Emerson Process Management IM-106-910Xi User Manual

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

O

2

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

O

2

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

O

2

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

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

2

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

2

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

O

2

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

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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

ii

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

2

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

2

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

2

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

2

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

iv

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: [phone]
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: [phone]-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: [e-mail]
World Wide Web: www.raihome.com

v

Xi Advanced Electronics

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November 2010

vi

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

2

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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

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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

2

1-3

Xi Advanced Electronics

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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

38890063

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

2

2

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)

2

2

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)

(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.

http://www.raihome.com

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.

2

2-2

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.

2-5

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.

2-6

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

2

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.

2-7

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

Instruction Manual

IM-106-910Xi, Original Issue

November 2010

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