Emerson Process Management IM-106-910Xi User Manual

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics for Zirconium Oxide Flue Gas O2 Probes

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Table of Contents

Essential Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i

SECTION i Introduction

SECTION 1 Description and Specifications

SECTION 2 Installation

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Technical Support Hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

System Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

Xi Advanced Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Xi Advanced Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Optional Flame Safety Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Traditional Architecture Cable Connections . . . . . . . . . . . . . . . . . 2-7

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Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

SECTION 3 Configuration of Xi Electronics

SECTION 4 Startup and Operation

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Xi Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Alarm Relay Output Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Analog Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Autocalibration Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Optional Advanced Features Inside the Xi . . . . . . . . . . . . . . . . . . . . . 3-6

Extended Process Temperature Range to 800

Stoichiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Programmable Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Operation via Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Startup Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Xi Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Password Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

System Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Probe Parameter Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Operation Via HART/AMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Field Communicator Signal Line Connections . . . . . . . . . . . . . . .4-10

Field Communicator Menu Trees. . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Off-line and On-line Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Calibration - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Calibration with Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Calibration with Xi and Field Communicator. . . . . . . . . . . . . . 4-15

D/A Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

D/A Trim with Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

°C (1472°F). . . . . . 3-6

SECTION 5 Troubleshooting

TOC-2

Overview of Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Identifying and Correcting Fault Indications. . . . . . . . . . . . . . . . . . . . . 5-3

Calibration Passes, but Still Reads Incorrectly . . . . . . . . . . . . . . . . . . 5-4

Probe Passes Calibration, O

How do I detect a plugged diffuser?. . . . . . . . . . . . . . . . . . . . . . . . 5-6

Can I calibrate a badly plugged diffuser?. . . . . . . . . . . . . . . . . . . .5-6

Still Reads High . . . . . . . . . . . . . . . 5-5

Still Reads Low. . . . . . . . . . . . . . . .5-6

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

SECTION 6 Maintenance and Service

SECTION 7 Replacement Parts

SECTION 8 Optional Accessories

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Xi Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

I/O Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

AC Relay Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Power Supply Board Replacement. . . . . . . . . . . . . . . . . . . . . . . .6-11

Xi Front Panel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

DR Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Xi Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Calibration Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

HART Handheld 375/475 Field Communicator . . . . . . . . . . . . . . . . . . 8-1

Asset Management Solutions (AMS). . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

By-Pass Packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SPS 4001B Single Probe Autocalibration Sequencer . . . . . . . . . . . . . 8-3

IMPS 4000 Intelligent Multiprobe Test Gas Sequencer. . . . . . . . . . . . 8-4

Calibration Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

OxyBalance Display and Averaging System . . . . . . . . . . . . . . . . . . . . 8-6

APPENDIX A XPS Information

APPENDIX B Safety Data

APPENDIX C Return of Material

XPS Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Remote XPS for 44V Probes - 6A00358G01 . . . . . . . . . . . . . . . . .A-1

Remote XPS for 115V Probes - 6A00358G03 . . . . . . . . . . . . . . . .A-2

Integral XPS 6A00365G01 with Xi (for 44V Probes) . . . . . . . . . . .A-3

Other XPS Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

TOC-3

Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

TOC-4

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Xi Advanced Electronics for

Zirconium Oxide Flue Gas O2 Probes

READ THIS PAGE BEFORE PROCEEDING!

ESSENTIAL INSTRUCTIONS

Emerson Process Management designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

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

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

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

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

• Install your equipment as specified in the Installation Instructions

of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and

pressure sources.

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

• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process Management. 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.

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NOTES:

The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic License for operation with the Xi Electronics. The AMS software must be upgraded to AMS 8.0 or above.

Contact Emerson Process Management’s Global Service Center (GSC) at 1-800-833-8314 to upgrade the 375 Field Communicator software to System Software 2.0 with Graphic License.

Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Section i Introduction

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page iii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iii

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page iv

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page iv

Technical Support Hotline . . . . . . . . . . . . . . . . . . . . . . . . .page v

PREFACE The purpose of this manual is to provide information concerning components,

functions, installation and maintenance of the Xi Electronics. Some sections may describe equipment not used in your configuration. The

user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.

DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES

found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure, condition, or statement.

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Instruction Manual

RISKOFELECTRICAL SHOCK

WARNING:REFER TOINSTRUCTIONMANUAL

PROTECTIVECONDUCT OR TERMINAL

EARTH(GROUND) TERMINAL

IM-106-910Xi, Original Issue

Xi Advanced Electronics

November 2010

SYMBOLS

NOTE TO USERS

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

OVERVIEW The Xi is specifically designed to control a zirconium oxide probe for

measuring oxygen, usually the O the Rosemount Analytical Customer Support Center (CSC) in Solon, Ohio, to get recommendations for other oxygen probes. 800-433-6076 (US and Canada).

remaining from a combustion process. Call

The Xi electronics has several main functions:

1. Heater Control - The electronics receives a type K thermocouple input from an O

probe and switches power on and off to the probe's heater in

order to maintain a temperature setpoint of 736 degrees C.

2. Signal Conditioning - The electronics receives the raw millivolt signal from the O

sensing cell, then linearizes and amplifies the signal to

provide a linear 4-20 mA output signal used for recording or as an input into a DCS system for control purposes.

3. Calibration - A bottled calibration gas of known value is typically flowed into the probe's sensor to verify that it is reading correctly. If the signal is out of calibration, the calibration gas is used to adjust the 4-20 mA output signal. During calibration the Xi prompts the technician to flow two calibration gases into the probe and, with the calibration gases flowing, automatically adjusts the O

signal. With the addition of a Single

Probe Sequencer (SPS), the Xi electronics can also switch the calibration gases on and off.

4. Diagnostics - Multiple alarms are available for display. The alarm displays are intended to assist a technician in locating where an instrument problem may reside.

The Xi electronics has been verified to operate the following probes:

• Westinghouse 218 and World Class

• Rosemount Analytical Oxymitter

• Yokogawa

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Technical Support Hotline

For assistance with technical problems, please call the Customer Support Center (CSC). The CSC is staffed 24 hours a day, 7 days a week.

Phone: 1-800-433-6076 1-440-914-1261 In addition to the CSC, you may also contact Field Watch. Field Watch

coordinates Emerson Process Management’s field service throughout the U.S. and abroad.

Phone: 1-800-654-RSMT (1-800-654-7768) Emerson Process Management may also be reached via the Internet through

e-mail and the World Wide Web: e-mail: GAS.CSC@emerson.com World Wide Web: www.raihome.com

Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Section 1 Description and Specifications

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-3

Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-4

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-6

COMPONENT CHECKLIST

SYSTEM OVERVIEW Scope

A typical Rosemount Analytical O2 Combustion Flue Gas Transmitter should contain the items shown in Figure 1-1. A complete Oxygen Analyzer system will include some or all of the equipment shown. However, this manual describes item 8 only. Record the part number, serial number, and order number for the Xi Electronics in the table located on the back cover of this manual.

Also, use the product matrix (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. Ensure the features and options specified by your order number are on or included with the unit.

This Instruction Manual is designed to supply details needed to install, start up, operate, and maintain the Xi Electronics. Signal conditioning electronics outputs a 4-20 mA signal representing an O additional details, can be accessed with the handheld HART Model 375/475 Field Communicator or Asset Management Solutions (AMS) software.

value. This information, plus

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Xi Advanced Electronics

Figure 1-1. Typical System Package

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

1. Instruction Manual

2. Weld Plate

3. Traditional Architecture Cable

4. O2 Probe

5. Reference Air Set (not used if SPS 4001B or IMPS 4000 is used)

6. HART® 375/475 Field Communicator Package (Optional)

7. Optional SPS 4001B or IMPS 4000 Autocalibration Sequencer

8. Xi Advanced Electronics

1-2

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

System Configurations Traditional Architecture, HART and Xi Communications

Some customers prefer not to mount electronics onto the probe, so a "traditional architecture" version is offered. This probe sends raw millivolt signals via a 7-conductor cable to the Xi electronics, Figure 1-2, which does all heater control and signal conditioning in addition to its display/keypad functions. The Xi Advanced Electronics is offered to support direct replacement probes with either 120 volt or 44 volt heaters.

Figure 1-2. Direct Replacement Probe with Traditional Architecture Electronics

Figure 1-3. O

Probe with Xi Electronics and Autocalibration Sequencer

1-3

Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Automatic Calibration

Communication Options

Calibrations consist of introducing bottled gases of known value into the probe so the electronics can make automatic adjustments to the O2 readings to match the bottled gas value. 0.4% O2 and 8% O2 (balance nitrogen) gases are recommended. Never use nitrogen or instrument air as calibration gases.

Flowmeters (for calibration gases) and regulators and flowmeters (for reference air) are available as loose components, mounted into an optional manual calibration switching panel, or as a fully automatic calibration system, Figure 1-3, where calibration solenoids are switched from the Xi Electronics. See IM-106-340AC, SPS 4000B Single Probe Autocalibration Sequencer or IM-106-400IMPS, IMPS 4000 Intelligent Multiprobe Test Gas Sequencer, for additional details.

Data Communications

An operator can configure and troubleshoot the O2 Probe system in one of two ways:

1. Using the Xi Advanced Electronics the Xi carries the following optional advanced features:

• Fully automatic calibration

• Flame safety interface

• High temperature operation [above 700°C (1292°F) standard temperature].

• Stoichiometer feature provides the ability to indicate O2 efficiency when the combustion process goes into reducing conditions (0% O2).

• Programmable reference provides enhanced accuracy when measuring at or near O2 level (20.95% O2).

2. Using the HART Interface. The Xi’s 4-20 mA output line transmits an analog signal proportional to the oxygen level. The HART output is superimposed on the 4-20 mA output line. This information can be accessed through the following:

• Rosemount Analytical Model 375/475 Field Communicator - The handheld communicator requires Device Description (DD) software specific to the Xi. The DD software will be supplied with many Model 375/475 units but can also be programmed into existing units at most Emerson Process Management service offices. See Section 4, Startup and Operation, for additional information.

• Personal Computer (PC) - The use of a personal computer requires AMS software available from Emerson Process Management.

• Delta V and Ovation Distributed Control System (DCS) with AMS-inside capability.

1-4

NOTE:

The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic License for operation with the Xi. The AMS software must be upgraded to AMS 8.0 or above.

Contact Emerson Process Management’s Global Service Center (GSC) at 1-800-833-8314 to upgrade the 375 Field Communicator software to System Software 2.0 with Graphic License.

Instruction Manual

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Analytical

IM-106-910Xi, Original Issue November 2010

Figure 1-4. Wireless THUM Adapter

Xi Advanced Electronics

3. The Xi can also transmit HART information wirelessly via a wireless THUM Adapter, Figure 1-4. The THUM Adapter threads into the Xi conduit port and converts the 4-20 mA O2 signal to a wireless protocol. All other HART information is also transmitted.

In addition to the wireless THUM Adapter, a hard-wire connection of the 4-20 mA signal to the DCS may be used at the same time. More detailed information regarding the application of the THUM Adapter is available in Product Data Sheet 00813-0100-4075. Note that the THUM Adapter may also be used with the Oxymitter, mounted integral to the probe, or to the Oxymitter remote electronics.

Figure 1-5. OxyBalance Displays

Optional OxyBalance Display and Averaging System

Receives up to eight 4-20 mA signals from individual Xi units. Trends individual outputs and calculates four programmable averages as additional 4-20 mA outputs. OxyBalance graphic displays are shown in Figure 1-5. See IM-106-4050, OxyBalance Oxygen Display and Averaging System, for additional details.

