
7.00
(178)
DIM "A"
3.6 (91) DIA NOMINAL
6.02
(153)
4.77
(121)
SEAL ASSY
DIFFUSER/DUST
VAL TABLE O
DIN
9.25
(235)
0.94
(24)
-3D39003
JIS
ANSI
TABLE 4. ABRASIVE SHIELD
FLANGE
DIM "B"
9.25
0.75
(235)
9.00
0.75
(229)
FLANGE
DIA
HOLE
86.5
50.5 (1283)
(19)
(19)
DIA
122.5
(2197)
7.48
(190)
7.48
(190)
7.50
(190)
EQ SP
ON BC
(8) HOLES
158.5
(3112)
(4026)
31
1. THESE FLAT-FACED FLANGES ARE MANUFACTURED TO ANSI, DIN, AND JIS BOLT PATTERNS
NOTES:
67
(787)
3 FT
(1702)
6 FT
DIM "A"
TABLE 3.
3.9
(99)
PROBE
SNUBBER/DUST
SEAL ASSEMBLY
(5)
0.2
AND ARE NOT PRESSURE RATED.
2. ALL DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.
DEFLECTOR ASSY
INSTALLATION/REM
103
(2616)
9 FT
35830003
139
(3531)
12 FT
Figure 2-3. Oxymitter 4000 with Abrasive Shield
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
2
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
WITH ABRASIVE SHIELD
TABLE 6. ADAPTER PLATE* DIMENSIONS FOR OXYMITTER 4000
JIS
(P/N 3535B58G04)
DIN
(P/N 3535B58G06)
ANSI
(P/N 3535B58G02)
IN.
(mm)
DIMENSIONS
JIS
(P/N 4512C35G01)
9.25
9.25
9.00
"A"
6.50
(235)
(235)
(229)
(165)
4.92
(125)
3.94
(100)
4.75
(121)
"B"
DIA
(M-12 x 1.75)
(M-20 x 2.5)
(M-16 x 2)
0.625-11
"C"
THREAD
(130)
5.118
(200)
7.894
7.48
(190)
7.50
(191)
"D"
DIA
ATTACHING HARDWARE.
*PART NUMBERS FOR ADAPTER PLATES INCLUDE
8 THREADED HOLES
EQUALLY SPACED ON
D DIA B.C.
o
22.5
A
CROSSHATCHED AREA IN 4
CORNERS MAY BE USED TO
PROVIDE ADDITIONAL HOLES FOR
FIELD BOLTING OF PLATE TO
OUTSIDE WALL SURFACE.
ADAPTER PLATE FOR 3, 6, 9,
AND 12 FT ABRASIVE SHIELD
INSTALLATIONS. SEE FIGURE 2-3.
ABRASIVE SHIELD
FLANGE O.D.
A
C
B
4 STUDS,
LOCKWASHERS AND
NUTS EQUALLY
SPACED ON
C DIA B.C.
B
ADAPTER PLATE
FOR OXYMITTER 4000
INSTALLATION. SEE
FIGURE 2-1.
35830004
TABLE 5. ADAPTER PLATE* DIMENSIONS FOR OXYMITTER 4000
DIN
(P/N 4512C36G01)
ANSI
(P/N 4512C34G01)
IN.
(mm)
DIMENSIONS
7.5
6.00
"A"
(191)
(153)
(M-16 x 2)
0.625-11
"B"
THREAD
(145)
5.708
4.75
(121)
"C"
DIA
ATTACHING HARDWARE.
*PART NUMBERS FOR ADAPTER PLATES INCLUDE
o
45
A
IN INCHES WITH
MILLIMETERS IN
PARENTHESES.
NOTE:DIMENSIONS ARE
A
C
2.500 DIA
(63.5)
Figure 2-4. Oxymitter 4000 Adapter Plate Dimensions
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
INSTALLATION FOR METAL
WALL STACK OR DUCT
CONSTRUCTION
Oxymitter 4000
INSTALLATION FOR MASONRY
WALL STACK CONSTRUCTION
MTG HOLES SHOWN ROTATED
o
45 OUT OF TRUE POSITION
WELD OR BOLT ADAPTER PLATE TO METAL WALL OF STACK OR DUCT. JOINT MUST BE AIRTIGHT.
0.50 [13]
3.75 [95]
MIN DIA HOLE IN WALL
STACK OR DUCT METAL WALL
0.50 [13]
BOLT ADAPTER
PLATE TO OUTSIDE
WALL SURFACE
FIELD WELD
PIPE TO
ADAPTER PLATE
MTG HOLES
SHOWN ROTATED
o
45 OUT OF
TRUE POSITION
JOINT MUST
BE AIRTIGHT
OUTSIDE WALL
SURFACE
NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPT
ADAPTER PLATE NOT FURNISHED BY ROSEMOUNT.
4.50 [114] O.D. REF
PIPE 4.00 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH BY CUSTOMER
MASONRY STACK WALL
2.50 [63.5]
WELD OR BOLT ADAPTER PLATE TO METAL WALL OF STACK OR DUCT. JOINT MUST BE AIRTIGHT.
MIN DIA HOLE IN WALL
STACK OR DUCT METAL WALL
NOTE: DIMENSIONS IN INCHES WITH
BOLT ADAPTER
PLATE TO OUTSIDE
WALL SURFACE
JOINT MUST
BE AIRTIGHT
OUTSIDE WALL
SURFACE
MILLIMETERS IN PARENTHESES.
FIELD WELD PIPE TO ADAPTER PLATE
3.50 [89] O.D. REF
PIPE 3.00 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH BY CUSTOMER
MASONRY STACK WALL
35830005
Figure 2-5. Oxymitter 4000 Adapter Plate Installation
2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
2
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
o
60 MAX
o
30 MIN
4.12
(105)
4.12
(105)
BRACE BARS (NOT BY ROSEMOUNT)
2.00 (51)
1.00 (25)
2 HOLES - 0.625 (16) DIA FOR
0.50 (12) DIA BOLT
1.00 (25) MAX
0.375 (10)
NOTE: DIMENSIONS IN INCHES WITH
MILLIMETERS IN PARETHESES.
VERTICAL BRACE CLAMP ASSY. HORIZONTAL BRACE CLAMP ASSY.
(BOTH BRACE CLAMP ASSEMBLIES ARE THE SAME. INSTALLATION AND LOCATION OF CLAMP ASSEMBLIES AND BRACE BARS TO BE DONE IN FIELD.)
5.62
(143)
5.62
(143)
ABRASIVE SHIELD
BY ROSEMOUNT
}
36.00 (914)
NOTE: BRACING IS FOR VERTICAL AND HORIZONTAL OXYMITTER 4000
INSTALLATION. EXTERNAL BRACING REQUIRED FOR 9 FT AND 12 FT (2.75 M AND 3.66 M) PROBES AS SHOWN ABOVE.
Figure 2-6. Oxymitter 4000 Bracing Installation
26170034
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
4. If using the optional ceramic diffusion element, the vee deflector must be cor­rectly oriented. Before inserting the Oxymitter 4000, check the direction of gas flow in the duct. Orient the vee de­flector so the apex points upstream to­ward the flow (Figure 2-7). This may be done by loosening the setscrews and rotating the vee deflector to the desired position. Retighten the setscrews.
5. In vertical installations, ensure the sys­tem cable drops vertically from the Oxymitter 4000 and the conduit is routed below the level of the electronics housing. This drip loop minimizes the possibility that moisture will damage the electronics (Figure 2-8).
GAS FLOW DIRECTION
VEE
DEFLECTOR
APEX
DIFFUSION
FILTER
ELEMENT
SETSCREW
DEFLECTOR
VEE
22220020
Figure 2-7. Orienting the Optional Vee Deflector
LINE
VOLTAGE
LOGIC I/O, 4-20 mA SIGNAL
REPLACE INSULATION
AFTER INSTALLING
OXYMITTER 4000
INSULATION
ADAPTER
Figure 2-8. Installation with Drip Loop and Insulation Removal
PLATE
E
V
I
-
L
A
E
R
T
E
I
H
P
S
O
M
T
G
A
N
I
N
E
R
V
A
I
W
S
O
L
P
U
C
-
-
X
E
R
I
C
N
E
H
W
T
H
G
I
T
N
I
P
-
E
E
K
DRIP LOOP
CAL.
GAS
STACK OR DUCT METAL WALL
29340005
2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
2
6. If the system has an abrasive shield, check the dust seal gaskets. The joints in the two gaskets must be staggered 180°. Also, make sure the gaskets are in the hub grooves as the Oxymitter 4000 slides into the 15° forcing cone in the abrasive shield.
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
Disconnect and lock out power before connecting the unit to the power supply.
NOTE
If process temperatures will exceed 392°F (200°C), use anti-seize com­pound on stud threads to ease future removal of Oxymitter 4000.
7. Insert probe through the opening in the mounting flange and bolt the unit to the flange. When probe lengths selected are 9 or 12 ft (2.74 or 3.66 m), special brackets are supplied to provide addi­tional support for the probe inside the flue or stack (Figure 2-6).
Uninsulated stacks or ducts may cause ambient temperatures around the electronics to exceed 149°F (65°C), which may cause overheating damage to the electronics.
8. If insulation is being removed to access the duct work for Oxymitter 4000 mounting, make sure the insulation is replaced afterward (Figure 2-8).
2-2 ELECTRICAL INSTALLATION (FOR
OXYMITTER 4000 WITHOUT SPS 4000)
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.
To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, con­nection to the main electrical power supply must be made through a circuit breaker (min 10 A) which will discon­nect all current-carrying conductors during a fault situation. This circuit breaker should also include a me­chanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 947.
NOTE
To maintain CE compliance, ensure a good connection exists between the mounting flange bolts and earth.
All wiring must conform to local and national codes.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9
a. Remove screw (32, Figure 6-1), gasket (33),
and cover lock (34). Remove terminal block cover (27).
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
b. Connect Line Voltage
Connect the line, or L1, wire to the L1 ter­minal and the neutral, or L2 wire, to the N terminal (Figure 2-9). The Oxymitter 4000 automatically will configure itself for 90-250 VAC line voltage and 50/60 Hz. The power supply requires no setup.
c. Connect 4-20 mA Signal and Logic
I/O/Calibration Handshake Leads (Figure 2-9)
1. 4-20 mA Signal. The 4-20 mA signal represents the O
value and can also
2
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 Handheld Communicator or AMS software.
2. Logic I/O/Calibration Handshake. The output can either be an alarm or pro­vide the handshaking to interface with an IMPS 4000. For more information, refer to paragraph 7-3 and the IMPS
4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin.
3. If autocalibration is not utilized, a common bi-directional logic contact is provided for any of the diagnostic alarms listed in Table 7-1. The assign­ment of alarms which can actuate this contact can be modified to one of seven additional groupings listed in Table 3-1.
The logic contact is self-powered, +5 VDC, 340 ohm series resistance. An interposing relay will be required if this contact is to be utilized to annunciate a higher voltage device, such as a light or horn, and may also be required for certain DCS input cards. A Potter & Brumfield R10S-E1Y1-J1.0K 3.2 mA DC or an equal interposing relay will be mounted where the contact wires ter­minate in the control/relay room.
d. Install terminal block cover (27, Figure 6-1)
and secure with cover lock (34), gasket (33), and screw (32).
AC TERMINAL
LINE VOLTAGE
(85 TO 264 VAC)
LOGIC I/O/
CALIBRATION HANDSHAKE
4-20 mA SIGNAL
LEFT SIDE OF
OXYMITTER 4000
COVER
AC L1
AC N
+
-
+
4-20
-
Figure 2-9. Terminal Block
TERMINAL
BLOCK
AC LINE
VOLTAGE PORT
GROUND LUGS
SIGNAL
PORT
26170016
2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
2
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
2-3 ELECTRICAL INSTALLATION (FOR OXY-
MITTER 4000 WITH SPS 4000)
All wiring must conform to local and national codes.
Disconnect and lock out power before connecting the unit to the power supply.
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.
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.
The following contacts are provided through the autocalibration system:
a. One contact closure per probe from the
control room to the SPS 4000 for “calibra­tion initiate”.
b. One contact output per probe from the SPS
4000 to the control room for “in calibration” notification.
c. One contact per probe from the SPS 4000
to the control room for “calibration failed” notification, which includes output from pressure switch indicating “cal gas bottles empty”.
NOTE
The 4-20 mA signal can be configured to respond normally during any cali­bration, or can be configured to hold the last O
value upon the intitiation of
2
calibration. Factory default is for the 4-20 mA signal to operate normally throughout calibration. Holding the last O
value may be useful if several
2
probes are being averaged for the purpose of automatic control. Unless several probes are being averaged, always place any control loops using the O
signal into manual prior to
2
calibrating.
Electrically connect the probe as follows:
d. Remove screws (26, Figure 6-11) securing
terminal cover (27). Remove the cover to expose terminal strip (25).
e. Connect Line Voltage
Autocalibration systems will inject gases into the probe and make electronic adjustments with no operator attention required. The SPS 4000 pro­vides solenoid valves and circuitry for calibrating a single Oxymitter 4000 unit.
The SPS 4000 autocalibration system utilizes the Oxymitter 4000’s bidirectional logic contact as a “handshake” signal. Therefore, this signal is not available for alarming purposes.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11