1-5

Xi Advanced Electronics

SPECIFICATIONS

Measurement Specifications

Net O2 Range: 0 to 50% O2 user scalable

Lowest Detectable Limit: 0.01% O Signal Stability: ±0.03% O Accuracy in Reducing Conditions: ±10% of reading or 0.1% O System Response in Reducing

Conditions: Ambient Temperature Effect on Xi

4-20 mA Signal:

Environmental Specifications

Xi Advanced Electronics: Type 4X/IP66, Polycarbonate Material

Ambient Temperature Limits: -20°C to 50°C (-4°F to 122°F)

Xi LCD display: Ambient Temperature Limits -20°C to 55°C (-4°F to 131°F)

General Purpose Certifications:

Installation Specifications

Mounting: Panel, wall, or pipe. Reference Air: 0.5 scfh (0,25 /min), clean, dry, instrument-quality air

Calibration: Semi-automatic or automatic Cal Gases: 0.4% O2 and 8% O2, balance N Traditional Architecture Cable 200 ft (61 m) maximum length Transmitter Electrical Power:

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

-2 to 50% O2 user scalable with stoichiometer

going from oxidizing to reducing -T90 in 120 seconds going from reducing to oxidizing -T90 in 30 seconds

less than 0.0025% O2 per degree Celsius

-20°C to 70°C (-4°F to 158°F) as measured by electronics

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

12 - 24 VDC (loop-powered from control room or Xi)

1-6

Electrical Power for Xi: 100-240VAC ±10%, 50/60 Hz Power Consumption of Xi: 12 VA maximum or

776 VA maximum with Traditional Architecture, 120V Probes 450VA maximum with Traditional Architecture,

44V Probes Alarm Relay Outputs: Two provided - 2 Amperes, 30 VDC, Form-C Optional Loss of Flame Input: Internally powered input to remove heater power

actuated via dry contact output from user’s* flame

scanner

Emerson Process Management has satisfied all obligations from the

European legislation to harmonize the product requirements in Europe. 1All static performance characteristics are with operating variables constant. Specifications subject to change without notice.

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Table 1-1. Product Matrix, Xi Advanced Electronics

Xi Xi Advanced Electronics

Code Remote Type

01 Single Channel 02 Single Channel, accepting a loss-of-flame input to remove heater power with flame status relay 03 Dual Channel 04 Single Channel Traditional Architecture for 120V probes 05 Single Channel Traditional Architecture for 44V probes

Code Mounting

00 No Hardware 01 Panel Mount Kit with Gasket 02 2" Pipe/Wall Mount Kit

Xi 01 01 00 01 01 01 Example

(1)

Code Cable

00 No Cable 10 20’ (6 m) Cable 11 40’ (12 m) Cable 12 60’ (18 m) Cable 13 80’ (24 m) Cable 14 100’ (30 m) Cable 15 150’ (45 m) Cable 16 200’ (60 m) Cable

Code Stoichiometer Function

00 None 01 Single Channel (Stoichiometer cell also required in probe) 02 Dual Channel (Stoichiometer cell also required in probe)

Code Programmable Reference Function

00 None 01 Single Channel 02 Dual Channel

Code 800 Deg C Process Function

00 None 01 Single Channel 02 Dual Channel

Xi Advanced Electronics

(1)

Note:

(1)

Requires external XPS Transmitter, P/N 6A00358G03.

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Xi Advanced Electronics

Table 1-2. Product Matrix, O2 Autocalibration Accessories

O2CAL O2 Autocalibration Accessories

Code Single Probe Sequencers Autocalibration Options

00 None 01 SPS 4001B Single Probe Sequencer, general purpose NEMA 4X, includes check valve for probe

Code Intelligent Multiprobe Sequencers (IMPS)

00 None 01 IMPS single-probe, general purpose NEMA 4X, includes check valve for probe 02 IMPS two-probe, general purpose NEMA 4X, includes check valve for probe 03 IMPS three-probe, general purpose NEMA 4X, includes check valve for probe 04 IMPS four-probe, general purpose NEMA 4X, includes check valve for probe 05 IMPS single-probe, 115V heated general purpose NEMA 4X, includes check valve for probe 06 IMPS two-probe, 115V heated general purpose NEMA 4X, includes check valve for probe 07 IMPS three-probe, 115V heated general purpose NEMA 4X, includes check valve for probe 08 IMPS four-probe, 115V heated general purpose NEMA 4X, includes check valve for probe 09 IMPS single-probe, 220V heated general purpose NEMA 4X, includes check valve for probe 10 IMPS two-probe, 220V heated general purpose NEMA 4X, includes check valve for probe 11 IMPS three-probe, 220V heated general purpose NEMA 4X, includes check valve for probe 12 IMPS four-probe, 220V heated general purpose NEMA 4X, includes check valve for probe

O2CAL 00 04 Example

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Table 1-3. Calibration Gases

Part Number Description

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

nitrogen - 550 liters each* 1A99119G02 Two flow regulators for calibration gas bottles 1A99119G03 Bottle rack

Note:

*Calibration gas bottles cannot be shipped via airfreight.

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Section 2 Installation

System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-2

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

Xi Advanced Electronics . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-2

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-5

Xi Advanced Electronics . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-5

Optional Flame Safety Interlock . . . . . . . . . . . . . . . . . . . . page 2-7

Traditional Architecture Cable Connections . . . . . . . . . .page 2-7

Before installing this equipment read the "Safety instructions for the wiring and installation of this apparatus" at the front of this Instruction Manual. Failure to follow safety instructions could result in serious injury or death.

Xi Advanced Electronics

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

The Xi Advanced Electronics can be installed in general purpose areas only. Do not install the Xi in hazardous areas or in the vicinity of flammable liquids.

If external loop power is used, the power supply must be a safety extra low voltage (SELV) type.

NOTE

All unused ports on the probe housing and Xi enclosure should be plugged with a suitable fitting.

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Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

SYSTEM CONSIDERATIONS

Figure 2-1. Typical System Installation

A typical system installation for a Xi and O2 Probe is shown in Figure 2-1.

MECHANICAL INSTALLATION

Xi Advanced Electronics

The Xi Advanced Electronics is available in a panel mounting, wall mounting, or pipe mounting configuration. Refer to Figure 2-2 or Figure 2-3 for the panel, wall, or pipe mounting details.

1. Ensure all components are available to install the Xi.

2. Select a mounting location near or removed from the O Consider the temperature limitations of the Xi (see "Specifications") when selecting the mounting location.

3. Mount the Xi at a height convenient for viewing and operating the interface. Approximately 5 ft (1,5 m) is recommended.

4. The keypad window on the Xi may have interior and exterior protective membranes. Remove the protective membranes prior to use of the Xi enclosure. Failure to remove the protective membranes may cause the display to appear distorted. The membrane may be difficult or impossible to remove after extended use at elevated temperatures.

Probe.

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Figure 2-2. Xi Advanced Electronics - Panel Mounting Details

Xi Advanced Electronics

2-3

Xi Advanced Electronics

Figure 2-3. Xi Advanced Electronics - Wall/Surface and Pipe Mounting Details

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

ELECTRICAL INSTALLATION

Xi Advanced Electronics

All wiring must conform to local and national codes. Multiple wiring diagrams are shown in this section. Always refer to the diagrams that apply to your transmitter configuration and disregard all other wiring diagrams.

Disconnect and lock out power before connecting the power supply.

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

To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, connection to the main electrical power supply must be made through a circuit breaker (min 10A) 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

Line voltage, signal, and relay wiring must be rated for at least 105

°C

(221°F).

NOTE

If metal conduit is used with the Xi the conduit should be reliably bonded to protective earth. The grounding plate inside the Xi is not bonded to PE and does not provide adequate grounding.

1. Remove cover screws from the front cover of the Xi. Swing down the front cover of the interface box.

2. Pull out the I/O board on the right-hand side of the card rack inside the Xi. If your system is configured to operate two transmitter probes there are two I/O interface boards.

3. See Figure 2-4. Connect the 4-20 mA signal wires at J4 of the I/O board. Attach the supplied ferrite clamp over the 4-20 mA OUT wires that extend past the shield.

NOTE

Installation of the ferrite clamp over the 4-20 mA OUT wires is required for compliance with the European EMC Directive.

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Xi Advanced Electronics

Figure 2-4. Signal Connections at I/O Board

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Figure 2-5. Alarm Indicator Relay Terminals

4. Terminate the shield of the 4-20 mA signal wires at the designated

5. Connect the signal wires from the SPS or IMPS (if used) to the

6. Connect the signal wires for the flame status input (if used) to the

7. Connect the customer’s alarm indicator devices to the alarm indicator

8. Reinstall the I/O board in the card rack of the Xi.

ground terminal of the Xi. Do not allow bare shield wires to contact the circuit boards. Insulate the shield wires prior to termination.

applicable terminals of J3. Refer to the SPS or IMPS instruction manual for wiring details.

applicable terminals of J2. The flame status sensing device is supplied by the customer. Refer to the applicable OEM documents for signal wiring details.

relay terminals. See Figure 2-5 for the alarm indicator relay terminals.

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Figure 2-6. Power Connections Xi Advanced Electronics

Xi Advanced Electronics

Optional Flame Safety Interlock

Traditional Architecture Cable Connections

9. If your system is configured for two channel operation, repeat steps 2 through 7 to connect the other signal wires.

10. Remove the connector from the power supply board located on the left-hand side of the card rack inside the Xi.

11. See Figure 2-6. Connect the line, or L1 wire to the L1 terminal and the neutral, or L2 wire, to the N terminal.

12. Reinstall the power supply connector in the power supply board.

13. Close and fasten the Xi cover.

A flame safety interlock by Emerson Process Management is available for heater power disconnect whenever there is a loss of the process flame or a heater runaway condition (heater over-temperature) in the O simplified wiring diagram for the flame safety interlock is shown in Figure 2-7. This input is internally powered by the Xi and is actuated via a dry contact output from the user’s flame scanner. A closed contact indicates a flame is present. An open contact indicates a loss of flame.

A traditional architecture configuration is used to provide for remote location of the transmitter electronics. All electronics are housed inside the Xi. A multi-conductor power/signal cable connects between the probe and the Xi. Use the following procedure to connect the traditional architecture probe to the Xi.

NOTE

The Traditional Architecture cable is provided at the specified length and is ready for installation. The cable glands must be properly terminated to maintain EMC/EMI noise protection.

Probe. A

1. Run the 7-conductor cable between the traditional architecture probe and the installation site for Xi. Use new cable conduit or trough as needed.

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Xi Advanced Electronics

Figure 2-7. Flame Safety Interlock - Wiring Diagram

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Figure 2-8. Traditional Architecture Cable Gland Assembly

2. Install the cable and lead wires to the probe per manufacturer’s instructions.

3. Install the cable at the probe housing and at the Xi enclosure according to the following procedure:

a. Unscrew locking nut from gland assembly, Figure 2-8, and slide

locking nut back along cable.

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

b. Pull the gland body away from the plastic insert. Use care not to

damage the cable shield braid.

c. Insert the cable wires into the proper entry port in either the probe

housing or the Xi enclosure.

d. At the probe housing, apply Teflon tape or similar sealing compound

to the tapered pipe threads. Thread the gland body into the probe housing until properly seated.

e. At the Xi enclosure, insert the gland body into the left front cable port

from the inside of the enclosure. Use the rubber O-ring provided to seal the cable port.

f. Ensure the cable shield braid is evenly formed over the gray insert.

When properly formed, the braid should be evenly spaced around the circumference of the insert and not extend beyond the narrow diameter portion.

g. Carefully press the gray insert into the gland body. The grooves on

the insert should align with similar grooves inside the gland body. Press the insert in until it bottoms out in the gland body.

h. Slide the locking nut up and thread it onto the gland body. Tighten

the locking nut so the rubber grommet inside the plastic insert compresses against the cable wall to provide an environmental seal.

4. At the Xi, connect the cable leads to the connectors on the transmitter I/O board as indicated in Figure 2-9.

Figure 2-9. Transmitter Board Connections at Xi - Traditional Architecture

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Xi Advanced Electronics

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IM-106-910Xi, Original Issue

November 2010

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IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Section 3 Configuration of Xi Electronics

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-1

Xi Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-2

Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-2

Alarm Relay Output Configuration . . . . . . . . . . . . . . . . . . page 3-3

Analog Output Configuration . . . . . . . . . . . . . . . . . . . . . .page 3-4

Autocalibration Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-5

Optional Advanced Features Inside the Xi . . . . . . . . . . . .page 3-6

Extended Process Temperature Range to 800

Stoichiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-7

Programmable Reference . . . . . . . . . . . . . . . . . . . . . . . . .page 3-7

VERIFY INSTALLATION

°C . . . . . . .page 3-6

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.

If external loop power is used, the power supply must be a safety extra low voltage (SELV) type.

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Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Xi Configuration

Refer to Figure 3-1 for the configuration of jumpers JP1 through JP8. The jumper configuration for your I/O board depends on the system design and system components used in your installation.

The setting of switch SW4 and the configuration of jumpers JP1 through JP8 must be verified on the I/O board in the Xi. All four dip switches on switch SW4 must be set to the OFF position, as shown.

Figure 3-1. I/O Board Jumper Configuration

SET TEST GAS VALUES

3-2

Use a Field Communicator or the Xi to set test gas values for calibration. A Xi shipped from the factory has test gas values for low and high set to 0.4%

and 8.0% respectively. This same process must be performed any time a replacement Transmitter Board, I/O Board or DR Board is installed.

Setting Test Gas Values Using Xi Keypad/Display

1. Press the MENU button once.

2. From the main menu, select PROBE 1.

3. From PROBE 1, select DETAILED SETUP.

4. From the DETAILED SETUP menu, select CAL SETUP.

5. From CAL SETUP, select Cal Gas 1. Enter the percent O

6. From CAL SETUP, select Cal Gas 2. Enter the percent O

low O

high O

test gas.

used for the

7. Press the LEFT arrow key several times to return to the main menu.

8. Repeat steps 2 through 6 for PROBE 2 if configured for dual channel.

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Setting Test Gas Values Using Field Communicator

1. Use the Field Communicator software to access the HART menu.

2. From the DEVICE SETUP menu, select DETAILED SETUP.

3. From the DETAILED SETUP menu, select CAL SETUP.

4. From CAL SETUP, select Cal Gas 1. Enter the percent O2 used for the

5. From CAL SETUP, select Cal Gas 2. Enter the percent O2 used for the

low O

test gas.

high O2 test gas.

ALARM RELAY OUTPUT CONFIGURATION

Table 3-1. Alarm Relay Output Configurations

The Xi has two dry contact Form-C alarm relay output signals that can be configured in eight different modes through the Xi keypad display or the 375/475 Field Communicator. A list of possible configurations is shown in Table 3-1. Each alarm relay output can be configured separately.

If the Xi is configured with the optional Flame Safety Interlock, Alarm 2 is configured with "Heater Relay" and prewired to the AC Relay Board. In this condition the relay configuration cannot be changed to any other setting. If the Xi is not configured with the optional Flame Safety Interlock, "Heater Relay" is not valid and cannot be chosen for Alarm 2.

Mode Configuration

No Alarm* The output is not configured for any alarm condition. Unit Alarm The output is configured for a Unit Alarm. Low O2 Alarm The output is configured for a Low O2 alarm. Low O2/Unit Alm The output is configured for a Unit alarm and a Low O2 alarm. Cal Recommended The output is configured for a Calibration Recommended

display.

Cal Rec/Unit Alm** The output is configured for a Unit alarm and a Calibration

Recommended display.

Low O2/Cal Rec The output is configured for a Low O2 alarm and a Calibration

Recommended display.

Low O2/Unit/Cal Rec The output is configured for a Low O2 alarm, a Unit alarm, and a

Calibration Recommended display.

Heater Relay The output is configured for Flame Safety Interlock.

* The default configuration for Alarm 2

** The default configuration for Alarm 1

Configuring Alarm Relays with the Xi Keypad/Display

1. Press the MENU button once.

2. From the main menu, select PROBE 1.

3. From PROBE 1, select DETAILED SETUP.

4. From the DETAILED SETUP menu, select ALARM RELAY.

5. From ALARM RELAY, select as follows:

Alm Relay1 - Alarm 1 mode Alm Relay2 - Alarm 2 mode Low O2 Alm SP - Low O2 alarm setpoint High Temp Alm SP - High temperature alarm setpoint

6. Press the LEFT arrow key several times to return to the main menu.

7. Repeat steps 2 through 6 for PROBE 2 if configured for dual channel.

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Xi Advanced Electronics

Configuring Alarm Relays with the Field Communicator

1. Use the 375/475 Field Communicator software to access the HART

2. From the DEVICE SETUP menu, select DETAILED SETUP.

3. From the DETAILED SETUP menu, select ALARM RELAY.

4. From ALARM RELAY, select as follows:

5. From CAL SETUP, select Cal Gas 2. Enter the percent O2 used for the

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

menu.

Alm Relay1 - Alarm 1 mode Alm Relay2 - Alarm 2 mode Low O2 Alm SP - Low O2 alarm setpoint High Temp Alm SP - High temperature alarm setpoint

high O2 test gas.

ANALOG OUTPUT CONFIGURATION

The analog output signal from the Xi can be configured for the 4-20 mA range and fault condition.

A Xi shipped from the factory has the analog outputs set to a 4 to 20 mA range with a 3.5 mA alarm level. This same process must be performed any time a replacement Transmitter Board or I/O Board is installed.

Configuring the Analog Output with the Xi Keypad/Display

1. Press the MENU button once.

2. From the main menu, select PROBE 1.

3. From PROBE 1, select DETAILED SETUP.

4. From the DETAILED SETUP menu, select ANALOG OUTPUT.

5. From ANALOG OUTPUT, set the following parameters:

O2 LRV - O2 value at the lower analog output value (0 mA or 4 mA) O2 URV - O2 value at the upper analog output value (20 mA) AO Range - Range of the analog output (0-20 mA or 4-20 mA) Signal Alarm Level - O2 alarm level (3.5 mA or 21.1 mA)

Configuring the Analog Output with the Field Communicator

1. Use the 375/475 Field Communicator software to access the HART menu.

2. From the DEVICE SETUP menu, select DETAILED SETUP.

3. From the DETAILED SETUP menu, select ANALOG OUTPUT.

4. From ANALOG OUTPUT, set the following parameters:

3-4

O2 LRV - O2 value at the lower analog output value (0 mA or 4 mA) O2 URV - O2 value at the upper analog output value (20 mA) O2 AO Range - Range of the analog output (0-20 mA or 4-20 mA) Signal Alarm Level - O2 alarm level (3.5 mA or 21.1 mA)

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

AUTOCALIBRATION SETUP

If autocalibration is desired, the Xi must be used with either an SPS 4001B or IMPS 4000. The Xi must be properly configured before autocalibration can take place. Refer to the applicable SPS 4001B or IMPS 4000 instruction manual for details on performing autocalibration. Refer to Section 4, Startup and Operation for details on manual calibration procedures.

A Xi is shipped from the factory without autocalibration configured. This same process must be performed any time a replacement I/O Board is installed.

Configuring Autocalibration with the Xi Keypad/Display

1. Press the MENU button once.

2. From the main menu, select PROBE 1.

3. From PROBE 1, select DETAILED SETUP.

4. From the DETAILED SETUP menu, select CAL SETUP.

5. From CAL SETUP, select Auto Cal.

6. Press the RIGHT arrow key to change the state from NO to YES.

Configuring Autocalibration with the Field Communicator

1. Use the 375/475 Field Communicator software to access the HART menu.

2. From the DEVICE SETUP menu, select DETAILED SETUP.

3. From the DETAILED SETUP menu, select CAL SETUP.

4. From CAL SETUP, select Auto Cal.

5. Press the RIGHT arrow key to change the state from NO to YES.

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Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

OPTIONAL ADVANCED FEATURES INSIDE THE Xi

Advanced features available inside the Xi are typically ordered as part of the initial package. However, these advanced features are also available for field retrofit.

A Xi is shipped from the factory with the optional enhanced software features enabled based on the configuration.

The I/O Board is shipped from the factory without any of the enhanced software features activated. These features must be activated once the new board has been installed and before the Remote Interface is put into service.

If the existing I/O Board has been operated with the Stoichiometric enhanced software feature, this feature must be activated in the new board before the Remote Interface is put back into service. Failure to do so will cause a false analog output signal to the DCS.

NOTE

For enhanced software feature option upgrades or to enable the feature to duplicate the existing configuration, contact Emerson Process Management at 1-800-433-6076. Reference the following:

Extended Process Temperature Range to 800°C (1472°F)

6A00269G01 Enhanced Software Option Upgrade, Stoichiometric Function 6A00269G02 Enhanced Software Option Upgrade, Programmable

Reference Function

6A00269G03 Enhanced Software Option Upgrade, 800°C Process

Function

The Oxygen Analyzer employs a heater and thermocouple to maintain a temperature setpoint at 736°C (1357°F). Temperature control is maintained within ±1°C to process temperatures of about 705°C (1300°F). This is satisfactory for most applications, but excursions to higher temperatures can occur in some processes. In these instances, the heater is turned off and the process temperature is used to heat the sensing cell.

The oxygen reading is adjusted immediately to compensate for the varying process temperatures. It should be noted that cell life will be reduced by continuous operation at temperatures above 705°C (1300°F). If process temperatures are expected to be continuously above 705°C, we recommend the use of an optional bypass or probe mounting jacket accessory. The extended temperature range feature is selected in the Xi product matrix, but may also be purchased as a field retrofit.

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IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Stoichiometer

Programmable Reference

Process upsets can sometimes cause a combustion process to go into sub-stoichiometric or reducing conditions. The oxygen readings from one or more probes may decline all the way to zero. The stoichiometer cell will measure the amount of oxygen deficiency during these reducing conditions. The trends in your DCS can be set up for a lower range limit of -1 or -2% oxygen to depict the level of oxygen deficiency.

The operator can see if his control recovery actions are having the desired effect. These types of events do not occur frequently, but knowing the parameters of the situation prevents over-correcting while coming out of the reducing condition.The stoichiometer feature requires purchasing the acid resistant stoichiometer cell and the stoichiometer feature inside the Xi.

NOTE

Make sure the DCS is configured for the same range as the Xi. For instance:

-1% O2 to 10% O2.

The zirconium oxide sensing technology has historically measured process oxygen by using ambient or instrument air as a reference (20.95% oxygen). The sensor develops most of its signal at the low oxygen levels typically found in combustion flue gasses (2-4% oxygen), and is most accurate at these levels. When measuring near 20.95% O2, the sensor develops only a few millivolts of signal, and accuracy degrades.

The programmable reference feature permits the user to use a bottled reference gas of low oxygen value (0.4% oxygen recommended). When measuring at or near 21% oxygen, a strong negative oxygen signal results, with much improved accuracy. A bottle of reference gas typically lasts about a month at the low flows required. Typical applications would be:

Flue gas recirculation - controlling the mixing of flue gasses into the burner windbox prior ahead of the burner to reduce NOx emissions.

Moisture monitoring - measuring the amount of moisture coming off of industrial dryers by noting the dilution effect water vapor has on the normal

20.95% ambient drying air. (Non-combustion drying processes only.) Enriched oxygen concentration - pure oxygen is sometimes mixed in with

the combustion air to increase heat at the flame. This is used in steel and other metals reduction processes and in some catalyst regenerators.

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November 2010

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Xi Advanced Electronics

Section 4 Startup and Operation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-1

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1

Operation via Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-2

Startup Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-2

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-2

Xi Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-2

Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-3

Xi Menu (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-4

System Parameter Descriptions . . . . . . . . . . . . . . . . . . . . page 4-7

Probe Parameter Descriptions . . . . . . . . . . . . . . . . . . . . .page 4-8

Operation Via HART/AMS . . . . . . . . . . . . . . . . . . . . . . . . . page 4-10

Field Communicator Signal Line Connections . . . . . . . . page 4-10

Field Communicator Menu Trees . . . . . . . . . . . . . . . . . . .page 4-11

Off-line and On-line Operations . . . . . . . . . . . . . . . . . . . .page 4-11

Calibration - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-14

O2 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-14

O2 Calibration with Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-14

O2 Calibration with Xi and Field Communicator . . . . . . .page 4-15

D/A Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-16

D/A Trim with Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-16

OVERVIEW

STARTUP

Interface to the Xi for setup, calibration and diagnostics can be via a 375/475 Field Communicator or Asset Management System.

Setup, calibration and diagnostic operations will differ depending on the selected interface for communications with the transmitter.

The O2 Probe will take approximately 45 minutes to warm up to the 736°C heater setpoint. The 4-20 mA signal will remain at a default value of 3.5 mA through this warm-up period. Once warm, the O2probe will be reading oxygen, and the 4-20 mA signal will be reading based on the default range of 0-10% O2.

NOTE

The Xi offers optional advanced features such as elevated process temperature capability to 800°C, autocalibration via an SPS solenoid box, a stoichiometer feature for indicating the level of oxygen deficiency in reducing conditions, and programmable reference to enhance accuracy at near ambient levels of O2.

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Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Operation via Xi

Startup Display

Figure 4-1. Xi Display (Typical)

The following procedures describe operations using the Xi to set up and calibrate the system. Additional operating instructions are included in the SPS 4001B or IMPS 4000 instruction manual, if applicable to your system.

The O2 Probe will take approximately 45 minutes to warm up to the 736°C heater setpoint. The 4-20 mA signal will remain at a default value of 3.5 mA through this warm-up period. Once warm, the probe will be reading oxygen and the 4-20 mA signal display will be the 0 to 10% O2 value.