Route the line voltage leads into the mani­fold through the 1/2 in. line voltage conduit fitting (Figure 2-2) and out through the bot­tom of the manifold. Connect the LINE IN and NEUTRAL leads to terminals L and N, respectively, as shown in Figure 2-10. Also, be sure to connect the ground wire to the ground lug. The unit automatically will con­figure itself for 90 to 250 VAC line voltage and 50/60 Hz. The power supply requires no setup.
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
f. Connect Remote Contact Input Wiring
To set up the SPS 4000 to initiate a calibra­tion from a remote location, route the 5 VDC calibration initiate contact input leads through the 1/2 in. NPT signal conduit port (Figure 2-2) and out through the bottom of the manifold. Connect the (+) and (-) CAL INITIATE leads to terminals 1 and 2, re­spectively, as shown in Figure 2-10.
g. Connect Relay Output Wiring
Relay connections are available 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. Route the relay output leads through the 1/2 in. NPT signal conduit port (Figure 2-2) and out through the bottom of the manifold. Connect the (+) and (-) CAL FAIL leads and the (+) and (-) IN CAL leads to terminals 7, 8, 9, and 10, respectively, as shown in Figure 2-10.
h. Connect 4-20 mA Signal Wiring
Route the 4-20 mA signal wiring into the manifold through the 1/2 in. NPT signal conduit port (Figure 2-2) and out through the bottom of the manifold. Connect the (+) and (-) signal leads to terminals 3 and 4, re­spectively, as shown in Figure 2-10.
i. Once all connections are made, install ter-
minal cover (27, Figure 6-11) and secure with screws (26).
2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
2
5 VDC
(SELF-POWERED)
TO REMOTE
CONTACT INPUT
CONNECTION
CAL INITIATE
+
-
4-20 mA
CONNECTION
+
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
5 - 30 VDC TO RELAY OUTPUT
CONNECTIONS
NOT USED
-
CAL FAIL
IN CAL
++
--
LINE IN
GROUND
NEUTRAL
90 - 250 VAC, 50/60 HZ LINE VOLTAGE INPUT
FACTORY WIRING TO OXYMITTER 4000
BLACK
FACTORY
WIRING
TO INTERFACE
BOARD
WHITE
YELLOW
FACTORY
WIRING TO
OXYMITTER
4000
BROWN
NOT USED
RED
BLUE
FACTORY WIRING
TO INTERFACE BOARD
ORANGE
GREEN
FACTORY WIRING
TO POWER SUPPLY
BOARD
26170027
Figure 2-10. SPS 4000 Electrical Connections
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-13
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
0.125-27 NPT FEMALE
OUTLET CONNECTION
1
4.81 (122.17)
FLOW SET
POINT KNOB
0.250 OR 6 MM O.D.
TUBE COMPRESSION
FITTING (SUPPLIED BY WECO)
Rosemount Analytical Inc.
SMART FAMILY
Orrville,OH 44667-0901
TM
HART
800-433-6076
TM
OXYMITTER 4000 SERIAL NO. TAG NO.
85-264VAC 48-62 Hz
500VA
WATTS:VOLTS:
4-20 mAR5 Amps
FUSE:LINEOUTPUT:
0.250 OR 6 MM O.D. TUBING (SUPPLIED BY CUSTOMER)
2
OUTLET
1.19 (30.22)
DRAIN VALVE
10.0
(254)
REF
TO ELECTRONICS
3
REF AIR SET
263C152G01
3.12 (79.25) MAX
2.250 (57.15)
0.25-18 NPT FEMALE INLET CONNECTION
2.0
(50.80)
1.50
(38.10)
NOTE: DIMENSIONS ARE IN INCHES WITH
2 MOUNTING HOLES
3.19 (81.03) LG
THROUGH BODY FOR
0.312 (7.92) DIA BOLTS
MILLIMETERS IN PARENTHESES.
8.50
(215.90)
MAX
1 FLOWMETER 0.2-2.0 SCFH 771B635H02
2 2" PRESSURE GAGE 0-15 PSIG 275431-006
3 COMBINATION FILTER-REG. 0-30 PSIG 4505C21G01
INSTRUMENT AIR SUPPLY 10-225 PSIG MAX PRESSURE
SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYMITTER 4000 PROBE HEAD.
Figure 2-11. Air Set, Plant Air Connection
2-4 PNEUMATIC INSTALLATION (FOR OXY-
MITTER 4000 WITHOUT SPS 4000)
kPag) maximum at 2 scfh (56.6 L/hr) maxi­mum; less than 40 parts-per-million total hydrocarbons. Regulator outlet pressure
a. Reference Air Package
After the Oxymitter 4000 is installed, con­nect the reference air set to the Oxymitter
4000. The reference air set should be in­stalled in accordance with Figure 2-11.
Instrument Air (Reference Air): 10 psig (68.95 kPag) minimum, 225 psig (1551.38
should be set at 5 psi (35 kPa). Reference air can be supplied by the reference air set of the IMPS 4000.
If using an IMPS 4000, refer to the IMPS 4000 Intelligent Multiprobe Test Gas Se­quencer Instruction Bulletin for the proper reference air connections.
26170035
2-14 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
2
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
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.
b. Calibration Gas
Two calibration gas concentrations are used with the Oxymitter 4000, Low Gas - 0.4% O and High Gas - 8% O2. See Figure 2-12 for the Oxymitter 4000 connections.
2-5 PNEUMATIC INSTALLATION (FOR OXY-
MITTER 4000 WITH SPS 4000)
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.
R
R
Rosemount Analytical Inc.
SMART FAMILY
Orrville,OH 44667-0901
TM
HART
800-433-6076
TM
OXYMITTER 4000 SERIAL NO.
CALIBRATION GAS
TAG NO. VOLTS: WATTS:
85-264VAC 48-62 Hz
4-20 mA
OUTPUT: LINE FUSE:
500VA
5 Amps
REFERENCE AIR
26170025
Figure 2-12. Oxymitter 4000 Gas Connections
Calibration Gas Connections
Locate the 1/4 in. calibration gas fittings on the SPS 4000 manifold (Figure 2-2). Con­nect O gas) to the HIGH CAL GAS IN fitting and O
2
calibration gas 2 (low calibration gas) to the LOW CAL GAS IN fitting. Ensure the cali-
calibration gas 1 (high calibration
2
2
bration gas pressure is set at 20 psi (138 kPa).
a. Reference Air Connection (Optional)
If the reference air option (which includes the reference air flowmeter, pressure regu­lator, and necessary tubing and fittings) is used, connect the instrument air to the 1/4 in. fitting on the reference air pressure regulator (Figure 2-2). The pressure regu­lator is factory set at 20 psi (138 kPa). Re­adjust by turning the knob on the top of the regulator to obtain the desired pressure.
If the SPS 4000 does not have the refer­ence air option, connect the reference air to the Oxymitter 4000 as instructed in para­graph 2-4.
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 area.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-15
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
2-16 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
3
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.
3-1 GENERAL
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
SECTION 3
STARTUP
2. Check the terminal block wiring. Be sure the power, 4-20 mA signal, and logic outputs are properly connected and secure.
3. Install the housing cover on the termi­nal block and secure with cover lock (34, Figure 6-1), gasket (33), and screw (32).
a. Verify Mechanical Installation
Ensure the Oxymitter 4000 is installed cor­rectly (Section 2, INSTALLATION).
b. Verify Terminal Block Wiring
1. Remove screw (32, Figure 6-1), gasket (33), and cover lock (34) that secure the terminal block cover. Remove the cover to expose the terminal block (Figure 3-1).
4-20
+
+
-
-
4-20 mA SIGNAL
LOGIC I/O
AC N
AC L1
TERMINAL BLOCK
OXYMITTER 4000 SERIAL NO. TAG NO.
85-264VAC 48-62 Hz
4-20 mA
OUTPUT:
TM
Rosemount Analytical Inc. Orrville,OH 44667-0901
800-433-6076
4. For an Oxymitter 4000 with an inte­grally mounted SPS 4000, remove screws (26, Figure 6-11) and terminal cover (27). Check that the power and signal terminations are properly con­nected to terminal strip (25) and secure according to instructions in Section 2, INSTALLATION.
5. Install terminal cover (27) and secure with screws (26).
OXYMITTER 4000 ELECTRONICS HOUSING
R
SMART FAMILY
TM
HART
500VA
WATTS:VOLTS:
5 Amps
FUSE:LINE
HEATERT/C
SW2
HEATER
DIAGNOSTIC
ALARMS
CALIBRATION
CALIBRATION RECOMMENDED
TEST
POINTS
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
02 CELL
02 CELL mV +
02 CELL mv -
HEATERT/C +
HEATERT/C -
CAL
TEST GAS +
PROCESS -
% 02
O N
J1
TP1
TP2
TP3
TP4
N
ED
R
RG
YEL
R
G
O
TP5
TP6
GROUND LUGS
26170036
Figure 3-1. Integral Electronics
Rosemount Analytical Inc. A Division of Emerson Process Management Startup 3-1
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
c. Verify Oxymitter 4000 Configuration
Oxymitter 4000
Located on the microprocessor board, the top board, are two switches that configure outputs for the Oxymitter 4000 (Figure 3-2). SW1 determines if the 4-20 mA signal is internally or externally powered. SW2 de­termines:
1. Oxymitter 4000 status, HART or LOCAL.
2. Oxygen range, 0 to 10% O 25% O
. (0 to 40% O2 is also configur-
2
or 0 to
2
able only through HART/AMS.)
3. The 4-20 mA signal, at fault or power up, 4 mA or 20 mA.
Remove power from the Oxymitter 4000 before changing defaults. If de­faults are changed under power, dam­age to the electronics package may occur.
d. SW1
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.
e. SW2
The factory sets this switch as follows:
1. Position 1 is HART/LOCAL. This switch controls the configuration of the Oxy­mitter 4000. The defaults cannot be changed via HART/AMS unless the switch is in the HART position. Placing this switch in the LOCAL position forces the O
range to the setting of
2
position 2. This switch must be placed in the LOCAL position or changes in position 2 will have no effect.
2. Position 2 determines the O
range.
2
This can be set to either 0 to 10% O or 0 to 25% O2. The factory setting is 0 to 10% O
.
2
Typically, the probe’s sensing cell, which is in direct contact with the pro­cess gases, is heated to approximately 1357°F (736°C), and the external tem­perature of the probe body may ex­ceed 842°F (450°C). If operating conditions also contain high oxygen levels and combustible gases, the Oxymitter 4000 may self-ignite.
If necessary, the O2 range can be con­figured from 0 to 40% O
. To select
2
values within this range, set position 1 of SW2 to HART and then enter the range via HART/AMS. Do not change position 1 of SW2 to LOCAL unless you want to operate in the range speci­fied by position 2 of SW2.
3. Position 3 determines the output at startup or at an alarm. The settings are 4 mA or 20 mA. The factory setting is 4 mA. At startup, the current at the ana­log output is 4 mA or 20 mA.
4. Position 4 is not used.
f. Once the cell is up to operating tempera-
ture, the O
percentage can be read:
2
1. Access TP5 and TP6 next to the mem­brane keypad. Attach a multimeter across TP5 and TP6. The calibration and process gases can now be moni­tored. Pressing the INC or DEC once will cause the output to switch from the process gas to the calibration gas. Pressing INC or DEC a second time will increase or decrease the calibra­tion gas parameter. If the keys have been inactive for one minute, the out­put reverts to the process gas. When a calibration has been initiated, the value at TP5 and TP6 is the % O
seen by
2
the cell. Oxygen levels, as seen on the multimeter, are:
8.0% O2 = 8.0 VDC
0.4% O2 = 0.4 VDC
2. HART/AMS.
2
3. Model 751. The loop-driven LCD display.
3-2 Startup Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
3
INTERNAL:
4-20 mA IS
INTERNALLY
POWERED
(DEFAULT)
EXTERNAL:
4-20 mA
REQUIRES
AN EXTERNAL
POWER SUPPLY
HART:
LOCAL: 0 TO 10% O / 0 TO 25% O :
4 mA/20 mA:
O RANGE SET BY HART/AMS
2
(FROM 0 TO 40% O ) O RANGE SET BY POS 2
2
2
ORANGE
2
2
WHEN ALARM EXISTS, OR ON POWER UP, CURRENT OUTPUT GOES TO THIS VALUE
2
Instruction Manual
IB-106-340 Rev. 2.4
HART
0 TO 10% O
NOT USED NOT USED
2
3.8 mA
DEFAULT
POSITION
(EX-FACTORY)
LOCAL
0 TO 25% O
22 mA
April, 2001
2
SW1
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
TEST
POINTS
INC INC
HIGH
GAS
LOW
GAS
DEC DEC
Figure 3-2. Oxymitter 4000 Defaults
HEATER T/C
HEATER
O2 CELL
CALIBRATION
O2 CELL mV +
O2 CELL mV -
HEATER T/C +
HEATER T/C -
CAL
TEST GAS +
PROCESS -
% O2
TP1
TP2
TP3
TP4
TP5
TP6
1 2 3 4
SW2
ON
J1
YEL
RED
GRN
ORG
29770004
Rosemount Analytical Inc. A Division of Emerson Process Management Startup 3-3
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000