Error Conditions

Xi Controls

If there is an error condition at startup, an alarm message will be displayed. Refer to Section 5: Troubleshooting, to determine the cause of the error. Clear the error and cycle power. The %O2 and temperature display should return less the alarm message.

The Xi can be used to change the software and alarm settings, to adjust the high and low gas settings, and to initiate the calibration sequence. Refer to the following control descriptions. Use the control keys on the front panel of the Xi, Figure 4-1, to navigate and edit the Xi menu, Figure 4-2.

MENU toggles between three Main menu options: System, Probe1, and Probe2 (if available). The top level of the selected main menu is displayed.

DIAG toggles between the Alarms list of the three main menus. All faults and warnings related to the selected main menu device are displayed.

ENTER saves newly entered data and returns you to previous menu level. EXIT returns you to the previous menu level without saving newly entered

data. When navigating the menu tree, pressing EXIT returns you to the Main menu.

UP/DOWN keys scroll up and down through menu items. During data entry the Up/Down keys increment and decrement the data values.

LEFT arrow key returns you to the previous menu level. During data entry, the left arrow key moves the cursor one digit to the left.

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RIGHT arrow key advances you to the next menu level and, when a menu item is highlighted, selects the item from a list of menu options. During data entry, the right arrow key moves the cursor one digit to the right.

Password Protection

Beginning with Xi system software version 1.05 or higher the main display and diagnostic screens of the Xi can be viewed at any time, but further access and unauthorized configuration changes can be prevented by enabling a password protection feature. However, the Xi is shipped with password protection disabled.

Password protection can be enabled by selecting: System Main Menu> Configure> LCD>Enable Password (see the Xi Menu, Figure 4-2).

The factory default upon enabling the password protection is ROSE, but the password can consist of any 4 alpha/numeric characters.

If the user forgets the password, call Rosemount Analytical technical support at 800-433-6076 to gain access to a master password.

A "Lock" icon will be displayed at the top right corner of the main display when password protection is in effect.

The password protection will relock itself after a certain number of seconds with no button pushes (defined as "revert time" in the same "LCD setup" menu). Users can also force the front panel to be locked by selecting System Main Menu >Log Off. The Log Off selection will perform no function if the password feature is disabled.

The Xi has a "Reset" function that reestablishes all factory default conditions, including the password protection feature, i.e. the password protection will fall back to a disabled condition after a reset.

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Figure 4-2. Xi Menu (Sheet 1 of 3)

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Figure 4-2. Xi Menu (Sheet 2 of 3)

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Figure 4-2. Xi Menu (Sheet 3 of 3)

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SYSTEM PARAMETER DESCRIPTIONS

Among the parameters available through the Xi and 375/475 Field Communicator menus are a number of "System Parameters". The system parameters define variables that configure the Xi in the transmitter system. System parameters are described in the following table.

CPU

Y Version -- Software version number for the CPU board. Y Build Num -- Software build number for the CPU board. Y Comm Status -- Communication status between the CPU and I/O boards. Y Restart Cntr -- Software restarts counter for the CPU board. N Poll Addr -- Polling Address - Address used to identify a Field Device; changeable by the user to control. N Serial Number -- I/O board serial number. N Features -- Available advanced software features for the I/O board.

N EE Erase Count -- This is for nonvolatile memory diagnostic only. Y Num Probe -- Number of probes configuration:

Y Probe Sel -- This parameter is applicable only if the Num Probe configuration is set to 2. It defines which

Y Probe 1 Enable -- Probe 1 state. If enabled, the probe menu will be displayed otherwise it will not be displayed.

Y Probe 2 Enable -- Probe 2 state. If enabled, the probe menu will be displayed otherwise it will not be displayed.

Y LineX Probe -- Probe number for line x. (1, 2) Y Line 1 Data -- Main display, line 1 data: 0 displays PV (O2), 1 displays SV (O2 Temp) Y Line 2 Data -- Main display, line 1 data: 0 displays PV (O2), 1 displays SV (O2 Temp) Y Line 3 DataL -- Main display, line 3 left hand side data:

Y Line 3 DataR -- Main display, line 3 right hand side data:

Y Line 4 DataL -- Main display, line 4 left hand side data:

Y Line 4 DataR -- Main display, line 4 right hand side data:

Y Revert Time min Xi display reverts to main display time. Also locks screen if password protection is enabled. Y Language -- 0 displays English

Y Contrast -- Display contrast: (120 to 200) Y Alarms -- See section 5, Troubleshooting, ”Alarm Indications”. Y Password -- Security Password Y Enable Password -- Enables/disables security password protection

PARAMETER NAME UNITS PARAMETER DESCRIPTION

ON: feature supported. OFF: feature not supported.

If set to 1, use One Probe configuration for the Main display. If set to 2, use Two Probes configuration for the Main display.

probe is to be displayed.

(No, Yes)

0 displays PV (O2) 1 displays SV (O2 Temp) 2 displays TV (Cell Imp) 3 displays 4V (Cell mV)

1 displays Spanish 2 displays German

4 displays CJC Temp 5 displays AO 6 displays OP Mode 7 displays Tag

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PROBE PARAMETER DESCRIPTIONS

Among the parameters available through the Xi and 375/475 Field Communicator menus are a number of "Probe Parameters". The probe parameters define variables that configure a specific probe in the transmitter system. Probe parameters are described in the following table.

TX I/O

Y Y O2 % Current oxygen concentration value (O2%). The value should reflect the last good O2 value if it

Y Y O2 Temp degC Current O2 sensor temperature. Y Y CJC Temp degC Current cold junction temperature.

N Y Elec Temp degC Current electronic temperature measured at the I/O board.

Y Y O2 Cell mV Raw mV value for ZrO2 sensor.

N Y TC Volt mV O2 T/C voltage.

Y Y Cell Imp Ohm Cell impedance/sensor resistance measured. Y Y Htr Volt Volt Heater voltage. Y Y CPU Volt Volt Transmitter CPU voltage. Y Y O2 AO mA Analog output value represents the O2 concentration measurement.

N Y O2 AO% % O2 analog output percentage for O2 AO.

Y Y O2 Temp Max degC This is the highest O2 sensor temperature reached since last reset. Y Y CJC Temp Max degC This is the highest temperature reached at the cold junction since last reset.

N Y Elec Temp Max degC This is the highest temperature reached at the I/O board since last reset.

Y Y Htr Volt Max degC This is the highest heater voltage reached since last reset. Y Y Htr Duty Cycle -- O2 heater duty cycle. Value between 0 and 1. Y Y PID SP degC PID temperature set point. Y Y Htr Ramp Rate degC/s Heater ramp rate calculated in degree C per second.

N Y Flame Stat In -- Flame status input state.

N Y SPS/IMPS In -- SPS/IMPS input state.

N Y SPS/IMPS Out -- SPS/IMPS output state.

N Y Alm Relay 1 Out -- Alarm Relay 1 output state.

N Y Alm Relay 2 Out -- Alarm Relay 2 output state.

Y Y OP Mode -- Device operating mode:

Y Y Tag -- Device tag. Y Y Device ID -- Unique Device ID number. (HART) Y Y PV is -- Primary variable assignment. (HART) Y Y SY is -- Secondary variable assignment. (HART) Y Y TY is -- Third variable assignment. (HART) Y Y QV is -- Fourth variable assignment. (HART) Y Y Cal Slope mV/Dec Current calibration slope. This is the slope value that was calculated as a result of the last

Y Y Cal Const mV Current calibration constant. This is the constant value that was calculated as a result of the last

Y Y Cal Imp Ohm Cell Impedance. This is the sensor resistance that was calculated as a result of the last

N Y Prev Slope mV/Dec Previous calibration slope. There are ten calibration results. 1 is the most recent and 10 is the

N Y Prev Const mV Previous calibration constant. There are ten calibration results. 1 is the most recent and 10 is

PARAMETER NAME UNITS PARAMETER DESCRIPTION

is in the "Lock" state during calibration.

(OFF/ON)

PO=Power up; WU=Warm Up (analog output is railed); NM=Normal operation; CA=Calibrating (analog output can be tracking or locked at last good value based on "AO Tracks" configuration); AL=Alarm detected (recoverable); SF=Alarm detected (non-recoverable)

successful calibration.

successful calibration. It is valid between -4mV and +10mV.

successful calibration.

least recent calibration slope.

the least recent calibration constant.

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TX I/O

N Y Prev Cal Imp Ohm Previous Cell Impedance. This is the sensor resistance that was calculated as a result of

N Y Failed Slope mV/Dec Failed calibration slope. N Y Failed Const mV Failed calibration constant. Y Y Cal Result mV Calibration result. N Y Delta Imp -- Delta impedance since last calibration. N Y Cal Step -- This represents the step of the calibration cycle is in. N Y Time Remain sec Time remaining in the present calibration cycle state. Y Y O2 Slope mV/Dec O2 slope. This is the slope value that will be used to calculate O2. Y Y O2 Const mV O2 constant. This is the constant value that will be used to calculate O2. N Y T90 Filter sec Analog output T90 time. It represents the time to take a step change in oxygen to reach 90% of

N Y O2 Cell Ref % O2 sensor reference gas percentage. It allows using a sensor reference gas other than air. N Y O2 Temp SP degC O2 sensor temperature set point. It allows measurement of oxygen with an elevated sensor

N Y Features -- Advanced software features.

Y Y O2 URV % Primary variable (O2%) upper range value. Y Y O2 LRV % Primary variable (O2%) lower range value. N Y O2 AO Range -- Analog output polarity. (0=4-20 mA; 1=20-4 mA) Y Y O2 Alarm Level -- O2 alarm level. (0=3.5 mA; 1=21.1 mA) N Y Alarm Relay 1 -- Alarm Relay 1 mode.

N Y Alarm Relay 2 -- Alarm Relay 2 mode. (no alarm; unit alarm; low O2 alarm; low O2/unit alarm

N Y Low O2 Alm % Low O2 alarm threshold. N Y Hi Temp Alm % High temperature alarm threshold. N Y AO Tracks -- Analog output track O2 sensor measurement during a calibration. (No, Yes). N Y Auto Cal -- Enable/disable automatic calibration.

N Y Start On CalRec -- Start automatic calibration on Cal Recommended state. (No, Yes) Y Y Cal Gas 1 % Test Gas 1 value. This is the actual value of the gas being applied during the Test Gas 1 phase

Y Y Cal Gas 2 % Test Gas 2 value. This is the actual value of the gas being applied during the Test Gas 2 phase

Y Y Gas Time sec Test Gas application time. This is the length of time test gases are applied to the O2 probe

Y Y Purge Time sec Test Gas purge time. This is the length of time before the output will be returned to the process

N Y Cal Interval hr Automatic calibration interval. The number 9999 disables the automatic timed calibration. N Y Next Cal Time hr Time remaining until the next automatic periodic calibration. The number 9999 disables the next

Y Y T EE Val -- Transmitter board nonvolatile memory diagnostic. N Y IO EE Val -- I/O board nonvolatile memory diagnostic. Y Y Version -- Software version number for the Transmitter. N Y Version -- Software version number for the I/O board. Y Y T Restart Cntr -- Software restarts count for the Transmitter. N Y IO Restart Cntr -- Software restarts count for the I/O board. Y Y Alarms -- Current Alarms (See section 5, Troubleshooting, ”Alarm Indications”.)

PARAMETER NAME UNITS PARAMETER DESCRIPTION

previous successful calibration. There are ten calibration results. Index 1 is the most recent and Index 10 is the least recent sensor resistance measured.

the final value at the filter output.

temperature. (0=736 degC set point; 1=834 degC set point)

(0=Stoichiometer; 1=Programmable Reference; 2=Elevated Temperature)

(no alarm; unit alarm; low O2 alarm; low O2/unit alarm; Cal recommended; Cal recommended/unit alarm; low O2/Cal recommended; low O2/unit alarm/Cal recommended)

Cal recommended; Cal recommended/unit alarm; low O2/Cal recommended; low O2/unit alarm/Cal recommended; Heater relay)

No = Set to Manual calibration mode. Yes = Set to Automatic calibration mode.

of a calibration.

during low or high Test Gas phase of a calibration.

reading after a calibration.

automatic timed calibration.

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OPERATION VIA HART/AMS

Field Communicator Signal Line Connections

The 375/475 Field Communicator is a handheld communications interface device. It provides a common communications link to all microprocesor-based instruments that are HART compatible. The handheld communicator contains a liquid crystal display (LCD) and 21 keys. A pocket-sized manual, included with the 375/475 Field Communicator, details the specific functions of all the keys.

The 375/475 Field 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 Xi's 4-20 mA current loop. The 375/475 Field Communicator does not disturb the 4-20 mA signal, since no net energy is added to the loop.

NOTES

The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic License for operation with the Xi. The AMS software must be upgraded to AMS 8.0 or above for operation with the Xi.

Contact Emerson Process Management’s Global Service Center (GSC) at 1-800-833-8314 to upgrade the 375 Field Communicator software to System Software 2.0 with Graphic License.

When working at the Xi, the 375/475 Field Communicator can be connected directly to test points TP21 and TP22 on the Xi I/O Board as shown in Figure 4-3. The AM+ and AM- test points are provided to monitor the 4-20 mA signal without breaking into the loop.

Figure 4-3. 375/475 Field Communicator Connection at the Xi

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Field Communicator Menu Trees

OFF-LINE AND ON-LINE OPERATIONS

Connect the 375/475 Field Communicator in the Xi (Xi-to-DCS) 4-20 mA signal loop or to the Xi terminals as shown in Figure 4-3 and refer to Figure 4-4 for the 375/475 Field Communicator Xi menu tree.

The 375/475 Field Communicator can be operated both off-line and on-line. Off-line operations are those in which the communicator is not connected to

the O2 Probe. Off-line operations can include interfacing the 375/475 Field Communicator with a PC (refer to applicable HART documentation regarding HART/PC applications.)

In the on-line mode, the 375/475 Field Communicator is connected to the 4-20 mA analog output signal line. The communicator is connected in parallel to the O2 Probe or in parallel to the 250 ohm load resistor.

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Figure 4-4. 375/475 Field Communicator Xi Menu Tree (Sheet 1 of 2)

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Figure 4-4. 375/475 Field Communicator Xi Menu Tree (Sheet 2 of 2)

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CALIBRATION GENERAL

O2 CALIBRATION

New O2 cells may operate for more than a year without requiring calibration, but older cells may require recalibration every few weeks as they near the end of their life.

CALIBRATION RECOMMENDED

is required. This strategy ensures that the O2 reading is always accurate and eliminates many unnecessary calibrations based on calendar days or weeks since previous calibration.

The O2 Probe(s) can be calibrated manually through the handheld 375/475 Field Communicator or the Xi. Fully automatic calibration can be performed automatically using the Xi and the SPS 4001B Single Probe Autocalibration Sequencer or the IMPS 4000 Intelligent Multiprobe Sequencer.

This section covers manual calibration. For automatic calibration details see the Instruction Manual for the SPS 4001B Single Probe Autocalibration Sequencer or the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer.

Calibration can be performed using three basic calibration methods. The methods available to you for use depend on the configuration of your system. The paragraphs that follow describe how to perform a calibration for three basic system configurations shown in Figure 4-5.

Included in the calibration procedures are instructions for setting up the calibration parameters. Setup of the calibration parameters should be performed before the first O2 calibration. Thereafter, perform calibration setup only as needed to change the calibration parameters or to reset the parameters following the replacement of primary system components.

alarm provides notice of when a calibration

Figure 4-5. Calibration Methods, Simplified

O2 Calibration with Xi

Before calibrating verify that the configuration gas parameters are correct. Refer to Section 3: Configuration of Xi Electronics.

For systems with configuration 1, shown in Figure 4-5, use the following procedure to perform a calibration using the Xi. If necessary, use the Xi menu tree in Figure 4-2 for reference.

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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 to select the menu item. To return to a preceding menu press the left arrow key.

1. From the Main Menu, select SYSTEM, to access the Xi System menu.

2. From the Xi SYSTEM menu, scroll down and select DETAILED SETUP.

3. Select menu item 4, CAL SETUP, to input the cal gas and flow times.

4. Return to the SYSTEM menu and select the last menu item, CALIBRATION, to access the CALIBRATION menu.

5. From the O2 CALIBRATION options, select Start Cal to start the O2 calibration procedure.

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

O2 Calibration with Xi and Field Communicator

6. In the first Start Cal screen, a "Loop should be removed from automatic control" warning appears. Remove the Xi from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

7. Follow the Xi display prompts to perform the O2 cal procedure.

For systems with configuration 2, shown in Figure 4-5, use the following procedure to perform a calibration of the system using the 375/475 Field Communicator. If necessary use the menu tree in Figure 4-4 for reference.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number. To return to a preceding menu, press the left arrow key.

1. Select DEVICE SETUP.

2. From the DEVICE SETUP screen select menu item 4, DETAILED SETUP.

3. Select menu item 3, CAL SETUP, to input the cal gas and gas flow times.

4. Return to the DEVICE SETUP screen and select menu item 2, DIAG/SERVICE.

5. From the DIAG/SERVICE screen, select menu item 3, CALIBRATION, to access the O2 CALIBRATION screen.

6. From the O2 CALIBRATION screen, select menu item 1, O2 CAL, to access the O2 calibration procedure.

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

7. In the first O2 CAL screen, a "Loop should be removed from automatic

8. Follow the handheld 375/475 Field Communicator display prompts to

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control" warning appears. Remove the Xi from any automatic control loop to avoid a potentially dangerous operating condition and press OK.

perform the O2 cal procedure.

D/A TRIM

Figure 4-6. D/A Trim Methods, Simplified

The D/A trim procedure is used to calibrate the 4-20 mA output signal to a precision mA measurement device.

The two paragraphs that follow describe how to perform a D/A trim for two of the three basic system configurations shown in Figure 4-10. Only the signal to the DCS needs to be trimmed.

D/A Trim with Xi

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For systems with configuration 1, shown in Figure 4-6, use the handheld 375/475 Field Communicator to access the D/A trim procedure according to the instructions that follow. Refer to the 375/475 Field Communicator Xi Menu Tree in Figure 4-2.

1. From the DEVICE SETUP screen select menu item 2, DIAG/SERVICE, to access the diagnostics and service menu options.

2. Select menu item 3, CALIBRATION, to access the calibration menu options.

3. Select menu item 3, 4-20 mA SIG, to access the 4-20 mA SIGNAL screen.

4. Select menu item 1, D/A Trim, to start the trim procedure.

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Section 5 Troubleshooting

Overview of Operating Principles . . . . . . . . . . . . . . . . . . .page 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-2

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-2

Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-3

Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . .page 5-3

Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-3

Identifying and Correcting Fault Indications . . . . . . . . . . page 5-3

Calibration Passes, but Still Reads Incorrectly . . . . . . . . page 5-4

Probe Passes Calibration, O Probe Passes Calibration, O

How do I detect a plugged diffuser? . . . . . . . . . . . . . . . . .page 5-6

Can I calibrate a badly plugged diffuser? . . . . . . . . . . . . page 5-6

Still Reads High . . . . . . . .page 5-5

Still Reads Low . . . . . . . . page 5-6

OVERVIEW OF OPERATING PRINCIPLES

When the Zirconium Oxide sensing cell is heated to its setpoint [736°C

°F)], the cell will generate a voltage that represents the difference

(1357 between the process O

instrument air).

When flowing calibration gases, the raw cell millivolt value should represent the levels on the chart in Figure 5-1. Note that the raw cell millivolt value increases logrithmically as the O

% and the reference O2% inside the probe (20.95%

concentration decreases.

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Figure 5-1. O2 Sensor mV Reading vs %O2 at 736°C (1357°F) (Reference Air, 20.95% O2)

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GENERAL

Grounding

5-2

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.

Consider the following equipment conditions, features, and requirements when troubleshooting a problem.

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.

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Electrical Noise

Electrostatic Discharge

ALARM INDICATIONS

The Xi has been designed to operate in the type of environment normally found in a boiler room or control room. Noise suppression circuits are employed on all field terminations and main inputs. When fault finding, evaluate the electrical noise being generated in the immediate circuitry of a faulty system. Ensure all cable shields are connected to earth.

Electrostatic discharge can damage the ICs used in the electronics. Before removing or handling the circuit boards, ensure you are at ground potential.

The first indication of a problem at the O2 measuring system usually comes from the operators running the process. Critical alarms that render the O2 measurement unusable will force the 4-20 mA analog output signal representing O2 to go to a default condition, as follows:

4-20 mA Signal Alarm Level

0 mA Transmitter unpowered, or completely failed

3.5 mA Critical Alarm - transmitter reading unusable (factory default)

3.8 mA 4 to 20 mA Normal Operation

20.5 mA Reading Over Range (Example - range is 0-10%. Current reading is 12%) >21 mA

Transmitter Condition

Reading Under Range (Example - user sets range to 2-10%. Current reading is 1.9%)

Critical Alarm - transmitter reading is unusable (user can choose this alarm level instead of the factory default level of 3.5 to 3.6 mA)

IDENTIFYING AND CORRECTING FAULT INDICATIONS

NOTE

To ensure correct operation you should make sure that the Digital Control System is configured to interpret these signal levels correctly.

Once an alarm condition is identified, the Xi offers a number of diagnostics to interpret the specific alarm.

Alarm indications are available via the Xi or the 375/475 Field Communicator and Rosemount Analytical's Asset Management software. When the error is corrected and/or power is cycled, the diagnostic alarms will clear or the next error on the priority list will appear.

There are two types of alarms; recoverable and non recoverable. If an existing alarm is recoverable, the alarm-active indication will disappear when the alarm condition no longer exists. If an alarm is not recoverable, the alarm indication will continue to be displayed after the cause of the alarm condition is corrected. AC power to the Xi must be cycled to clear a non-recoverable alarm.

Alarm messages are displayed on the Xi display window when the alarm status display is accessed via the Xi menu. A listing of the alarm/fault messages and the related fault status descriptions are shown in Table 5-1.

Fault conditions that give no fault indication and that allow the probe to pass calibration are listed and discussed after Table 5-1.

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Table 5-1. Diagnostic/Unit Alarm Fault Definitions

Message Status Self Clearing

NV Mem Fail A checksum error was detected in the nonvolatile memory configuration data when the unit was

turned on.

Factory Mode On Xi box I/O board, SW4, position 1 is set on "ON". On transmitter electronics board, SW1,

position 1 is set to "ON". This setting should only be used in the factory.

Board Temp Hi The transmitter electronic board temperature reading is above 126°C or the

Xi unit I/O board temperature reading is above 86°C.

O2 Htr Ramp Rate The O2 sensor heater ramp rate is greater than max allowed ramp rate indicating a run away

heater condition.

O2 Sensor Open The cell impedance voltage is reading less than -1.1 VDC indicating the O2 sensor wires may be

disconnected or the O2 sensor junction may be open.

O2 TC Open The O2 cell heater thermocouple voltage is reading more than the hardware configured threshold

voltage. This indicates the thermocouple wires may be disconnected or the thermocouple junction may be open.

O2 Temp Low The heater temperature is below the minimum temperature. The predefined low temperature

threshold is the 726°C.

O2 Temp High The heater temperature is above the defined temperature threshold. The high temperature

threshold is the defined by the "High Temp Alm SP" parameter. The default value is 750°C. O2 T/C Shorted The O2 sensor heater temperature thermocouple voltage is shorted. Yes O2 T/C Reversed The O2 sensor heater temperature thermocouple voltage is reading a negative voltage indicating

the thermocouple wire connections may be reversed. O2 Htr Failure The O2 sensor heater temperature is not responding to the controller and can't reach final

temperature set by the device, indicating the O2 heater may have failed. No Flame The Flame Status Relay Input is set to the OFF state indicating it is not safe to operate the O2

heater and the heater should be turned off. Xmtr Disconnect Communication failures detected between transmitter and the I/O board indicating the transmitter

has been disconnected from the I/O board. Cal Recommended Probe calibration is recommended. The cell impedance is above 100 ohms and has shifted 50

ohms since the last calibration; the accuracy of the O2 reading may be compromised. Cal Failed A calibration error occurred during the last calibration. The measured slope or constant is outside

the acceptable range. (Slope: 34.5 to 57.5 mv/decade) (Constant: ±20 mv) Cell Imp High The O2 sensor impedance/cell resistance value measurement is greater than 2000 Ohms

indicates the cell may be beyond its useful life. CPU Voltage Low The CPU voltage is less than 2.7 V indicating the CPU voltage is too low. Yes CPU Voltage High The CPU voltage is more than 3.3 V indicating the CPU voltage is too high. Yes Htr Voltage Low The heater voltage for the O2 cell heater is below 35 volts. Yes Htr Voltage High The heater voltage for the O2 cell heater is above 264 volts. Yes Low O2 The O2 reading is below the "Low O2 Alm SP". Yes

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Yes

CALIBRATION PASSES, BUT STILL READS INCORRECTLY

5-4

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

An incorrect flow rate of calibration gases can cause a shifted calibration. If the flow rate of calibration gases is too low, process gases can mix in with the calibration gases causing a mixture at the cell that is different than what is noted on the calibration gas bottles. Always set the calibration flow rate when a new diffuser is installed, and never readjust this flow rate until another new diffuser is installed. For applications with heavy particulate loading, see "Probe Passes Calibration, But O2 Still Appears To Read Low".