3-2 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 4000. The configu­ration of this signal depends on the setting of the LOGIC I/O PIN MODE via HART/AMS. The ten different modes available are explained in Table 3-1.
a. 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, Rose­mount recommends connecting the output to a Potter & Bromfield 3.2 mA DC relay (P/N R10S-E1Y1-J1.0K).
Table 3-1. Logic I/O Configuration
Mode Configuration
Of the ten modes in Table 3-1, modes 0 through 7 are the alarm modes. The factory default is mode 5 for Oxymitter 4000 units without an IMPS 4000 or SPS 4000. In this mode, the output will signal when a unit alarm or a CALIBRATION RECOM­MENDED indication occurs.
b. Calibration Handshake Signal
If using an optional IMPS 4000 or SPS 4000, the logic I/O must be configured for calibration handshaking. Of the ten modes in Table 3-1, only modes 8 and 9 are con­figured for calibration handshaking. For an Oxymitter 4000 with an IMPS 4000 or an SPS 4000, 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.
0 The unit is not configured for any alarm condition.
1 The unit is configured for a Unit Alarm.
2 The unit is configured for Low O2.
3 The unit is configured for both a Unit Alarm and Low O2.
4 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.
6 The unit is configured for both a Low O2 and High AC Impedance/CALIBRATION
RECOMMENDED.
7 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 4000.
CALIBRATION RECOMMENDED will initiate the calibration cycle.
9 The unit is configured for a calibration handshake. CALIBRATION RECOM-
MENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4000.
*The default condition for an Oxymitter 4000 without an IMPS 4000 or SPS 4000.
**The default condition for an Oxymitter 4000 with an IMPS 4000 or SPS 4000.
3-4 Startup Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
3
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
POINTS
INC INC
HIGH
GAS
DEC DEC
TEST
CALIBRATION
LOW
GAS
HEATER T/C
HEATER
O2 CELL
O2 CELL mV +
O2 CELL mv -
HEATER T/C +
HEATER T/C -
CAL
TEST GAS +
PROCESS -
% O2
TP1
TP2
TP3
TP4
TP5
TP6
SW2
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
HEATER T/C
HEATER
O CELL
2
ON
J1
YEL
RED
GRN
ORG
CALIBRATION
HEATER T/C
HEATER
O CELL
2
CALIBRATION
2 3 4 1 2 3 4
1
LIGHTING SEQUENCE DURING NORMAL OPERATION
2 3 4 1 2 3 4
1
LIGHTING SEQUENCE DURING WARM-UP
22220056
Figure 3-3. Startup and Normal Operation