No or improper reference air supplied.

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Probe Passes Calibration, O2 Still Reads High

Figure 5-2. Probe Leakage Paths

External Reference Air Leak - There may be a leak that is permitting ambient air to mix with the process gases. Since many combustion processes are slightly negative in pressure, ambient air can be drawn into the cell area, biasing the O2 reading upward.

1. Make sure that the calibration gas line is capped tightly between calibrations.

2. If autocal is used, make sure the check valve is seating properly.

Internal Reference Air Leak - See Figure 5-2. There may be a leak inside the O2 Probe itself, permitting the reference air (20.95% O2) to mix with the process gases at the cell. To confirm this leak condition, pressurize the inside (reference side) of the probe by plugging the reference air exhaust port with your finger for 1 minute. (The conduit ports where the signal and power wires pass may also need to be sealed.) The O2 reading should decrease slightly. If the O2 reading increases during this test there is a leak inside the probe.

1. Acid condensation inside the probe can degrade the hose that carries the cal gas to the cell. Inspect this hose. Dislodging or improper installation of the cal gas or reference air hose can cause a leakage path.

2. The sensing cell is fastened to the end of the probe tube and uses a corrugated washer to separate the process gases from the ambient reference air. The corrugated washer may be damaged by corrosion. Discard used washer.

NOTE

You should aways install a new corrugated washer whenever you remove the sensing cell from the probe.

Bad Reference Side Cell Electrode - A bad reference side cell electrode can cause an elevated O2 reading.This fault is usually indicated by a frequent "Calibration Recommended" alarm and increasing cell impedance readings. A high cell impedance can be calibrated out, but if the impedance continues to increase rapidly, the sensing cell must be replaced.

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November 2010

Probe Passes Calibration, O

Still

Reads Low

How do I detect a plugged diffuser?

Can I calibrate a badly plugged diffuser?

The diffusion element at the end of the probe is a passive filter. It plugs very slowly, since there is no active flow being drawn across it. In applications that have a heavy particulate loading (coal or wood fired boilers, cement and lime kilns, catalyst regeneration, recovery boilers, etc.), this diffusion element will eventually plug.

NOTE

It is important not to pressurize the sensing cell during calibrations by flowing excessive cal gas against a plugged diffuser. Always use a two-stage regulator for setting calibration gas pressure. Calibration flow rates should be set only when a new diffuser is installed. As the diffuser plugs, do not adjust the flow rates upward.

The O2 cell's speed of response will degrade. The O2 trend in the control room will become smoother.

When calibrating, the calibration gas flow rate will be noted to be lower. Never readjust this flow upwards to correct for a plugged diffuser. Adjust this flow only when a new diffuser is installed.

Always note the time it takes for the cell to recover to the normal process value after the cal gas is removed. As the diffuser plugs, this recovery time will get longer and longer. Use the Calibration Record provided to record and track Calibration Response times.

It may not be possible to immediately replace a plugged diffuser while the process is on line.

One can calibrate the probe without pressurizing the cell by adjusting the calibration gas flow rate downward before calibration. For instance, say the process is at 3%, and the first calibration gas is 8%. Adjust the flow of cal gas downward until the reading begins to migrate from 8% to lower values, indicating that process gases are now mixing in with the calibration gases.

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Adjust the flow rate back up until this mixing is just eliminated. Calibrate at this flow rate. Replace the diffuser at the first opportunity.

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

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IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Calibration Record

For

Rosemount Analytical In Situ O2 Probe

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

Date Slope Constant Impedance Response

initial

Response

final

Notes: Response

Response

When the second calibration gas is turned off, note the number of seconds required for the O2 value to begin migrating

initial

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

final

process value.

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Xi Advanced Electronics

Section 6 Maintenance and Service

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-2

Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-2

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-2

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-2

Xi Components Replacement . . . . . . . . . . . . . . . . . . . . . .page 6-3

I/O Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6-4

AC Relay Board Replacement . . . . . . . . . . . . . . . . . . . . . .page 6-8

Power Supply Board Replacement . . . . . . . . . . . . . . . . . .page 6-11

Xi Front Panel Replacement . . . . . . . . . . . . . . . . . . . . . . .page 6-12

DR Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6-14

OVERVIEW

MAINTENANCE INTERVALS

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

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.

The maintenance interval required is quite variable, depending on the type of service the analyzer is placed into. The zirconium oxide sensing cell is non-depleting, and has no specific shelf life or a defined life in flue gas operation. The cell of a probe that is mounted inside a boiler that is burning natural gas may shift very little over several years. Acidic compounds are the main aggressors to the sensing cell, typically SO2 resulting from sulfur contained in coal and heavy oil fuels, and also HCl from the combustion of plastics in municipal incinerators and in industrial thermal oxidizers. Sensing cells may experience significant degradation and signal shift in this type of service, particularly if the operating levels of O2 are very low (below 1% O2).

A calibration check is generally recommended on a quarterly basis (every 3 months) by flowing bottled gas to the probe. (Make sure that the operations personnel are notified when doing this, and also make sure that the O2 control loop is placed in manual mode). If the probe readings vary significantly from the bottle values, then a formal calibration should be conducted as noted in Section 4: Startup and Operation.

http://www.raihome.com

The Xi offers a "calibration recommended" diagnostic that will indicate when the probe needs to be calibrated.

Xi Advanced Electronics

Combustion processes that have a high level of ash or other particulate content will cause the diffusion element on the end of the probe to plug off. A badly plugged diffuser will cause a slower speed of response to changing O levels in the process. This can usually be seen on the recorded trends in the control room.

When performing a calibration check or actual calibration, the calibration flow meter may read lower if the diffuser is badly plugged. (Never increase the flow rate back up, however, as this can cause a shifted calibration. Adjust the calibration flow rate only when a new diffuser is installed). Always record the response time back to the process after the calibration gases are removed, as noted on the calibration record at the end of this section. Diffuser pluggage can be tracked through this record.

A visual inspection of the probe should be conducted during plant outages, paying particular attention to condensed components. Condensation can be reduced or eliminated by insulating the probe installation, including the probe mount, flange, and dual blue housings.

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November 2010

CALIBRATION The Xi can calibrate an O

via a handheld 375/475 Field Communicator, or automatically through the SPS 4001B Single Probe Autocalibration Sequencer or the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer.

Probe manually through the front panel display or

Automatic Calibration The Xi can be used with the SPS 4001B or IMPS 4000 in order to perform an

auto / semi-auto calibration. Manual for further details on how to configure and perform an automatic calibration.

Refer to the SPS 4001B or IMPS 4000 Instruction

Manual Calibration Refer to the "Calibration - General" in Section 4: Startup and Operation to

perform a manual calibration.

REPLACEMENT PARTS Refer to Section 7: Replacement Parts for individual replacement parts and

part replacement kits. Part replacement kits are available for each of the components discussed in this section.

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Xi Advanced Electronics

Xi COMPONENTS REPLACEMENT

Figure 6-1. Xi Components

Each of the following procedures details how to replace a specific component of the Xi. Most of these procedures include component setup instructions that must be performed before returning the related O2 Probe to service. Refer to Figure 6-1 and Figure 6-2 for illustrations of the Xi components.

Component replacement kits are available for each of the components replaced in this repair section. Refer to Section 7: Replacement Parts for kit part numbers.

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Figure 6-2. Xi Front Panel Components

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

I/O Board Replacement

Use the procedure that follows to replace and set up the I/O board in the Xi.

Disconnect and lock out power before working on any electrical components.

If the existing I/O Board has been operated with the Stoichiometric enhanced software feature, this feature must be activated in the new board before the Xi Electronics is put back into service. Failure to do so will cause a false analog output signal to the DCS.

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IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Replacing an Existing I/O Board

1. Loosen the four screws securing the Xi cover. The screws are captive and do not need to be completely removed.

2. Swing the Xi cover down to expose the inner components.

3. Disconnect the 10-pin ribbon cable from the I/O Board. A new cable is supplied in the replacement kit and should be used if the old one is damaged.

4. Tag and disconnect wiring for Alarm Outputs, Flame Status Input and/or SPS/IMPS as applicable.

5. Slide the I/O Board part way out of the Xi enclosure.

6. Disconnect the 4-position plug for the transmitter probe and output wiring. Remove the I/O Board completely from the Xi enclosure.

7. See Figure 6-3. Set jumpers JP1, JP2, JP5, JP7 and JP8 to their proper positions using the old I/O Board as a guide.

8. Set switch SW4 to their proper positions using the old I/O Board as a guide.

9. Partially slide the new I/O Board into the Xi enclosure. Ensure the board is correctly aligned within the slots in the enclosure.

10. Connect the 4-position plug for the transmitter probe and output wiring. Slide the I/O Board completely into the Xi enclosure.

Figure 6-3. I/O Board Jumper & Switch Settings

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11. Reinstall wiring for Alarm Outputs, Flame Status Input and/or SPS/IMPS

12. Connect the ribbon cable to the I/O Board. A new cable is supplied and

13. Swing the Xi cover up in place and tighten the four screws.

14. Prior to operating the O2 Probe and the Xi, all optional software

Part Number Software Option

6A00269G01 Enhanced Software Option Upgrade, Stoichiometric Function 6A00269G02 Enhanced Software Option Upgrade, Programmable Reference Function 6A00269G03 Enhanced Software Option Upgrade, 850°C Process Function

NOTE

For enhanced software upgrades or to enable optional software features previously used in your Xi configuration, contact Rosemount Analytical Inc. at 1-800-433-6076.

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

as applicable. See Figure 6-4 and Figure 6-5 for wiring diagrams. See Figure 6-6 for I/O board positions in the Xi enclosure.

should be used if the old one is damaged.

enhancements (previously enabled or not) must be enabled. Notify Rosemount Analytical Inc. and reference the following part numbers to enable the related software options:

15. Recalibrate the O2 Probe according to the applicable calibration

Figure 6-4. I/O Board Wiring Connections

instructions in Section 4: Startup and Operation.

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IM-106-910Xi, Original Issue November 2010

Figure 6-5. I/O Board Flame Safety Interlock Wiring

Xi Advanced Electronics

Figure 6-6. I/O Board Positions in the Xi Enclosure

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Instruction Manual

IM-106-910Xi, Original Issue

November 2010

AC Relay Board Replacement

Use the procedure that follows to replace and set up the AC Relay board in the Xi.

Disconnect and lock out power before working on any electrical components.

Replacing an Existing AC ReIay Board

1. Loosen the four screws securing the Xi cover. The screws are captive and do not need to be completely removed.

2. Swing the Xi cover down to expose the inner components.

3. Tag and disconnect wiring for the Relay In.

4. Slide the AC Relay Board part way out of the Xi enclosure.

5. Tag and disconnect the two 3-position plugs for the AC input and transmitter probe heater wiring. Remove the AC Relay Board completely from the Xi enclosure.

6. Partially slide the new AC Relay Board into the Xi enclosure. Ensure the board is correctly aligned within the slots in the enclosure.

7. Connect the two 3-position plugs for the AC input and transmitter probe heater wiring. Slide the AC Relay Board fully into the Xi enclosure.

Figure 6-7. I/O & AC Relay Board Flame Safety Interlock Wiring

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8. Reinstall wiring for Relay In. See Figure 6-7 for wiring diagram.

9. Swing the cover up in place and tighten the four screws.

Installing and configuring an AC Relay Board for the Flame Status Interlock function will dedicate alarm output 2 for this function. Once configured for Flame Status Interlock, the software will override any previous alarm assignments for alarm output 2 and not allow it to be used for any other function.

Adding an AC Relay Board to the Xi

1. Loosen the four screws securing the Xi cover. The screws are captive and do not need to be completely removed.

2. Swing the Xi cover down to expose the inner components.

3. Slide the I/O Board part way out of the Xi enclosure.

4. Make the following jumper and switch settings: a. Set SW4, Position 4 "ON" and all other positions "OFF". b. Move the jumpers for both JP1 and JP2 to pins 1 and 2.

5. The I/O Board must be relocated to the right-most slot inside the Xi enclosure. If there is enough service loop on the existing wiring, slide the I/O Board completely out of the enclosure and re-install it in the right-most slot. Ensure the board is correctly aligned within the slots. See Figure 6-8 for the correct location of the I/O Board.

NOTES

An AC Relay Board can only be added to single channel Xi, i.e. only one I/O Board controlling one O2 Probe.

The Flame Status Interlock function requires a contact closure on the digital input of the I/O Board to indicate a flame is present. When properly connected and configured, AC power will be applied to the transmitter only when the flame is present.

6. If there is not sufficient wiring, tag and disconnect all wiring, and relocate the board. Then reinstall the wiring.

7. Partially slide the AC Relay Board into the left-most slot of the Xi enclosure. The component side of the AC Relay board will be to the right with the fuse holder at the top. Ensure the board is correctly aligned within the slots in the enclosure. See Figure 6-8 for the correct location of the AC Relay Board.

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8. Connect two wires approximately 6" long each between the "HTR COM"

9. Connect the flame status indicator contact to the "DI+" and "DI-" on the

10. Connect the AC input and output wiring to the Transmitter. See

11. Slide the AC Relay Board completely into the Xi enclosure.

12. Swing the cover up in place and tighten the four screws.

Figure 6-8. I/O and AC Relay Board Position in Xi Enclosure

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

and the "HTR NC" connections on the I/O Board and the "RELAY IN" connections on the AC Relay Board; observe polarity. See Figure 6-7 for wiring details.

AC Relay Board. See Figure 6-7 for wiring details.

Figure 6-7 for wiring details.

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IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Power Supply Board Replacement

Use the procedure that follows to replace the Power Supply board in the Xi. Use this procedure to replace an original Linear Power Supply board or the current configuration Switching Power Supply board.

Disconnect and lock out power before working on any electrical components.

1. Loosen the four screws securing the Xi cover. The screws are captive and do not need to be completely removed.

2. Swing the Xi cover down to expose the inner components.

3. Refer to the wiring diagram in Figure 6-9. Unplug the AC input wiring plug from the Power Supply board. A new plug is supplied in the replacement kit and should be used if the existing plug is damaged.

4. Disconnect the 14-pin ribbon cable from the Power Supply board.

5. Remove the two long screws that secure the bracket (9, Figure 6-1) to the Xi enclosure.

6. Hold the AC input wiring to the right and slide the Power Supply board out of the Xi enclosure.

7. Install the new mounting bracket (9, Figure 6-1) on the new Power Supply board (10, Figure 6-1). A new bracket and mounting screws are provided in the replacement kit.

8. Slide the Power Supply board into the mating slots in the Xi Enclosure. Make sure the board is correctly aligned in the slots.

9. Install and tighten the bracket mounting screws. Two new screws are provided in the replacement kit and should be used if the existing screws are damaged.

Figure 6-9. Power Supply Board Wiring

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Xi Advanced Electronics

10. Connect the ribbon cable to the Power Supply board. A new ribbon

11. Connect the AC power plug to the Power Supply board.

12. Swing the Xi cover up and tighten the four mounting screws.

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IM-106-910Xi, Original Issue

November 2010

cable (7, Figure 6-1) is provided in the replacement kit and should be used if the existing cable is damaged.

Xi Front Panel Replacement

Use the procedure that follows to replace the front panel on the Xi. Replacement kits with and without the CPU board are available. Use the instructions that apply to the replacement kit you have.

Disconnect and lock out power before working on any electrical components.

Replacing Front Panel Assembly without CPU Board

1. Loosen the four screws securing the Xi cover. The screws are captive and do not need to be completely removed.

2. Swing the Xi cover down to expose the inner components.

3. Disconnect the 14-pin ribbon cable going to the Power Supply board. A new cable is supplied in the replacement kit and should be used if the old one is damaged.

4. Disconnect the 10-pin ribbon cable(s) going to the I/O Board(s). One new cable is supplied in the replacement kit and should be used if either of the ribbon cables are damaged.

5. Remove the wire hinge from the right side of the Xi cover. A paper clip or similar device can be inserted into the hole on the left side of the cover to push the hinge out of the cover. A new hinge pin is supplied in the replacement kit and should be used if the old one is damaged.

6. Position the new front panel assembly in place and reinstall the hinge pin. Ensure the hinge pin is fully seated into the Xi cover.

6-12

The new front panel assembly may be supplied with protective clear membranes over the interior and exterior of the window. Failure to remove the exterior protective membrane may cause the display to appear distorted. The membrane may be difficult or impossible to remove after extended use at elevated temperatures.

7. The keypad window on the new front panel may be supplied with interior and exterior protective membranes. Remove the protective membranes prior to final assembly and use of the Xi enclosure.

8. Reconnect the 10-pin ribbon cable from the I/O Board.

9. Reconnect the 14-pin ribbon cable from the Power Supply Board.

10. Swing the Xi cover up in place and tighten the four screws.

11. If necessary, reconfigure the appearance of the main display. Refer to Section 3: Configuration of Xi Electronics.

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IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Replacing Front Panel Assembly without CPU Board

1. Loosen the four screws securing the Xi cover. The screws are captive and do not need to be completely removed.

2. Swing the Xi cover down to expose the inner components.

3. Disconnect the 14-pin ribbon cable going to the Power Supply board. A new cable is supplied in the replacement kit and should be used if the old one is damaged.

4. Disconnect the 10-pin ribbon cable(s) going to the I/O Board(s). One new cable is supplied in the replacement kit and should be used if either of the ribbon cables are damaged.

6. Place the front panel assembly on the bench. Remove the 4 screws securing the CPU board to the front cover.

NOTE

Prior to disassembly, observe the position of the plastic bumper with rubber insert as it is installed over the CPU board. The two longer screws are used on the top edge of the CPU board passing through the bumper.

7. Lift the CPU board off of the front cover using care not to damage the board.

8. Disconnect the keypad overlay ribbon cable from the CPU board. Discard the used front cover with the keypad overlay attached.

9. The keypad window on the new front panel may be supplied with interior and exterior protective membranes. Remove the protective membranes prior to final assembly and use of the Xi enclosure.

NOTE

Prior to assembly, it is recommended that the inside of the keypad overlay window and LCD display window be gently cleaned to remove fingerprints and accumulated dust.

10. Clean the inside of the keypad overlay window and LCD display window to remove fingerprints and accumulated dust. Use only a soft cloth; do not use any detergents or chemicals.

11. Connect the keypad overlay ribbon cable on the new front panel assembly to the CPU board. Use care not to damage the board.

12. Position the CPU board in place in the front panel assembly.

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Xi Advanced Electronics

13. Reinstall the bumper and 4 screws to secure the CPU board in place.

14. Position the front panel assembly and reinstall the hinge pin. Ensure the

15. Reconnect the 10-pin ribbon cable from the I/O Board.

16. Reconnect the 14-pin ribbon cable from the Power Supply Board.

17. Swing the Xi cover up in place and tighten the four screws.

18. If necessary, reconfigure the appearance of the main display. Refer to

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

The two longer screws are used with the plastic bumper on the top edge of the CPU board.

hinge pin is fully seated into the Xi cover.

Section 3: Configuration of Xi Electronics.

DR Board Replacement

Use the procedure that follows to replace the DR board in the Xi that is connected to a Direct Replacement probe.

Disconnect and lock out power before working on any electrical components.

1. Loosen the four screws securing the Xi cover. The screws are captive and do not need to be completely removed.

2. Swing the Xi cover down to expose the inner components.

3. Slide the DR board part way out of the Xi enclosure.

4. Unplug the wiring harness plug from the connector J8 located on the bottom, left-hand side of the board. Refer to Figure 6-10.

5. Unplug the wiring harness plugs from the connectors J1, J2, and J3 located on the top, right-hand side of the board. Refer to Figure 6-11.

6. Tag and disconnect the wiring to connector J4.

7. Remove the DR board from the Xi enclosure.

8. Partially slide the new DR board into the mating slots in the Xi Enclosure. Make sure the board is correctly aligned in the slots.

9. Refer to the wiring diagram in Figure 6-10. Reconnect the wiring to connector J4.

10. Connect the wiring harness plugs to connectors J1, J2, J3, and J8.

11. Slide the DR board completely into the Xi enclosure.

12. Swing the Xi cover up and tighten the four mounting screws.

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Figure 6-10. DR Board Wiring, Right-Hand Side

Xi Advanced Electronics

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Figure 6-11. DR Board Wiring, Left-Hand Side

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November 2010

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Section 7 Replacement Parts

Xi Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7-1

Calibration Components . . . . . . . . . . . . . . . . . . . . . . . . . .page 7-2

Xi Electronics

Table 7-1. Replacement Parts for Xi

Part Number Description

6A00265G01 Kit, Power Supply Board (Obsolete - Replaced by 6A00329G01) 6A00329G01 Kit, Switching Power Supply Board 6A00266G01 Kit, I/O Board* 6A00267G01 Kit, AC Relay Board 6A00328G01 Kit, DR Board 6A00268G01 Kit, Front Panel with Overlay & CPU Board 6A00268G02 Kit, Front Panel with Overlay 6A00269G01 Enhanced Software Option Upgrade, Stoichiometric Function 6A00269G02 Enhanced Software Option Upgrade, Programmable Reference Function 6A00269G03 Enhanced Software Option Upgrade, 800°C Process Function 6A00237H24 Kit, Pipe & Wall Mount 6A00237H33 Kit, Panel Mount 6A00243G01 Ribbon Cable, 10 Pin (CPU Board to I/O Board) 6A00242G01 Ribbon Cable, 14 Pin (CPU Board to Power Supply Board) 6A00291H01 Insulator 6A00381G01 Kit, Hole Plug & Gland 6A00285H01 Gasket, Panel 6A00287H01 Gasket, Cover

Note:

If the existing I/O Board has been operated with the Stoichiometric enhanced software feature, this feature must be activated in the new board before the Xi is put back into service. Failure to do so will cause a false analog output signal to the DCS.

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Xi Advanced Electronics

Calibration Components

Table 7-2. Replacement Parts for Calibration Components

Part Number Description

1A99119G01 Calibration Gas Bottles - 0.4% and 8% O2, balance

1A99119G02 Two Flow Regulators (for calibration gas bottles) 1A99119G03 Bottle rack

*Note:

Calibration gas bottles cannot be shipped via airfreight

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

nitrogen - 550 liters each*

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Instruction Manual

HART Communicator

MAN4275A00

English

38890059

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Section 8 Optional Accessories

HART Handheld 375/475 Field Communicator . . . . . . . . . page 8-1

Asset Management Solutions (AMS) . . . . . . . . . . . . . . . . page 8-2

By-Pass Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 8-2

SPS 4001B Single Probe Autocalibration Sequencer . . . page 8-3 IMPS 4000 Intelligent Multiprobe Test Gas Sequencer . .page 8-4

O2 Calibration Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 8-5

OxyBalance Display and Averaging System . . . . . . . . . . page 8-6

HART HANDHELD 375/475 FIELD COMMUNICATOR

Figure 8-1. 375/475 Field Communicator

http://www.raihome.com

The 375/475 Field Communicator is an interface device that provides a common communication link to HART-compatible instruments, such as the Xi. HART Communications Protocol permits all the information available from the Xi's electronics to be transmitted over standard 4-20 mA signal wires. By attaching the 375/475 Field Communicator at a termination point along the 4-20 mA signal line, a technician can diagnose problems and configure and calibrate the Xi as if he or she were standing in front of the instrument.

For more information, call Rosemount Analytical Inc. at 1-800-433-6076.

Xi Advanced Electronics

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

ASSET MANAGEMENT SOLUTIONS (AMS)

BY-PASS PACKAGES

Asset Management Solutions (AMS) software works in conjunction with the HART Communication Protocol and offers the capability to communicate with all HART plant devices from a single computer terminal.

For more information, call Rosemount Analytical Inc. at 1-800-433-6076.

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

For more information, call Rosemount Analytical Inc. at 1-800-433-6076.

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IM-106-910Xi, Original Issue November 2010

SPS 4001B SINGLE PROBE AUTOCALIBRATION SEQUENCER

Figure 8-2. SPS 4001B

Xi Advanced Electronics

Rosemount Analytical Inc. specifically designed the SPS 4001B Single Probe Autocalibration Sequencer to provide the capability to perform automatic or on-demand calibrations. The SPS 4001B is fully enclosed in a NEMA cabinet suited for wall-mounting. This cabinet provides added protection against dust and minor impacts.