3-3 RECOMMENDED CONFIGURATION

a. 4-20 mA Signal Upon Critical Alarm
Rosemount recommends that the factory default be utilized. The 4-20 mA signal will go to the 3.8 mA level upon any critical alarm which will cause the O
reading to be
2
unusable. Customer can also select 22 mA as the failure setting if normal operations cause O
(4 mA) level.
O
2
If the O
readings to go below the zero %
2
measurement is being utilized as
2
part of an automatic control loop, the loop should be placed into manual upon this fail­ure event or other appropriate action should be taken.
b. Calibration
Rosemount recommends utilizing an auto­calibration system, actuated by the “calibra­tion recommended” diagnostic. New O 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 O
2
always accurate, and eliminates many un-
2
reading is
necessary calibrations based on calendar days or weeks since previous calibration. When utilizing the SPS 4000 or the IMPS 4000, consider wiring some or all associ­ated alarm contacts.
1. CALIBRATION INITIATE. Contact from the control room to an SPS 4000 or IMPS 4000 (one per probe) provides the ability to manually initiate a calibra­tion at any time from the control room. Note that calibrations can also be initi­ated from a HART handheld communi­cator, from Asset Management Solutions software, or from the keypad on the Oxymitter 4000.
2. IN CALIBRATION. One contact per probe provides notification to the con­trol room that the “calibration recom­mended” diagnostic has initiated an automatic calibration through the SPS 4000 or IMPS 4000. If the O
signal is
2
being utilized in an automatic control loop, this contact should be utilized to place the control loop into manual dur­ing calibration.
Rosemount Analytical Inc. A Division of Emerson Process Management Startup 3-5
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
3. CALIBRATION FAILED. One contact per probe from an SPS 4000 or IMPS 4000 to the control room for notification that the calibration procedure failed. Grouped with this alarm is an output from a pressure switch which indicates when the calibration gas bottles are empty.
4. 4-20 mA SIGNAL DURING CALI­BRATION. The 4-20 mA signal can be configured to respond normally during any calibration, or can be configured to hold the last O of calibration. Factory default is for the 4-20 mA signal to operate normally throughout calibration. Holding the last O
2
probes are being averaged for the pur­pose of automatic control. Unless sev­eral probes are being averaged, always place any control loops using the O signal into manual prior to calibrating.

3-4 POWER UP

value upon the initiation
2
value may be useful if several
c. Error
If there is an error condition at startup, one of the diagnostics LEDs will be blinking. Refer to Section 7, TROUBLESHOOTING, to determine the cause of the error. Clear the error, cycle power, and the operating display should return.
d. Keypad
The five membrane keys on the membrane keypad are only used during calibration to adjust the high and low gas and to initiate the calibration sequence (Figure 3-4).
3-5 START UP OXYMITTER 4000
CALIBRATION
Refer to Section 6, MAINTENANCE AND SERVICE, for calibration instructions.

3-6 IMPS 4000 CONNECTIONS

2
See the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for wiring and pneumatic connections.
a. Startup Display
When power is applied to the probe, the cell heater turns on. It takes approximately one half hour for the cell to heat to operating temperature. This condition is indicated by the top four LEDs (DIAGNOSTIC ALARMS) on the membrane keypad (Figure 3-3). Starting with the CALIBRATION LED, the LEDs light in ascending order until all four LEDs are on. At this point, all four turn off and the cycle starts again. This ramp cycle continues until the cell is up to operating temperature.
b. Operating Display
The ramp cycle turns into a cycle where the diagnostic LEDs light in sequence from the top to the bottom, one at a time. After the bottom LED turns on, the sequence starts again at the top with the HEATER T/C LED (Figure 3-3).
MEMBRANE
KEYS
HEATER T/C
DIAGNOSTIC
CALIBRATION RECOMMENDED
MEMBRANE
KEYS
ALARMS
TEST
POINTS
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
HEATER 02 CELL
CALIBRATION
02 CELL mV + 02 CELL mv ­HEATER T/C + HEATER T/C -
CAL
TEST GAS +
PROCESS -
% 02
Figure 3-4. Calibration Keys
DIAGNOSTIC
LEDS
MEMBRANE
KEY
22220023
3-6 Startup Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
4
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
SECTION 4
OPERATION
4-1 GENERAL
a. Overview
Ensure the Oxymitter 4000 is at normal op­eration. The diagnostic LEDs will display the operating cycle. All other LEDs should be off (Figure 4-1).
1. DIAGNOSTIC ALARM LEDS. If there is an error in the system, one of these LEDs will flash various blink codes (Section 7, TROUBLESHOOTING). In the case of multiple errors, only one will be displayed based on a priority system. Correct the problem and cycle power. The operating display will return or the next error will be displayed. The alarms are:
HEATER T/C HEATER O CALIBRATION
2. CALIBRATION RECOMMENDED LED. Turns on when the system de­termines a calibration is recommended.
3. TEST POINTS. Test points 1 through 6 will allow you to monitor with a mul­timeter: the heater thermocouple, O cell millivolt, and the process O2.
(a) TP1 and TP2 monitor the oxygen
CELL
2
cell millivolt output which equates to the percentage of oxygen present.
4. CAL LED. The CAL LED is on steady or flashing during calibration. Further information is available in Section 6, MAINTENANCE AND SERVICE.
5. Keys.
(a) INC and DEC. The INC and DEC
keys are used to set the values of the calibration gases. Attach a multimeter across TP5 and TP6. The calibration and process gases can now be monitored. Pressing the INC or DEC once will cause the output to switch from the proc­ess gas to the calibration gas. Pressing INC or DEC a second time will increase or decrease the calibration gas parameter. If the keys have been inactive for one minute, the output reverts to the process gas. When a calibration has been initiated, the value at TP5 and TP6 is the % O the cell. Oxygen levels, as seen on the multimeter, are:
8.0% O
0.4% O
2
(b) CAL. The CAL key can:
= 8.0 volts DC
2
= 0.4 volts DC
2
1 Initiate a calibration.
2 Sequence through calibration.
3 Abort the calibration.
seen by
2
(b) TP3 and TP4 monitor the heater
thermocouple.
(c) TP5 and TP6 monitor the process
gas or the calibration gas parameter.
Rosemount Analytical Inc. A Division of Emerson Process Management Operation 4-1
b. Model 751 Remote Powered Loop LCD
Display (Optional)
Refer to Remote Powered Loop LCD man­ual for calibration and operation.
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
TEST
POINTS
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
HEATER T/C
HEATER
O2 CELL
CALIBRATION
O2 CELL mV +
O2 CELL mv ­HEATER T/C + HEATER T/C -
CAL
TEST GAS +
PROCESS -
% O2
TP1
TP2
TP3
TP4
TP5
TP6
SW2
Oxymitter 4000
HEATER T/C
ON
J1
YEL
RED
GRN
ORG
CAL LED
HEATER
O CELL
2
CALIBRATION
2 3 4 1 2 3 4
1
LIGHTING SEQUENCE DURING NORMAL OPERATION
22220055
Figure 4-1. Normal Operation
4-2 Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
5
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
SECTION 5
HART/AMS
5-1 OVERVIEW
The HART Communicator is a handheld com­munications interface device. It provides a common communications link to all microproc­essor-based instruments that are HART com­patible. The handheld communicator contains an 8 × 21 character liquid crystal display (LCD) and 25 keys. A pocket-sized manual, included with the HART Communicator, details the spe­cific functions of all the keys.
To interface with the Oxymitter 4000, the HART Communicator requires a termination point along the 4-20 mA current loop and a minimum load resistance of 250 ohms between the com­municator and the power supply. The HART Communicator accomplishes its task using a frequency shift keying (FSK) technique. With the use of FSK, high-frequency digital communica­tion signals are superimposed on the 4-20 mA Oxymitter 4000 current loop. The communicator does not disturb the 4-20 mA signal since no net energy is added to the loop.
The HART Communicator may be interfaced with a personal computer (PC), providing spe­cial software has been installed. To connect the HART Communicator to a PC, an interface adapter is required. Refer to the proper HART Communicator documentation in regard to the PC interface option.
a. Method 1, For Load Resistance
> 250 Ohms
Refer to Figure 5-1 and the following steps to connect the HART Communicator to a signal line 250 ohms or more of load resistance.
Explosions can result in death or seri­ous injury. Do not make connections to the HART Communicator's serial port, 4-20 mV signal line, or NiCad recharger jack in an explosive atmosphere.
Using the supplied lead set, connect the HART Communicator in parallel to the Oxymitter 4000. Use any wiring termination points in the analog output 4-20 mA signal line.
b. Method 2, For Load Resistance
< 250 Ohms
Refer to Figure 5-2 and the following steps to connect the HART Communicator to a signal line with less than 250 ohms load resistance.
5-2 HART COMMUNICATOR SIGNAL LINE
CONNECTIONS
The HART Communicator can connect to the Oxymitter 4000 analog output signal line at any wiring termination in the 4-20 mA current loop. There are two methods of connecting the HART Communicator to the signal line. For applica­tions in which the signal line has a load resis­tance of 250 ohms or more, refer to method 1. For applications in which the signal line load resistance is less than 250 ohms, refer to method 2.
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-1
Explosions can result in death or seri­ous injury. Do not make connections to the HART Communicator's serial port, 4-20 mA signal line, or NiCad recharger jack in an explosive atmosphere.
1. At a convenient point, break the analog output 4-20 mA signal line and install the optional 250 ohm load resistor.
2. Plug the load resistor into the loop connectors (located on the rear panel of the HART Communicator).
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
AC L1
AC N
+
-
+
4-20
-
Oxymitter 4000
RL 250≥Ω
4-20 mA SIGNAL LINE
TERMINAL BLOCK
ANALOG OUTPUT DEVICE
LOOP CONNECTORS
SERIALPORT & BATTERY
CHARGER MUST
NOT BE USED IN
HAZARDOUS AREAS
LOOP CONNECTORS
USE INTERFACE 00275 0013 ONLY
SERIAL PORT
HART
COMMUNICATOR
LEAD SET
HART COMMUNICATOR
REAR PANEL
Figure 5-1. Signal Line Connections, ≥≥≥≥ 250 Ohms Lead Resistance
AC L1
4-20
AC N
+
-
+
-
4-20 mA SIGNAL LINE
RL < 250Ω
23230001
TERMINAL BLOCK
LOOP CONNECTORS
ANALOG OUTPUT DEVICE
250 OHM
LOAD
SERIALPORT & BATTERY
CHARGERMUST
NOTBE USED IN
HAZARDOUSAREAS
LOOPCONNECTORS
USEINTERFACE 002750013 ONLY
SERIAL PORT
RESISTOR
(NOTE 1)
HART
COMMUNICATOR
NOTE: THE SIGNAL LOOP MUST BE BROKEN
HART COMMUNICATOR
REAR PANEL
TO INSERT THE OPTIONAL 250 OHM LOAD RESISTOR.
23230002
Figure 5-2. Signal Line Connections, < 250 Ohms Lead Resistance
5-2 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
5
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
5-3 HART COMMUNICATOR PC
CONNECTIONS
There is an option to interface the HART Com­municator with a personal computer. Load the designated AMS software into the PC. Then link the HART Communicator to the PC using the interface PC adapter that connects to the serial port (on the communicator rear panel).
Refer to the proper HART Communicator docu­mentation in regard to the PC interface option.

5-4 OFF-LINE AND ON-LINE OPERATIONS

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

5-5 LOGIC I/O CONIFGURATIONS

The Oxymitter 4000 logic I/O output can be configured for ten different modes through HART/AMS. The factory default condition is Mode 5. A list of possible configurations appear in Table 5-1.
The Unit Alarm configuration available for Modes 1, 3, 5, and 7 refers to the diagnostic alarm faults in Table 7-1.
5-6 MENU TREE FOR HART COMMUNICA-
TOR/OXYMITTER 4000 APPLICATIONS
NOTE
If the HART Communicator is turned on while connected to the 4-20 mA
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-3
This section consists of a menu tree for the HART Communicator. This menu is specific to Oxymitter 4000 applications.
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Mode Configuration
0 The unit is not configured for any alarm condition.
1 The unit is configured for a Unit Alarm.
2 The unit is configured for Low O2.
3 The unit is configured for both a Unit Alarm and Low O2.
4 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.
6 The unit is configured for both a Low O2 and High AC Impedance/CALIBRATION
RECOMMENDED.
7 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 4000.
CALIBRATION RECOMMENDED will initiate the calibration cycle.
Oxymitter 4000
Table 5-1. Logic I/O Configuration
9 The unit is configured for a calibration handshake. CALIBRATION RECOM-
MENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4000.
*The default condition for an Oxymitter 4000 without an IMPS 4000 or SPS 4000.
**The default condition for an Oxymitter 4000 with an IMPS 4000 or SPS 4000.
5-4 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
5
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
DEVICE SETUP PV PV AO PV LRV PV URV
PROCESS VARIABLES
DIAG/SERVICE
VIEW FLD DEV VARS
VIEW OUTPUT VARS
VIEW FLD DEV mV
STATUS
O2 value O2 cell temp CJ temp
VIEW PV-Aout
VIEW SV
VIEW TV
VIEW 4V
Cell mV Cell TC mV CJ mV
Status Group 1
Status Group 2
Status Group 3
Operate Model
AO Saturated
AO Fixed
Max Case Temp
PV is PV O2 value PV % rnge PV AO
SV is Cold Junct SV __ mV
TV is Cell TV __ mV
4V is Cell TC 4V __ mV
Open T/C Shorted T/C Reversed T/C Heater Open Cell Temp Very HI High Case Temp
Cell Temp Low Cell Temp High Cell Open High Cell Imp. CK.ER - EEPROM Cal.Error Slope Cal. Recommended
Cal. Error Const. Last Cal. Failed
AO1 Out Rnge lim
Loop test method...
PERFORM O2 CAL
O2 CAL STATUS
LAST CALCONSTANTS
RESET CALCONSTANTS
D/A trim method
O2 Cal
Optrak TG?
CalState
CalState TimeRemain Present O2
Cal slope Cal const Cell Imp
Reset CalConstants method...
(CONTINUED ON
SHEET 2)
LOOP TEST
O2 CALIBRATE
D/A TRIM
Figure 5-3. Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 1 of 3)
O2 Cal method...
Refer to para. 7-7 for the complete O2 calibration method using the HART Communicator.
26170028
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-5
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
(CONTINUED FROM
SHEET 1)
BASIC SETUP
Ta g
ASSIGN PV&SV
SELECT O2 RANGE
DEVICE INFORMATION
S/W VERSION INFO
SENSORS
PV is Oxygen SV is Cold Junct TV is Cell 4V is Cell TC
URV ____% LRV ____%
Dev id Descriptor Message Date Final asmbly num Snsr s/n
Ver Chk sum Bld num Bld date
O2 O2 CELLTEMP COLDJUNCTEMP O2 CELL MV O2 CELLTCMV COLD JUNC MV
LIMITS DISPLAYED
DEVICE SETUP PV PV AO PV LRV PV URV
DETAILED SETUP
(CONTINUED ON
SHEET 3)
SIGNAL CONDITION
OUTPUT CONDITION
O2
O2 CALIBRATION
O2 ALARMS
PV URV PV LRV PV % rnge
ANALOG OUTPUT
HART OUTPUT
ALARM OUTPUT
SLOPE
CONSTANT
HighTG LowTG OPtrak TG? TGtime PurgeTime Cal Mode Cal Intrvl h Next CalTime h
LoAlarmSP
PV AO ____ mA PV AO Alrm typ
LOOP TEST
D/A TRIM
Poll addr Num req preams
Logic I/O Pin State Logic I/O Pin Mode
OP locks OP tracks
Manual Auto
Loop test method...
D/A trim method...
No Alarm Unit Alarm Low O2 Alarm Low O2/Unit Alarm Cal Rec Cal Rec/Unit Alarm Low O2/Cal Rec Low O2/Unit/Cal Rec Cal Rec/Handshake Handshake
35830006
Figure 5-3. Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 2 of 3)
5-6 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
5
(CONTINUED FROM
SHEET 2)
REVIEW
DEVICE INFORMATION
CAL INFO
Manufacturer Model Dev id Ta g Descriptor Message Date Final asmbly num Snsr s/n Fld dev rev Hardware rev Software rev Universal rev
Optrak TG? Tgtime PurgeTime LowTG HighTG Cal slope Cal const CellImp Imp Delta
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
DEVICE SETUP PV PV AO PV LRV PV URV
DEVICE CONFIG
OUTPUTS CONFIG
Slope Constant
URV LRV LoAlarmSP I/O Pin Mode Poll addr Num req preams
26170030
Figure 5-3. Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 3 of 3)
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-7
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
5-7 HART COMMUNICATOR MANUAL
O
CAL METHOD
2
To perform a calibration using the HART Com­municator, use the following procedure. If nec­essary, use the menu tree in Figure 7-3 (sheet 1 of 3) for reference.
NOTE
To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right ar­row key or use the number keypad to select the menu item number.
To return to a preceding menu, press the left arrow key.
a. From the PERFORM O2 CAL screen, select
menu item 1, O2 CAL, to access the O2 calibration procedure.
Failure to remove the Oxymitter 4000 from automatic control loops prior to performing this procedure may result in a dangerous operating condition.
b. In the first O2 CAL screen, a “Loop should
be removed from automatic control” warning appears. Remove the Oxymitter 4000 from any automatic control loops to avoid a po­tentially dangerous operating condition and press OK.
c. The next several screens indicate the cali-
bration status. At each of the following status prompts, select menu item 2, NEXT CAL STEP:
COMPLETE CAL RECOMMENDED APPLY GAS 1 GAS 1 FLOW
d. At this point, select menu item 4, EXIT, to
leave the O2 CAL procedure.
e. From the PERFORM O2 CAL screen, view
menu item 3, CALSTATE, to monitor the calibration status as it updates. Or, access
the O2 CALIBRATE screen and select menu item 2, O2 CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O2, as the calibration status updates.
f. When CALSTATE displays APPLY GAS 2,
return to the O2 CAL procedure.
g. When the “Loop should be removed from
automatic control” warning appears, press OK.
h. At the APPLY GAS 2 status prompt, select
menu item 2, NEXT CAL STEP. When the status displays GAS 2 FLOW, select menu item 4, EXIT, to leave the O2 CAL proce­dure.
i. From the PERFORM O2 CAL screen, view
menu item 3, CALSTATE, to monitor the calibration status as it updates. Or, access the O2 CALIBRATE screen and select menu item 2, O2 CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O2, as the calibration status updates.
j. When CALSTATE displays STOP GAS, re-
turn to the O2 CAL procedure.
k. When the “Loop should be returned to
automatic control” message appears, return the Oxymitter 4000 to the automatic control loops previously removed and press OK.
l. At the STOP GAS status prompt, select
menu item 2, NEXT CAL STEP. When the status displays PURGING, select menu item 4, EXIT, to leave the O2 CAL procedure.
m. From the PERFORM O2 CAL screen, view
menu item 3, CALSTATE, to monitor the calibration status as it updates. Or, access the O2 CALIBRATE screen and select menu item 2, O2 CAL STATUS, to view menu item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3, PRESENT O2, as the calibration status updates.
n. When CALSTATE displays COMPLETE,
the calibration is finished.
5-8 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
5
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
5-8 DEFINING A TIMED CALIBRATION VIA
HART
Use the following procedure to specify a time interval (in hours) at which the Oxymitter 4000 will be automatically calibrated.
NOTE
To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right ar­row key or use the number keypad to select the menu item number.
To return to a preceding menu, press the left arrow key.
a. From the DEVICE SETUP screen, select
DETAILED SETUP.
b. From the DETAILED SETUP screen, select
O2 CALIBRATION.
c. From the O2 CALIBRATION screen, select
menu item 6, CAL MODE. Set the CAL MODE to AUTO.
d. Return to the O2 CALIBRATION screen and
select menu item 7, CAL INTRVL.
e. At the prompt, input a time interval (in
hours) at which an automatic calibration will occur and press ENTER.
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 5-9
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
5-10 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
SECTION 6
MAINTENANCE AND SERVICE
6-1 OVERVIEW
This section identifies the calibration methods available and provides the procedures to main­tain and service the Oxymitter 4000 and optional integrally mounted SPS 4000.
Install all protective equipment covers and safety ground leads after equip­ment repair or service. Failure to in­stall covers and ground leads could result in serious injury or death.
6-2 CALIBRATION
a. During a calibration, two calibration gases
with known O the Oxymitter 4000. Slope and constant values calculated from the two calibration gases determine if the Oxymitter 4000 is correctly measuring the net concentration of O
in the industrial process.
2
Before calibrating the Oxymitter 4000, verify that the calibration gas parameters are cor­rect by setting the gas concentrations used when calibrating the unit (See paragraph 4-1a.5) and by setting the calibration gas flowmeter.
The calibration gas flowmeter regulates the calibration gas flow and must be set to 5 scfh. However, only adjust the flowmeter to 5 scfh after placing a new diffusion ele­ment on the end of the Oxymitter 4000. Adjusting the flowmeter at any other time can pressurize the cell and bias the calibration.
In applications with a heavy dust loading, the O
probe diffusion element may become
2
plugged over time, causing a slower speed of response. The best way to detect a plugged diffusion element is to note the time it takes the Oxymitter 4000 to return to the normal process reading after the last cali­bration gas is removed and the calibration gas line is blocked off. A plugged element also can be indicated by a slightly lower reading on the flowmeter.
concentrations are applied to
2
Change the diffusion element when the cali­bration gas flowmeter reads slightly lower during calibration or when the response time to the process flue gases becomes very slow. Each time the diffusion element is changed, reset the calibration gas flowmeter to 5 scfh and calibrate the Oxymitter 4000. To change the diffusion element, refer to paragraph 6-8.
b. Three types of calibration methods are
available: automatic, semi-automatic, and manual.
NOTE
A calibration can be aborted any time during the process by pressing the CAL key (Figure 6-2) on the Oxymitter 4000 keypad three times in a three second interval or via HART/AMS or an IMPS 4000. An aborted calibration will retain the values of the previous good calibration.
1. Automatic Calibration. Automatic cali­brations require no operator action. However, the calibration gases must be permanently piped to the Oxymitter 4000, an SPS 4000 or IMPS 4000 must be installed to sequence the gases, and the Oxymitter 4000’s logic I/O must be set to mode 8 via HART/ AMS so the sequencer and Oxymitter 4000 can communicate.
Depending on your system setup, an automatic calibration can be initiated by the following methods:
(a) The Oxymitter 4000’s CALIBRA-
TION RECOMMENDED alarm sig­nals that a calibration is required.
(b) Enter a “time since last cal” pa-
rameter (CAL INTRVL) via HART/ AMS that will initiate an automatic calibration at a scheduled time in­terval (in hours). To configure the CAL INTRVL parameter, refer to paragraph 5-8.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-1
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
Note: The Electronic Assembly, item 12,
consists of items 13 through 20.
12
17
18
13
11
14
D
IA
G N
O
S
A
T
L
IC
AR
H
E
M
A
TE
S
C
R A LIB
T
H
/C
E
R
A
T
A
C
02 C
ER
TIO
A
LIB
N
E
R
R
LL
A
EC
T
IO
O
N
M
TE
M
E
P
S
ND
O
T
IN
0
E
2 C
T
D
S
E
0
LL m
2 C
E
H
V
LL m
E
+
A
TE
IN
H
v
R
E
C
-
A
T/C
TE
IN
R
+
H IG
C
T
H
/C
G
-
A
S
LOW G
D
A
S
E
C
C
A
L
D
E
C
T
E
S
T
G
P
R
A
O
S
C
+
E
S
%
S
0
-
2
16
Note: Not all parts shown.
19
15
10
20
32
21
33
34
22
26
25
23
24
33
32
27
1. Heater Strut Assembly
2. Diffusion Assembly (Snubber)
34
3. Retainer Screw
4. Cell and Flange Assembly
5. Corrugated Seal
6. Probe Tube Assembly
7. Screw
8. Tube Connector
9. Gas Port
10. O-ring
11. Right Housing Cover
12. Electronic Assembly
13. Screw
14. Membrane Keypad
15. Snap Connector
16. Captive Screw
7
17. Microprocessor Board
18. Fuse Cap
19. Fuse
20. Power Supply Board
21. Electronic Housing
22. Screw
23. Lock Washer
24. Cable Clamp
25. Terminal Block
6
26. Captive Screw
5
28
9
8
4
3
1
2
29
30
31
27. Left Housing Cover
28. Silicon Tube
29. Tube Clamp
30. Screw
31. Washer
32. Screw
33. Gasket
34. Cover Lock
26170019
Figure 6-1. Oxymitter 4000 Exploded View
6-2 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
4000’s logic I/O must be set to mode 8 or 9 via HART/AMS so the sequencer and Oxymitter 4000 can communicate.
HEATER T/C
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
TEST
POINTS
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
HEATER
O2 CELL
CALIBRATION
O2 CELL mV +
O2 CELL mv -
HEATER T/C +
HEATER T/C -
CAL
TEST GAS +
PROCESS -
% O2
Figure 6-2. Membrane Keypad
(c) If using an IMPS 4000, enter a time
interval via the IMPS 4000 keypad that will initiate an automatic cali­bration at a scheduled time interval (in hours). To set the CalIntvX pa­rameter of the CHANGE PRESETS display mode, refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for more information.
Once an automatic calibration is initi­ated, by any of the methods previously described, the Oxymitter 4000’s CALI­BRATION RECOMMENDED alarm signals an IMPS 4000 or SPS 4000 to initiate a calibration. The sequencer sends an “in cal” signal to the control room so that any automatic control loops can be placed in manual. Then, the sequencer begins to sequence the calibration gases.
2. Semi-Automatic Calibration. Semi­automatic calibrations only require op­erator initiation. However, the calibra­tion gases must be permanently piped to the Oxymitter 4000, an SPS 4000 or IMPS 4000 must be installed to se­quence the gases, and the Oxymitter
22220067
Depending on your system setup, a semi-automatic calibration can be initi­ated by the following methods:
(a) Oxymitter 4000. Press the CAL
key on the Oxymitter 4000 keypad.
(b) IMPS 4000. Use the IMPS 4000
keypad to change the InitCalX pa­rameter of the CHANGE PRE­SETS display mode from 0000 to
0001. Refer to the IMPS 4000 In­telligent Multiprobe Test Gas Se­quencer Instruction Bulletin for more information.
(c) HART. Use the HART Communi-
cator to access the O menu and perform the O
CALIBRATE
2
CAL
2
method. Refer to paragraph 5-7 for the complete calibration procedure.
(d) AMS. Refer to AMS documenta-
tion for more information.
(e) Remote Contact. Initiate a calibra-
tion from a remote location via the remote contact input connection provided by an IMPS 4000 or SPS
4000. Refer to the documentation available for the control system in use for more information.
Once a semi-automatic calibration is initiated, by any of the methods previ­ously described, the Oxymitter 4000’s CALIBRATION RECOMMENDED alarm signals an IMPS 4000 or SPS 4000 to initiate a calibration. The se­quencer sends an “in cal” signal to the control room so that any automatic control loops can be placed in manual. Then, the sequencer begins to se­quence the calibration gases.
3. Manual Calibration. Manual calibra­tions must be performed at the Oxy­mitter 4000 site and require operator intervention throughout the process.
Manual calibration instructions can also be found, in condensed form, on the inside of the right electronics housing cover (Figure 6-3).
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-3
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
ALARMS
LED
HEATER T/C
HEATER
O2 CELL
CALIBRATION
FLASHES
1
2
3
4
1
2
3
4
5
1 3
4
1
2
3
INVALID SLOPE
NOT USED
MANUAL CALIBRATION
PLACE CONTROL LOOP
*
STATUS
OPEN
SHORTED
REVERSED
A/D COMM
ERROR
OPEN
HIGH HIGH
TEMP
HIGH CASE
TEMP
LOW TEMP
HIGH TEMP
OPEN
BAD
EPROM
CORRUPT
INVALID
CONSTANT
LAST CAL
FAILED
SW2 DIP SWITCH
HART
0-10%
4mA 20mA
IN MANUAL IF CAL LED ON
*
GO TO STEP 2
1
2
3
4
5
6
7
8
LOCAL 0-25%
NOT USED
PUSH CAL
CAL LED ON
PUSH CAL
CAL LED FLASH
APPLY TG1
PUSH CAL
CAL LED ON SOLID WAIT FOR FLASH
REMOVE TG1 & APPLY TG2
PUSH CAL
CAL LED ON SOLID WAIT FOR FLASH
2 FLASH-VALID CAL
3 FLASH-INVALID CAL
REMOVE TG2
PUSH CAL
CAL LED ON FOR PURGE TIME CAL LED OFF
Oxymitter 4000
Figure 6-3. Inside Right Cover
Use the following to perform a manual calibration:
(a) Place control loop in manual.
(b) Verify the calibration gas parame-
ters are correct (paragraph 6-2a).
(c) If performing a manual calibration
with CALIBRATION RECOM­MENDED LED off and the CAL LED off, start at step 1.
(d) If performing a manual calibration
with CALIBRATION RECOM­MENDED LED on and the CAL LED on, start at step 2.
1 Push the CAL key. The CALI-
BRATION RECOMMENDED LED will come on and the CAL LED will be on solid. If a multimeter is attached across TP5 and TP6, the reading will display the percentage of oxygen seen by the cell.
29770005
2 Push the CAL key. The CALI-
BRATION RECOMMENDED LED will turn off and the CAL LED will flash continuously. The Oxymitter 4000 can be configured so that the 4­20 mA signal will hold the last value. The default condition is for the output to track. the flashing LED indicates that the Oxymitter 4000 is ready to accept the first calibration gas.
3 Apply the first calibration gas.
(Electronics will abort the cali­bration if step 4 is not done within 30 minutes).
4 Push the CAL key; the CAL
LED will be on solid. A timer is activated to allow the calibra­tion gas adequate time to flow (default time of five minutes). When the timer times out, the Oxymitter 4000 has taken the
6-4 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
readings using the first cali­bration gas and the CAL LED will flash continuously. The flashing indicates the Oxy­mitter 4000 is ready to take readings using the second calibration gas.
5 Remove the first calibration
gas and apply the second calibration gas. (Electronics will abort the calibration if step 6 is not done within 30 minutes).
6 Push the CAL key; the CAL
LED will be on solid. The timer is activated for the sec­ond calibration gas flow. When the timer times out, the CAL LED will flash a 2 pattern flash or a 3 pattern flash (2 pattern flash equals a valid calibration, 3 pattern flash equals an invalid calibration).
If the slope or the constant is out of specification, a diag­nostic alarm LED will be flashing. The diagnostic alarm will remain active until the purge cycle is over. If the three pattern flash occurs without a diagnostic alarm, the calibration gases could be the same or the calibration gas was not turned on.
The CAL LED flashing indi­cates the calibration is done. (See Section 7, TROUBLE­SHOOTING, for an explana­tion of the 2 pattern and 3 pattern flashes).
7 Remove the second calibra-
tion gas and cap off the cali­bration gas port.
8 Push the CAL key; the CAL
LED will be on solid as the unit purges. (Default purge time is three minutes). When the purge is complete, the CAL LED will turn off and the Oxymitter 4000 output un­locks from its held value and begins to read the process O
If the calibration was valid, the DI­AGNOSTIC ALARMS LEDs will in­dicate normal operation. If the new calibration values, slope or con­stant, is not within the parameters, the DIAGNOSTIC ALARMS LED will indicate an alarm. (See Section 7, TROUBLESHOOTING, for alarm codes). If the calibration was invalid, the Oxymitter 4000 will re­turn to normal operation, as it was before a calibration was initiated, and the parameters will not be updated.
(e) Place control loop in automatic.

6-3 LED STATUS INDICATORS

a. Diagnostic/Unit Alarms
Table 6-1 lists the types and status of alarms that will be encountered. (See Section 7, TROUBLESHOOTING, for a de­tailed description of each fault).
b. When the electronics determines a calibra-
tion is recommended, the CALIBRATION RECOMMENDED LED is on solid.
c. The CAL LED turns on when a calibration is
recommended and is on during the calibra­tion process. During calibration, the CAL LED can be flashing, which would indicate operator action is requested, or on solid, which indicates calculations and measure­ments are in progress.
.
2
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-5
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
HEATER T/C
HEATER
CALIBRATION
Oxymitter 4000
Table 6-1. Diagnostic/Unit Alarms
LED Flashes Status Fault
1 OPEN 1 2 SHORTED 2 3 REVERSED 3 4 A/D COMM ERROR 4
1 OPEN 5 2 HIGH HIGH TEMP 6 3 HIGH CASE TEMP 7 4LOW TEMP8 5HIGH TEMP9
1HIGH mV10 3 BAD 11O2 CELL 4 EEPROM CORRUPT 12
1 INVALID SLOPE 13 2 INVALID CONSTANT 14 3 LAST CALIBRATION FAILED 15
LEFT SIDE OF
OXYMITTER 4000
MOUNTING
SCREW
SIGNAL
PORT
LOGIC I/O
4 TO 20 mA
SIGNAL
4-20
+
-
MOUNTING
SCREW
(90 TO 250 VAC)
+
-
GROUND
LUGS
LINE VOLTAGE
AC TERMINAL
AC L1
AC N
COVER
MOUNTING
TERMINAL
BLOCK
AC LINE VOLTAGE PORT
SCREW
R
Rosemount Analytical Inc. Orrville,OH 44667-0901
800-433-6076
TM
OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: WATTS:
85-264VAC 48-62 Hz
4-20 mA
OUTPUT: LINE FUSE:
SMART FAMILY HART
TM
R
500VA
5 Amps
26170017
Figure 6-4. Terminal Block
6-6 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
6
It is recommended that the Oxymitter 4000 be removed from the stack for all service activities. The unit should be allowed to cool and be taken to a clean work area. Failure to comply may cause severe burns.
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
(f) Loosen the logic I/O and the 4-
20 mA signal terminal screws. Remove the leads from the termi­nals and slide the wires out of the signal port.
(g) Remove insulation to access the
mounting bolts. Unbolt the Oxy­mitter 4000 from the stack and take it to a clean work area.
Disconnect and lock out power before working on any electrical components. There is voltage up to 115 VAC.
6-4 OXYMITTER 4000
REMOVAL/REPLACEMENT
a. Oxymitter 4000 (without Integrally
Mounted SPS 4000)
1. Remove.
(a) Turn off power to the system.
(b) Shut off the calibration gases at
the cylinders and the instrument air.
(c) Disconnect the calibration gas and
instrument air lines from the Oxy­mitter 4000.
(d) While facing the Oxymitter 4000
and looking at the Rosemount la­bel, remove screw (32, Figure 6-1), gasket (33) and cover lock (34) se­curing left housing cover (27). Re­move the cover to expose the terminal block (Figure 6-4).
(e) Loosen the screw on the AC termi-
nal cover and slide the cover back to access the neutral and line ter­minals. Loosen the AC line and neutral terminal screws and re­move the leads. Loosen the ground lug screws and remove the leads. Slide the line power leads out of the AC line voltage port.
(h) Allow the unit to cool to a comfort-
able working temperature.
2. Replace.
(a) Bolt the Oxymitter 4000 to the
stack and install insulation.
(b) Insert the logic I/O and 4-20 mA
leads in the signal port and con­nect to the logic I/O and 4-20 mA screw terminals (Figure 6-4).
(c) Insert the power leads in the AC
line voltage port and connect to the AC line screw terminals. Connect the line, or L1, wire to the L1 ter­minal, and the neutral, or L2, wire to the N terminal. Slide the AC terminal cover over the terminal connection and tighten the cover screw.
(d) Install left housing cover (27,
Figure 6-1) and ensure it is tight. Secure the cover using cover lock (34), gasket (33), and screw (32).
(e) Connect the calibration gas and in-
strument air lines to the Oxymitter
4000.
(f) Turn on the calibration gases at
the cylinders and turn on instru­ment air.
(g) Restore power to the system.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-7
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
b. Oxymitter 4000 (with Integrally Mounted
SPS 4000)
1. Remove.
(a) Turn off power to the system.
(b) Shut off the calibration gases at
the cylinders and the instrument air.
(c) Disconnect the instrument air and
calibration gas lines from the SPS
4000. If the instrument air does not flow through the SPS 4000, dis­connect the instrument air directly at the Oxymitter 4000.
(d) Remove the screws securing the
terminal cover to the SPS 4000 manifold. Remove the terminal cover to expose the terminal strip.
(e) Tag all customer-wired leads that
are connected to the terminal strip before removing.
(f) On the terminal strip, loosen the
screws securing the customer­wired LINE IN and NEUTRAL leads to terminals L and N (Figure 2-10). Also, remove the customer­wired ground lead from the ground lug. Remove the leads from the terminal strip and slide them from the manifold through the line volt­age conduit port.
(i) Allow the unit to cool to a comfort-
able working temperature.
2. Replace.
(a) Bolt the Oxymitter 4000/SPS 4000
assembly to the stack and install insulation.
(b) Follow the instructions in para-
graph 2-3 to connect the line volt­age and signal leads to an Oxy­mitter 4000/ SPS 4000 assembly.
(c) Follow the instructions in para-
graph 2-5 to connect the calibra­tion gases and instrument air to an Oxymitter 4000/SPS 4000 assem­bly. Turn on the calibration gases at the cylinders and turn on instru­ment air.
(d) Restore power to the system.
6-5 ELECTRONICS REPLACEMENT
Each of the following procedures details how to remove and replace a specific electronic com­ponent of the Oxymitter 4000.
NOTE
Recalibration is required whenever electronic cards or sensing cell is re­placed.
a. Entire Electronics Replacement
(with Housing)
(g) Next, loosen the screws of remote
contact input terminals 1 and 2; 4­20 mA terminals 3 and 4; and relay output terminals 7, 8, 9, and 10. Remove the leads from the termi­nal strip and slide them from the manifold through the signal conduit port.
(h) Remove insulation to access the
mounting bolts. Unbolt the Oxy­mitter 4000/SPS 4000 assembly from the stack and take the entire assembly to a clean work area.
6-8 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Only perform this procedure on Oxy­mitter 4000 units without integrally mounted SPS 4000 units. If it is neces­sary to replace the entire electronics on an Oxymitter 4000/ SPS 4000 as­sembly, contact Rosemount for further instructions.
1. Follow the instructions in paragraph 6-4a.1 to remove the Oxymitter 4000 from the stack or duct. If removing an Oxymitter 4000/SPS 4000 assembly, follow the instructions in paragraph 6-4b.1.
NOTE
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
MOUNTING SCREW
R
Rosemount Analytical Inc. Orrville,OH 44667-0901
800-433-6076
TM
OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: WATTS:
85-264VAC 48-62 Hz
4-20 mA
OUTPUT: LINE FUSE:
MOUNTING
SCREW
R
SMART FAMILY
TM
HART
500VA
5 Amps
Figure 6-5. Electronic Assembly
2. Remove the right housing cover un­covering the electronic assembly (Figure 6-5).
3. Depress and remove the J1 (cell and T/C) connector from the J1 socket. Loosen the three captive mounting screws on the microprocessor board (top board).
4. The J8 connector (heater leads) can be accessed by moving the J1 connector leads out of the slot on the microproc­essor board and sliding the electronic assembly partially out of the housing (Figure 6-6).
5. Squeeze the J8 connector on the sides and carefully remove. The electronic assembly can now be completely re­moved from the housing.
6. Remove the four screws (7, Figure 6-1) from the probe finned housing. The probe and the electronic housing can now be separated.
7. When reinstalling or replacing the electronic housing, make sure that O­ring (10) is in good condition. Place the J1 and J8 connectors in the hole on the flat side of the electronic housing.
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
TEST
POINTS
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
8. Hold the J1 and J8 connectors out and to the probe side of the electronic housing. Make sure that the conduit port of the electronic housing is on the same side as the CAL and REF gas ports. Replace the four screws and tighten.
9. Reconnect the J8 connector to the power supply board. Make sure the connector is secure.
5A
250VAC
TIME LAG
3D39619G
REV
Figure 6-6. J8 Connector
HEATER T/C
HEATER
O2 CELL
CALIBRATION
O2 CELL mV +
O2 CELL mv -
HEATER T/C +
HEATER T/C -
CAL
TEST GAS +
PROCESS -
% O2
1
1
+
SW2
ON
J1
TP1
TP2
TP3
TP4
TP5
TP6
RED
J1
YEL
GRN
ORG
MOUNTING SCREW
26170018
+
POWER
SUPPLY
+
+
+
+
+
+
+
BOARD
J8
22220061
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-9
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
10. Holding the J1 connector leads, slide the electronic assembly the rest of the way into the housing. Align the elec­tronic assembly so that it fits flush on the pins. To ensure that it is flush, gently try to rotate the electronics. If the electronics rotates, repeat the alignment.
11. Reconnect the J1 connector to the mi­croprocessor board. Ensure the con­nector is secure and tighten the three captive screws on the microprocessor board (top board).
12. Replace the housing cover and ensure it is tight.
13. Follow the instructions in paragraph 6-4a.2 to install the Oxymitter 4000 into the stack or duct. If installing an Oxy­mitter 4000/ SPS 4000 assembly, fol­low the instructions in paragraph 6-4b.2.
b. Electronic Assembly Replacement
(Figure 6-5)
1. Remove the right housing cover un­covering the electronic assembly.
6. Holding the J1 connector leads, slide the electronic assembly the rest of the way into the housing. Align the elec­tronic assembly so that it fits flush on the pins. To ensure that it is flush, gently try to rotate the electronics. If the electronics rotates, repeat the alignment.
7. Reconnect the J1 connector to the mi­croprocessor board. Ensure the con­nector is secure and tighten the three captive screws on the microprocessor board (top board).
8. Replace the housing cover and ensure it is tight.
c. Terminal Block Replacement (Figure 6-4)
1. Loosen the mounting screws on the terminal block and carefully lift the block out of the housing.
2. Carefully align the new terminal block on the pins so that it sits flat in the housing. The round end of the terminal block should be on the opposite side of the housing conduit ports and should not be able to rotate.
2. Depress and remove the J1 (cell and T/C) connector from the J1 socket. Loosen the three captive mounting screws on the microprocessor board (top board).
3. The J8 connector (heater leads) can be accessed by moving the J1 connector leads out of the slot on the microproc­essor board and sliding the electronic assembly partially out of the housing (Figure 6-6).
4. Squeeze the J8 connector on the sides and carefully remove. The electronic assembly can now be completely re­moved from the housing.
5. Reconnect the J8 connector to the power supply board. Make sure the connector is secure.
6-10 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
d. Fuse Replacement (Figure 6-5)
3. Tighten the three mounting screws and ensure the terminal block is secure in the housing.
1. Remove the right housing cover un­covering the electronic assembly.
2. Depress and remove the J1 (cell and T/C) connector from the J1 socket. Loosen the three captive mounting screws on the microprocessor board (top board).
3. The J8 connector (heater leads) can be accessed by moving the J1 connector leads out of the slot on the microproc­essor board and sliding the electronic assembly partially out of the housing (Figure 6-6).
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
POWER SUPPLY
BOARD
FUSE
1
+
+
+
+
5A
250VAC
3
D
3
96
TIME LAG
1
9
G
1
+
REV
+
+
+
22220058
+
Figure 6-7. Fuse Location
4. Squeeze the J8 connector on the sides and carefully remove. The electronic assembly can now be completely re­moved from the housing.
5. Completely remove the three mounting screws on the microprocessor board.
6. Turn the electronic assembly over so that you are looking at the bottom of the power supply printed circuit board. Gently depress the two white posts one at a time. Carefully separate the power supply board from the microprocessor board.
7. Remove the fuse and replace it with a new one (Figure 6-7).
8. Align the white posts with the post holes on the power supply board and the pin connector on the power supply board with the connector port on the back of the microprocessor board. Gently push the boards together until the white posts snap in place. Ensure
the assembly is secure by gently trying to separate the boards.
9. Reconnect connector J8 to the power supply board. Make sure the connector is secure.
10. Holding the J1 connector leads, slide the electronic assembly the rest of the way into the housing. Align the elec­tronic assembly so that it fits flush on the pins. To ensure that it is flush, gently try to rotate the electronics. If the electronics rotates, repeat the alignment.
11. Reconnect the J1 connector to the mi­croprocessor board. Ensure the con­nector is secure and tighten the three captive screws on the microprocessor board (top board).
12. Replace the housing cover and ensure that it is tight.
6-6 ENTIRE PROBE REPLACEMENT
(EXCLUDING ELECTRONICS)
Do not attempt to replace the probe until all other possibilities for poor performance have been considered. If probe replacement is needed, see Table 8-1 for part numbers.
a. Follow the instructions in paragraph 6-4a.1
to remove the Oxymitter 4000 from the stack or duct. If removing an Oxymitter 4000 with an integrally mounted SPS 4000, follow the instructions in paragraph 6-4b.1.
b. Separate the probe and the electronics
housing per paragraph 6-5a, steps 2 through 6.
c. Reinstall electronics on the new probe per
paragraph 6-5a, steps 7 through 13.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-11
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000

6-7 HEATER STRUT REPLACEMENT

This paragraph covers heater strut replacement. Do not attempt to replace the heater strut until all other possibilities for poor performance have been considered. If heater strut replacement is needed, order a replacement heater strut. (Table 9-1).
Use heat resistant gloves and clothing when removing probe. Do not attempt to work on the probe until it has cooled to room temperature. The probe can be as hot as 800°F (427°C). This can cause severe burns.
NOTE
If the Oxymitter 4000 has an integrally mounted SPS 4000, it is not necessary to remove the sequencer when re­placing the heater strut.
a. Follow the instructions in paragraph 6-4a.1
to remove the Oxymitter 4000 from the
stack or duct. If removing an Oxymitter 4000/SPS 4000 assembly, follow the in­structions in paragraph 6-4b.1.
b. Remove entire electronics per paragraph
6-5a, steps 2 through 6.
NOTE
If the Oxymitter 4000 is equipped with an integrally mounted SPS 4000 and installed in corrosive conditions, stainless steel gas tubes are used in­stead of silicon or Teflon tubes.
c. Carefully remove the CAL and REF gas sili-
con tubes by pulling them off the CAL and REF gas ports. Pull the silicon tubes off the CAL and REF gas lines.
d. Loosen, but do not remove, the three
screws (30, Figure 6-1) on the strut in the finned housing. The spring tension should release and the strut moves up.
e. Grasp the wire loop and carefully slide the
strut out of the probe tube (Figure 6-8).
V-DEFLECTOR
CERAMIC
DIFFUSER
ASSEMBLY
WIRE
LOOP
CERAMIC SUPPORT ROD
CELL FLANGE
HEATER
22220050
Figure 6-8. Heater Strut Assembly
6-12 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
f. When replacing the strut, align the slot on
the heater plate with the calibration gas line in the probe tube. Slide the strut into the probe tube. It will turn to align the hole on the back plate of the strut with the calibra­tion gas line. When the hole and the cali­bration gas line are aligned correctly, the strut will slide in the rest of the way.
g. Push down on the back plate of the strut to
make sure you have spring tension and then tighten the three screws on the back plate.
h. Replace the CAL and REF gas silicon
tubes.
i. Install the entire electronics per paragraph
6-5a, steps 7 through 13.
j. Follow the instructions in paragraph 6-4a.2
to install the Oxymitter 4000 into the stack or duct. If installing an Oxymitter 4000/SPS 4000 assembly, follow the instructions in paragraph 6-4b.2.

6-8 CELL REPLACEMENT

This paragraph covers oxygen sensing cell re­placement. Do not attempt to replace the cell until all other possibilities for poor performance have been considered. If cell replacement is needed, order the cell replacement kit (Table 9-1).
The cell replacement kit (Figure 6-9) contains a cell and flange assembly, corrugated seal, setscrews, socket head cap screws, and anti­seize compound. The items are carefully pack­aged to preserve precise surface finishes. Do not remove items from the packaging until they are ready to be used. Spanner wrenches and hex wrenches needed for this procedure are part of an available special tools kit (Table 9-1).
Use heat-resistant gloves and clothing when removing the probe. Do not at­tempt to work on these components until they have cooled to room tem­perature. Probe components can be as hot as 800°F (427°C). This can cause severe burns.
PROBE TUBE
(NOT INCLUDED
IN KIT)
CORRUGATED
SEAL
CALIBRATION GAS
PASSAGE
Figure 6-9. Cell Replacement Kit
CELL AND
FLANGE
ASSEMBLY
SOCKET HEAD
CAP SCREWS
22220028
Disconnect and lock out power before working on any electrical components. There is voltage of up to 115 VAC.
Do not remove the cell unless certain it needs to be replaced. Removal may damage the cell and platinum pad. Go through the complete troubleshooting procedure to make sure the cell needs to be replaced before removing it.
a. Follow the instructions in paragraph 6-4a.1
to remove the Oxymitter 4000 from the stack or duct. If removing an Oxymitter 4000/SPS 4000 assembly, follow the in­structions in paragraph 6-4b.1.
b. If the probe uses the standard diffusion
element, use a spanner wrench to remove the diffusion element.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-13
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
NOTE
To determine if the diffusion element needs to be replaced, refer to para­graph 6-2.
c. If equipped with the optional ceramic diffu-
sion assembly, remove and discard the setscrews and remove the vee deflector (Figure 6-10). Use spanner wrenches from the probe disassembly kit (Table 9-1), to turn the hub free from the retainer. Inspect the diffusion element. If damaged, replace the element.
d. Loosen the four socket head cap screws
from the cell and flange assembly and re­move the assembly and the corrugated seal. The cell flange has a notch that may be used to gently pry the flange away from the probe. Note that the contact pad inside of the probe will sometimes fuse to the oxy­gen sensing cell. If the cell is fused to the contact pad, push the cell assembly back into the probe (against spring pressure) and quickly twist the cell assembly. The cell and contact pad should separate. If the contact pad stays fused to the cell, a new contact/thermocouple assembly must be in­stalled. Disconnect the cell and the thermo­couple wires at the probe electronics and withdraw the cell with the wires still attached.
e. Remove entire electronics per paragraph
6-5a, steps 2 through 6.
f. If the contact assembly is damaged, replace
the strut or the contact pad. Instructions for replacing the contact pad are in the cell re­placement kit.
g. Remove and discard the corrugated seal.
Clean the mating faces of the probe tube and retainer. Remove burrs and raised surfaces with a block of wood and crocus cloth. Clean the threads on the retainer and hub.
h. Rub a small amount of anti-seize compound
on both sides of the new corrugated seal.
i. Assemble the cell and flange assembly, cor-
rugated seal, and probe tube. Make sure the calibration tube lines up with the cali­bration gas passage in each component. Apply a small amount of anti-seize com­pound to the screw threads and use the screws to secure assembly. Torque to 35 in­lbs (4 N·m).
j. Install the entire electronics per paragraph
6-5a, steps 7 through 13.
k. Apply anti-seize compound to the threads of
the cell assembly, hub, and setscrews. Re­install the hub on the cell assembly. Using pin spanner wrenches, torque to 10 ft-lbs (14 N·m). If applicable, reinstall the vee de­flector, orienting apex toward gas flow. Se­cure with the setscrews and anti-seize compound. Torque to 25 in-lbs (2.8 N·m).
l. On systems equipped with an abrasive
shield, install the dust seal gaskets, with joints 180° apart.
m. Reinstall the probe and gasket on the stack
flange.
n. Follow the instructions in paragraph 6-4a.2
to install the Oxymitter 4000 into the stack or duct. If installing an Oxymitter 4000/SPS 4000 assembly, follow the instructions in paragraph 6-4b.2. If there is an abrasive shield in the stack, make sure the dust seal gaskets are in place as they enter the 15° reducing cone.
o. Turn on power and monitor thermocouple
output. It should stabilize at 29.3+0.2 mV. Set reference air flow at 2 scfh (56.6 l/hr). After the Oxymitter 4000 stabilizes, calibrate the unit. If new components have been in­stalled, repeat calibration after 24 hours of operation.
6-14 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
RETAINER
OPTIONAL CERAMIC
DIFFUSION ELEMENT
HUB
CEMENT
PORT
CEMENT
FILLET
Figure 6-10. Ceramic Diffusion Element
Replacement
6-9 CERAMIC DIFFUSION ELEMENT
REPLACEMENT
NOTE
This refers to the ceramic diffusion element only.
a. General
The diffusion element protects the cell from particles in process gases. Normally, it does not need to be replaced because the vee deflector protects it from particulate erosion. In severe environments, the filter may be broken or subject to excessive erosion. Ex­amine the ceramic diffusion element when­ever removing the probe for any purpose. Replace if damaged.
Damage to the ceramic diffusion element may become apparent during calibration. Compare probe response with previous re­sponse. A broken diffusion element will cause a slower response to calibration gas.
SETSCREW
VEE
DEFLECTOR
22220029
Hex wrenches needed to remove setscrews and socket head screws in the following procedure are available as part of a Probe Disassembly Kit, Table 9-1.
b. Replacement Procedure
1. Follow the instructions in paragraph 6-4a to remove the Hazardous Area Oxymitter 4000 from the stack or duct.
2. Loosen setscrews, Figure 6-10, using hex wrench from Probe Disassembly Kit, Table 9-1, and remove vee deflec­tor. Inspect setscrews. If damaged, re­place with stainless setscrews coated with anti-seize compound.
3. On systems equipped with abrasive shield, remove dual dust seal gaskets.
4. Use spanner wrenches from Probe Disassembly Kit, Table 9-1, to turn hub free from retainer.
5. Put hub in vise. Break out old ceramic diffusion element with chisel along ce­ment line. Use a 3/8 in. (9.5 mm) pin punch and clean fillet from the cement port.
6. Break out remaining ceramic diffusion element by tapping lightly around hub with hammer. Clean grooves with pointed tool if necessary.
7. Replace ceramic diffusion element us­ing the ceramic diffusion element re­placement kit in Table 9-1. This consists of a diffusion element, ce­ment, setscrews, anti-seize compound, and instructions.
8. Test fit replacement ceramic diffusion element to be sure seat is clean.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-15
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Do not get cement on ceramic diffu­sion element except where it touches the hub. Any cement on ceramic diffu­sion element blocks airflow through element. Wiping wet cement off of ce­ramic only forces cement into pores. Also, do not get any cement onto the flame arrester element.
Oxymitter 4000
6-10 SPS 4000 MAINTENANCE AND
COMPONENT REPLACEMENT
These paragraphs describe SPS 4000 mainte­nance and component replacement procedures. Replacement parts referenced are available from Rosemount. Refer to Section 9, RE­PLACEMENT PARTS, for part numbers and or­dering information.
9. Thoroughly mix cement and insert tip of squeeze bottle into cement port. Tilt bottle and squeeze while simultane­ously turning ceramic diffusion element into seat. Do not get any cement on upper part of ceramic diffusion ele­ment. Ensure complete penetration of cement around 3 grooves in hub. Ce­ment should extrude from opposite hole. Wipe excess material back into holes and wipe top fillet of cement to form a uniform fillet. (A cotton swab is useful for this.) Clean any excess ce­ment from hub with water.
10. Allow filter to dry at room temperature overnight or 1 to 2 hours at 200°F (93°C).
11. Wipe a heavy layer of anti-seize com­pound onto the threads and mating surfaces of the flame arrester, diffusion hub, and probe tube.
12. Assemble flame arrester and diffusion hub with two pin spanner wrenches. Torque to 10 ft-lbs (14 N·m). Secure with hub retaining setscrew.
Install all protective equipment covers and safety ground leads after equip­ment repair or service. Failure to in­stall covers and ground leads could result in serious injury or death.
a. Fuse Replacement
The SPS 4000 has a fuse (17, Figure 6-11) on the power supply board (18). Refer to Table 9-3 for replacement fuse specifica­tions. Perform the following procedure to check or replace the fuse.
Disconnect and lock out power before working on any electrical components.
1. Turn off power to the system.
2. Remove screw (7, Figure 6-11) secur­ing manifold cover lock (6) and remove the lock.
3. Remove manifold cover (14).
13. On systems equipped with abrasive shield, install dust seal gaskets with joints 180° apart.
14. Reinstall vee deflector, orienting apex toward gas flow. Apply anti-seize com­pound to setscrews and tighten with hex wrench.
15. Reinstall probe on stack flange.
6-16 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
4. Remove fuseholder (16) by pushing in the top and turning 1/4 turn counter­clockwise. Remove fuse (17).
5. After checking or replacing fuse (17), install fuseholder (16) by pushing in the top and turning 1/4 turn clockwise.
6. Install manifold cover (14), and secure with manifold cover lock (6) and screw (7).
Oxymitter 4000
6
1. Screw
2. Attaching Bracket
3. Bushing
4. Bushing Gasket
5. Manifold
6. Manifold Cover Lock
7. Screw
8. O-Ring
9. Spacer
10. Screw
11. Screw
12. Pressure Switch
13. Calibration Gas 2 Solenoid
14. Manifold Cover
15. Cover O-Ring
16. Fuseholder
17. Fuse
18. Power Supply Board
19. Interface Board
20. Calibration Gas 1 Solenoid
21. Washer
22. Stop Nut
23. Ground Nut
24. Terminal Base
25. Terminal Strip
26. Screw
27. Terminal Cover
28. Terminal Cover Gasket
29. Screw
30. Screw
27
28
29
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
1
2
3
4
30
3
14
15
16
26
20
25
24
19
18
17
13
23
22
21
11
10
12
Figure 6-11. SPS 4000 Manifold Assembly
4
5
8
9
6
7
26170023
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 6-17
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
b. Board Replacement
Perform the following procedure to replace power supply board (18, Figure 6-11) or in­terface board (19).
Disconnect and lock out power before working on any electrical components.
1. Turn off power to the system.
2. Remove screw (7) securing manifold cover lock (6) and remove the lock.
3. Remove manifold cover (14).
4. Remove two screws (11) attaching spacers (9) to manifold (5).
5. Being careful not to disconnect the board wiring, carefully lift power supply board (18) and interface board (19) from manifold (5) and set aside. Do not lose O-rings (8) from the bottom of spacers (9).
6. Tag all leads on the board to be re­placed to simplify installation.
10. Connect replacement board to board (18 or 19).
11. Install screws (10), washers (21), and stop nuts (22) to secure power supply board (18) and interface board (19) to spacers (9).
12. Install all applicable leads in the appro­priate locations on the power supply board or interface board as shown in Figure 6-12.
13. Install power supply board (18, Figure 6-11) and interface board (19) into manifold (5). Align spacers (9) with the mounting holes on the manifold and secure with screws (11). Ensure O-rings (8) are installed between the spacers and the manifold surface.
14. Install manifold cover (14) and secure with manifold cover lock (6) and screw (7).
c. Solenoid Replacement
The SPS 4000 manifold has a calibration gas 1 (high calibration gas) solenoid (20, Figure 6-11) and a calibration gas 2 (low calibration gas) solenoid (13).
7. See Figure 6-12. If removing the power supply board, remove the line voltage input leads from connector J7. Also, unplug calibration gas 1 solenoid leads from connector J5, calibration gas 2 solenoid leads from connector J4, and pressure switch leads from connector J2.
See Figure 6-12. If removing the inter­face board, remove the CAL INITIATE leads from connector J3, CAL FAIL and IN CAL leads from connector J4, and logic I/O handshake connection from connector J5.
8. Remove stop nuts (22, Figure 6-11), washers (21), and screws (10) secur­ing power supply board (18) and inter­face board (19) to spacers (9).
9. Carefully separate boards (18 and 19).
6-18 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Disconnect and lock out power before working on any electrical components.
1. Turn off power to the system.
2. Shut off the calibration gases at the cylinders.
3. Remove screw (7) securing manifold cover lock (6) and remove the lock.
4. Remove manifold cover (14).
5. Remove two screws (11) attaching spacers (9) to manifold (5).
6. Being careful not to disconnect the board wiring, carefully lift the board and spacer assembly from manifold (5) and set aside. Do not lose O-rings (8) from the bottom of spacers (9).
Oxymitter 4000
6
TO PRESSURE
SWITCH
LINE IN
LINE
VOLTAGE
INPUT
NEUTRAL
GROUND
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
POWER SUPPLY BOARD
TO CALIBRATION GAS 1 SOLENOID
TO CALIBRATION GAS 2 SOLENOID
GROUND
VAC INPUT TO OXYMITTER 4000
L1
N
INTERFACE BOARD
BLACK WHITE
RED BLUE ORANGE GREEN
VIOLET GRAY
+
CAL INITIATE
-
+
CAL FAIL
­+
IN CAL
-
LOGIC I/O
+
HANDSHAKE TO OXYMITTER 4000
-
REMOTE CONTACT INPUT
RELAY OUTPUTS
26170004
Figure 6-12. Power Supply Board and Interface Board Connections
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Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
7. Tag and unplug solenoid (13 or 20) leads from power supply board (18). Refer to Figure 6-12. Calibration gas 1 solenoid wires connect to connector J5, and calibration gas 2 solenoid wires connect to connector J4.
8. Remove the top nut of solenoid (13 or 20, Figure 6-11) securing the coil as­sembly and washer to the base. Re­move the coil assembly, including the leads, and washer. Place a 13/16 in. deep socket over the solenoid base and remove.
When installing a solenoid, do not over-tighten. Damage to the solenoid may occur.
9. Install the new solenoid base. Be careful not to overtighten. Install the new washer and coil assembly and se­cure with the top nut. Connect the leads to the proper connector on power supply board (18). Refer to Figure 6-12 if necessary.
10. Carefully install the board and spacer assembly into manifold (5, Figure 6-11) by aligning spacers (9) with the mounting holes on the manifold and securing with screws (11). Ensure O-rings (8) are installed between the spacers and the manifold surface.
11. Install manifold cover (14), and secure with manifold cover lock (6) and screw (7).
12. Turn on the calibration gases at the cylinders.
d. Pressure Switch Replacement
3. Remove screw (7) securing manifold cover lock (6) and remove the lock.
4. Remove manifold cover (14).
5. Remove two screws (11) attaching spacers (9) to manifold (5).
6. Being careful not to disconnect the board wiring, carefully lift the board and spacer assembly from manifold (5) and set aside. Do not lose O-rings (8) from the bottom of spacers (9).
7. Tag and remove the leads from pres­sure switch (12).
8. Place a 1-1/16 in. 6-point socket over pressure switch (12) and remove.
When installing the pressure switch, do not overtighten. Damage to the solenoid may occur.
9. Install new pressure switch (12). Be careful not to overtighten. Connect the leads to the proper terminals on the pressure switch.
10. Carefully install the board and spacer assembly into manifold (5) by aligning spacers (9) with the mounting holes on the manifold and securing with screws (11). Ensure o-rings (8) are installed between the spacers and the manifold surface.
11. Install manifold cover (14), and secure with manifold cover lock (6) and screw (7).
12. Turn on the calibration gases at the cylinders.
Use the following procedure to replace pressure switch (12, Figure 6-11).
1. Turn off power to the system.
2. Shut off the calibration gases at the cylinders.
6-20 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
e. Check Valve Replacement
Check valve (19, Figure 6-13) may stick or become plugged over time. Replace when necessary. If condensation deposits are noted upon removal, consider insulating the check valve.
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
f. Pressure Regulator (Optional)
Maintenance
1. Pressure Adjustments. Reference air pressure regulator (8, Figure 6-13) is factory set to 20 psi (138 kPa). Adjust using the knob on top of the pressure regulator if necessary.
Do not use fingers to release valve stem. The valve may release air at high pressures and cause injury.
2. Condensation Drain. To drain excess moisture from the filter bowl of refer­ence air pressure regulator (8), use a screwdriver or comparable tool to peri­odically release valve stem on the bot­tom of the regulator.
g. Flowmeter Adjustments
1. Calibration Gas Flowmeter. Calibration gas flowmeter (17, Figure 6-13) regu­lates the calibration gas flow and must be set to 5 scfh. However, only adjust the flowmeter to 5 scfh after placing a new diffusion element on the end of the Oxymitter 4000. Adjusting the flowme­ter at any other time can pressurize the cell and bias the calibration.
In applications with a heavy dust load­ing, the O may become plugged over time, caus­ing a slower speed of response. The best way to detect a plugged diffusion element is to note the time it takes the Oxymitter 4000 to return to the normal process reading after the last calibra­tion gas is removed and the calibration gas line is blocked off. A plugged ele­ment also can be indicated by a slightly lower reading on the flowmeter.
probe diffusion element
2
Change the diffusion element when the calibration gas flowmeter reads slightly lower during calibration or when the re­sponse time to the process flue gases becomes very slow. Each time the diffu­sion element is changed, reset the cali­bration gas flowmeter to 5 scfh and calibrate the Oxymitter 4000. For more information on changing the diffusion element, refer to paragraph 6-8.
2. Reference Air Flowmeter (Optional). Reference air flowmeter (16, Figure 6-13) regulates the reference air and must be set to 2 scfh. Adjust the flow with the knob on the bottom of the ref­erence air flowmeter when necessary.
h. Flowmeter Replacement
Use this procedure to replace either refer­ence air flowmeter (16, Figure 6-13) or cali­bration gas flowmeter (17).
1. Turn off power to the system.
2. Shut off the calibration gases at the cylinders.
3. Loosen, but do not remove, four screws (13) securing flowmeter bracket (25) to the manifold.
4. Flex the bottom of flowmeter bracket (25) downward and away to disengage and remove from the manifold.
5. For reference air flowmeter (16), re­move pressure regulator (8) by discon­necting tubing (11) from elbow fitting (10). Also, disconnect tubing (24) from straight fitting (23).
For calibration gas flowmeter (17), dis­connect tubing (18) at elbow fitting (21). Also, disconnect gas tubing (2) from elbow fitting (15).
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Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
6. Remove screws (6) and bracket (5) se­curing flowmeter (16 or 17) to flowme­ter bracket (25).
7. Remove flowmeter (16 or 17), with in­stalled fittings, from flowmeter bracket (25).
8. For reference air flowmeter (16), re­move elbow street fittings (14 and 22). It is not necessary to remove fittings (10 and 23) from the street fittings.
For calibration gas flowmeter (17), re­move elbow fittings (15 and 21).
9. Apply pipe thread sealant to the threads of top fittings (22 or 21) and bottom fittings (14 or 15) and install fit­tings into new flowmeter (16 or 17).
10. Position flowmeter (16 or 17) into flowmeter bracket (25) and secure with bracket (5) and screw (6).
11. For reference air flowmeter (16), con­nect tubing (11) to elbow fitting (10) and install pressure regulator (9). Also, connect tubing (24) to straight fitting (23).
For calibration gas flowmeter (17), connect tubing (2) to elbow fitting (15) and connect tubing (18) to elbow fitting (21).
12. Slide the top slots of flowmeter bracket (25) onto screws (13). Flex the bottom of the bracket downward and toward the manifold to engage the bottom bracket slots and screws. Tighten screws.
13. Turn on the calibration gases at the cylinders.
6-22 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
6
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
NOTE: A STANDARD SPS 4000 IS EQUIPPED WITH
(REF.)
TEFLON TUBING AND BRASS FITTINGS. OPTIONAL STAINLESS STEEL TUBING AND FITTINGS ARE ALSO AVAILABLE. REFER TO SECTION VIII, REPLACEMENT PARTS, FOR ORDERING INFORMATION.
20
24
19
23
18
2
21
22
25
15
14
13
1
2
3
4
6
5
7
12
11
8
9
17
16
1. Elbow Fitting
2. Tubing
3. Straight Fitting
4. Elbow Fitting
5. Bracket
6. Screw
7. Conduit Fitting
8. Reference Air Pressure Regulator (Optional)
10
9. Straight Fitting (Optional)
10. Elbow Fitting (Optional)
11. Tubing (Optional)
12. Elbow Fitting (Optional)
13. Screw
14. Elbow Street Fitting (Optional)
15. Elbow Fitting
16. Reference Air Flowmeter (Optional)
17. Calibration Gas Flowmeter
18. Tubing
19. Check Valve
20. Flare Fitting
21. Elbow Fitting
22. Elbow Street Fitting (Optional)
23. Straight Fitting (Optional)
24. Tubing
25. Flowmeter Bracket
26170012
Figure 6-13. Calibration Gas and Reference Air Components
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Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
6-24 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Oxymitter 4000
7
Instruction Manual
IB-106-340 Rev. 2.4
April, 2001
SECTION 7
TROUBLESHOOTING
c. Loose Integrated Circuits
Install all protective equipment covers and safety ground leads after trouble­shooting. Failure to install covers and ground leads could result in serious injury or death.
7-1 GENERAL
The troubleshooting section describes how to identify and isolate faults that may develop in the Oxymitter 4000. Also, additional troubleshooting information is provided in paragraph 7-5 for those units with the optional SPS 4000. When trouble­shooting the Oxymitter 4000, reference the fol­lowing information.
a. Grounding
It is essential that adequate grounding pre­cautions are taken when installing the sys­tem. Thoroughly check both the probe and electronics to ensure the grounding quality has not degraded during fault finding. The system provides facilities for 100% effective grounding and the total elimination of ground loops.
b. Electrical Noise
The Oxymitter 4000 uses a microprocessor and supporting integrated circuits (IC). If the electronics are handled roughly during in­stallation or located where subjected to se­vere vibration, the ICs could work loose. Before troubleshooting the system, ensure all ICs are fully seated.
d. Electrostatic Discharge
Electrostatic discharge can damage the ICs used in the electronics. Before removing or handling the processor board or the ICs, ensure you are at ground potential.

7-2 ALARM INDICATIONS

The majority of the fault conditions for the Oxy­mitter 4000 will be indicated by one of the four LEDs referred to as diagnostic, or unit, alarms on the operator’s keypad. An LED will flash a code that will correspond to an error message. Only one LED will blink at a time. An alarm code guide is provided inside the screw cover for the electronics. All alarm indications will be avail­able via the HART Model 275 handheld com­municator and Rosemount’s Asset Management software. When the error is corrected and/or power is cycled, the diagnostic alarms will clear or the next error on the priority list will appear.
The Oxymitter 4000 has been designed to operate in the type of environment normally found in a boiler room or control room. Noise suppression circuits are employed on all field terminations and main inputs. When fault finding, evaluate the electrical noise being generated in the immediate circuitry of a faulty system. Also, ensure all cable shields are connected to earth.
Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 7-1

7-3 ALARM CONTACTS

a. If autocalibration is not utilized, a common
bi-directional logic contact is provided for any of the diagnostic alarms listed in Table 7-1. The assignment of alarms which can actuate this contact can be modified to one of seven additional groupings listed in Table 5-1.
Instruction Manual
IB-106-340 Rev. 2.4 April, 2001
Oxymitter 4000
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.
b. If autocalibration systems are utilized, the
bidirectional logic contact is utilized as a “handshake” signal between the autocali­bration system (SPS 4000 or IMPS 4000) and is unavailable for alarming purposes. The following additional contacts are pro­vided through the autocalibration systems:
1. SPS 4000 and IMPS 4000, 1-4 probes.
(a) One contact closure per probe
from the control room to the SPS 4000 or IMPS 4000 for “calibration initiate”.
(b) One contact output per probe from
the SPS 4000 or IMPS 4000 to the control room for “in calibration” notification.
(c) Once contact output per probe
from the SPS 4000 or IMPS 4000 to the control room for “calibration failed” notification. (Includes output from pressure switch indicating “cal gas bottles empty”).
2. Additional IMPS 4000 Alarm Contacts.
(a) One contact per IMPS 4000 for
“low calibration gas flowing”.
(b) One contact per IMPS 4000 for
“high calibration gas flowing”.
NOTE
The 4-20 mA signal can be configured to respond normally during any cali­bration, or can be configured to hold the last O
value upon the initiation of
2
calibration. Factory default is for the 4-20 mA signal to operate normally throughout calibration. Holding the last O
value may be useful if several
2
probes are being averaged for the purpose of automatic control. Unless several probes are being averaged, always place any control loops using the O
signal into manual prior to
2
calibrating.
7-4 IDENTIFYING AND CORRECTING ALARM
INDICATIONS
Faults in the Oxymitter 4000 are indicated using the four diagnostic, or unit, alarms. The pattern of repeating blinks will define the problem. A condensed table of the errors and the corre­sponding blink codes can be found on the inside right cover of the electronics housing. Table 7-1 also identifies the blink code and fault status of each LED as well as the output of the 4-20 mA signal line and a fault number that corresponds to the troubleshooting instructions provided in this section.
7-2 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management
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