The SPS 4001B works in conjunction with the Xi, eliminating out-of-calibration occurrences and the need to send a technician to the installation site.

For more information, call Rosemount Analytical Inc. at 1-800-433-6076.

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38890096

IMPS 4000 INTELLIGENT MULTIPROBE TEST GAS SEQUENCER

Figure 8-3. IMPS 4000

The IMPS 4000 Intelligent Multiprobe Test Gas Sequencer is housed within an IP56 (NEMA 4X) enclosure and has the intelligence to provide calibration gas sequencing of up to four Xi’s to accommodate automatic and semi-automatic calibration routines.

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IM-106-910Xi, Original Issue

November 2010

This sequencer works in conjunction with the CALIBRATION RECOMMENDED feature, eliminating out-of-calibration occurrences and the need to send a technician to the installation site. In addition, the IMPS 4000 provides a remote contact input to initiate a calibration from a remote location and relay outputs to alert when a calibration is in progress, an O2 Probe is out of calibration, calibration gases are on, and calibration gas pressure is low.

For more information, call Rosemount Analytical Inc. at 1-800-433-6076.

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38890098

IM-106-910Xi, Original Issue November 2010

O2 CALIBRATION GAS

Figure 8-4. Calibration Gas Bottles

Xi Advanced Electronics

Rosemount Analytical's O2 Calibration Gas and Service Kits have been carefully designed to provide a more convenient and fully portable means of testing, calibrating, and servicing.

Rosemount Analytical's oxygen analyzers. These lightweight, disposable gas cylinders eliminate the need to rent gas bottles.

For more information, call Rosemount Analytical Inc. at 1-800-433-6076.

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38890099

Analytical

OXYBALANCE DISPLAY AND AVERAGING SYSTEM

Figure 8-5. OxyBalance

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Optional OxyBalance Display and Averaging System. Reviews up to eight 4-20 mA signals from individual probes. Trends individual outputs, calculates four programmable averages as additional 4-20 mA outputs.

For more information, call Rosemount Analytical Inc. at 1-800-433-6076.

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Appendix A XPS Information

XPS Equipment Description . . . . . . . . . . . . . . . . . . . . . . .page A-1

Remote XPS for 44V Probes - 6A00358G01 . . . . . . . . . . .page A-1

Remote XPS for 115V Probes - 6A00358G03 . . . . . . . . . .page A-2

Integral XPS 6A00365G01 with Xi (for 44V Probes) . . . . .page A-3

Other XPS Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-10

Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . .page A-10

XPS EQUIPMENT DESCRIPTION

Remote XPS for 44V Probes - 6A00358G01

The XPS is primarily an interfacing electronics box installed between an

Probe and the Xi electronics. There are three variants of the XPS

electronics box, each with specific functions.

1. Remote XPS - 6A00358G01 for 44V Probes

2. Remote XPS - 6A00358G03 for 115V Probes

3. Integral XPS - 6A00365G01 for 44V Probes

This version of the XPS is for use with Westinghouse/Rosemount Analytical World Class probes that use a 44 volt heater, and when the O 120/240V, 50/60Hz power source. The 6A00358G01 version contains electronics to receive and process multiple raw signals from the probe.

Signal wires between the O following:

1. Thermocouple - 2 conductors (type K lead wire)

2. Sensing Cell - 2 conductors

3. Heater - 3 conductors

4. Shield

This version of the XPS provides for probe heater control and signal conditioning. The signal conditioning electronics result in a linear 4-20 mA

signal.

No operator interface is included. Thereby, the 4-20 mA signal typically goes to a Xi Advanced electronics unit. Alternately, a handheld HART 375/475 Field Communicator can be used as the operator interface. However, the Xi or the field communicator must be the dedicated communication device. The Xi and the field communicator cannot be used at the same time.

Probe and the G01 version XPS include the

Probe uses a

http://www.raihome.com

For heater control the G01 version of the XPS includes a transformer. The transformer converts 120/240V AC input power to the 44V AC heater voltage used in the Westinghouse/Rosemount Analytical World Class probe.

Xi Advanced Electronics

Figure A-1. Remote XPS 6A00358G01 and 6A00358G03 Mounting

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

Remote XPS for 115V Probes - 6A00358G03

A-2

The 6A00358G03 version of the XPS is similar to the 6A00358G01 described above except that it does not include the transformer. The 6A00358G03 version controls any Westinghouse/Rosemount Analytical O a 115V heater. Applicable probes include Models 218 and 218A, Oxymitter, X-STREAM, or Model 6888 probes.

probe that uses

Instruction Manual

IM-106-910Xi, Original Issue November 2010

Xi Advanced Electronics

Integral XPS 6A00365G01 with Xi (for 44V Probes)

Figure A-2. Integral XPS with Xi and 6A00365G01 Mounting

This XPS equipment configuration includes the XPS and a Xi Advanced Electronics unit installed on a common mounting plate. This configuration is intended to replace a World Class Intelligent Field Transmitter (IFT) where the required input line voltage is 120/240V AC, particularly for 240 VAC applications.

Other XPS Uses

Two XPS units can be wired to two O2 Probes and back to one dual-channel Xi. This avoids having to purchase a Xi for each probe and eliminates one of two signal cables that would otherwise be required to communicate between the Xi and XPS units.

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Xi Advanced Electronics

Figure A-3. Remote XPS 6A00358G01 Wiring Diagram (Sheet 1 of 2)

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Figure A-3. Remote XPS 6A00358G01 Wiring Diagram (Sheet 2 of 2)

Xi Advanced Electronics

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Xi Advanced Electronics

Figure A-4. Remote XPS 6A00358G03 Wiring Diagram (Sheet 1 of 2)

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

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Instruction Manual

IM-106-910Xi, Original Issue November 2010

Figure A-4. Remote XPS 6A00358G03 Wiring Diagram (Sheet 2 of 2)

Xi Advanced Electronics

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Xi Advanced Electronics

Figure A-5. Integral XPS 6A00365G01 Wiring Diagram (Sheet 1 of 2)

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

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Figure A-5. Integral XPS 6A00365G01 Wiring Diagram (Sheet 2 of 2)

Xi Advanced Electronics

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Xi Advanced Electronics

SPECIFICATIONS

Part Number Description

6A00358G01 for 44V Probes

6A00358G03 for 120V Probes

6A00365G01 for 44V Probes

General Purpose Certifications:

RECOMMENDED SPARE PARTS

Table A-1. Spare Parts

Part Number Description

1A99763H01 Kit, Replacement Enclosure Mounting Feet 6A00418G01 Kit, DR Board 6A00419G01 Kit, Toroid Transformer 6A00420G01 Kit, Fuses (Reference 3.15 A, 250V, Littlefuse P/N 218 3.15)

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

120/240V, 50/60 Hz, 140VA, -20°C to +55°C, 95% Relative Humidity, Type 4X, IP66

120/240V, 50/60 Hz, 776VA, -20°C to +55°C, 95% Relative Humidity, Type 4X, IP66

120/240V, 50/60 Hz, 140VA, -20°C to +55°C, 95% Relative Humidity, Type 4X, IP66

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Appendix B Safety Data

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B-2

Xi Advanced Electronics

http://www.raihome.com

Xi Advanced Electronics

SAFETY INSTRUCTIONS IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING

AND INSTALLATION OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external, where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment - and then only by trained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

11. Where equipment or labels are marked "Do Not Open While Energized" or similar, there is a danger of ignition in areas where an explosive atmosphere is present. This equipment should only be opened when power is removed and adequate time as specified on the label or in the instruction manual has been allowed for the equipment to cool down and then only by trained service personnel.

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IM-106-910Xi, Original Issue

November 2010

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Instruction Manual

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DŮLEŽITÉ

Bezpečnostní pokyny pro zapojení a instalaci zařízení Následující bezpečnostní pokyny se speciálně vztahují na všechny

členské státy EU. Pokyny by měly být přísně dodržovány, aby se zajistilo splnění Směrnice o nízkém napětí. Pokud nejsou pokyny nahrazeny místními či národními normami, měly by je dodržovat i nečlenské státy EU.

1. U všech zemnicích bodů, interních a externích, by mělo být vytvořeno odpovídající uzemnění.

2. Po instalaci nebo odstranění problémů musí být vyměněny všechny bezpečnostní kryty a uzemnění. Vždy musí být zajištěna integrita všech zemnicích svorek.

3. Sí˙ové kabely by měly odpovídat požadavkům normy IEC227 nebo IEC245.

4. Všechna zapojení by měla být vhodná pro použití při vnějších teplotách nad 75 °C.

5. Všechna použitá kabelová hrdla by měla mít takové vnitřní rozměry, aby zajistila odpovídající zakotvení kabelu.

6. Správnou činnost zařízení zajistíte, vytvoříte-li připojení k napájecímu zdroji pouze přes jistič, který v případě poruchy odpojí všechny obvody s konduktory. Jistič může také obsahovat mechanický odpojovač. Pokud ho neobsahuje, musí být zajištěn a jasně označen jiný způsob odpojení zařízení od zdroje. Jističe nebo přepínače musí odpovídat uznávaným normám, např. IEC947. Všechna zapojení musí odpovídat místním normám.

7. Je-li zařízení nebo kryt označen symbolem na pravé straně, pravděpodobně se uvnitř nachází nebezpečné napětí. Tyto kryty by měly být sejmuty pouze po odpojení zařízení od zdroje - a to pouze kvalifikovaným zaměstnancem.

8. Je-li zařízení nebo kryt označen symbolem na pravé straně, povrch zařízení může být velmi horký. Tyto kryty by měly být sejmuty pouze kvalifikovaným zaměstnancem po odpojení zařízení od zdroje. Některé povrchy mohou být stále horké.

9. Je-li zařízení nebo kryt označen symbolem na pravé straně, přečtěte si nejprve instrukce v návodu k obsluze.

10. Všechny grafické symboly používané u výrobku pocházejí z následujících norem: EN61010-1, IEC417 a ISO3864.

11. Pokud je zařízení nebo štítky označeno varováním „Je-li zařízení pod napětím, neotvírejte jej“ či podobným, může dojít ve výbušném prostředí ke vznícení. Zařízení lze otevřít pouze po jeho odpojení od zdroje a ponechání dostatečného času na vychladnutí, jak je uvedeno na štítku nebo v návodu k obsluze - a to pouze kvalifikovaným zaměstnancem.

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Xi Advanced Electronics

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr. Følgende sikkerhedsinstruktioner gælder specifikt i alle

EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bør også følges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og

2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og

3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.

4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur

5. Alle benyttede kabelforskruninger skal have en intern dimension, så

6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse

7. Hvor udstyr eller dæksler er mærket med dette symbol,

8. Hvor udstyr eller dæksler er mærket med dette symbol,

9. Hvor udstyr eller dæksler er mærket med dette symbol,

10. Alle benyttede grafiske symboler i dette udstyr findes i

11. Når udstyr eller etiketter er mærket "Må ikke åbnes, mens udstyret

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IM-106-910Xi, Original Issue

November 2010

VIGTIGT

eksterne, hvor disse forefindes.

jordforbindelser reetableres.

højere end 75°C.

passende kabelaflastning kan etableres.

mod indirekte berøring gennem afbryder (min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsitua-tion. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og mærkes som sådan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947.

er farlige spændinger normalt forekom-mende bagved. Disse dæksler bør kun afmonteres, når forsyningsspændingen er frakoblet - og da kun af instrueret servicepersonale.

forefindes meget varme overflader bagved. Disse dæksler bør kun afmonteres af instrueret servicepersonale, når forsyningsspænding er frakoblet. Visse overflader vil stadig være for varme at berøre i op til 45 minutter efter frakobling.

se da i betjeningsmanual for instruktion.

én eller flere af følgende standarder:- EN61010-1, IEC417 & ISO3864.

tilføres strøm” eller lignende, er der fare for antændelse i områder, hvor der er en eksplosiv atmosfære. Dette udstyr må kun åbnes, når strømkilden er fjernet, og der er gået tilstrækkelig tid til, at udstyret er kølet ned. Den nødvendige tid hertil er angivet på etiketten eller i brugervejledningen. Udstyret må kun åbnes af en faglært person.

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Emerson Process Management IM-106-910Xi User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual