GE Sensing XMO2 Operating Manual

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Measurement & Control Oxygen Analysis

XMO2-IDM

User’s Manual

910-141 Rev. F

October 2013

XMO2-IDM

Oxygen Analyzer

User’s Manual

910-141 Rev. F October 2013

ATTENTION! This manual should be used only for XMO2 units with the IDM User Program (Option D = 3 or 4).

For XMO2 units with the Terminal User Program (Option D = 1 or 2), manual number 910-141A must be used.

www.ge-mcs.com

Technical content subject to change without notice.

[no content intended for this page]

Preface

Information Paragraphs

Note: These paragraphs provide information that provides a deeper understanding of the situation, but is not

essential to the proper completion of the instructions.

IMPORTANT: These paragraphs provide information that emphasizes instructions that are essential to proper setup of

the equipment. Failure to follow these instructions carefully may cause unreliable performance.

CAUTION! This symbol indicates a risk of potential minor personal injury and/or severe

damage to the equipment, unless these instructions are followed carefully.

WARNING! This symbol indicates a risk of potential serious personal injury, unless these

instructions are followed carefully.

Safety Issues

WARNING! It is the responsibility of the user to make sure all local, county, state and national

codes, regulations, rules and laws related to safety and safe operating conditions are met for each installation.

Auxiliary Equipment

Local Safety Standards

The user must make sure that he operates all auxiliary equipment in accordance with local codes, standards, regulations, or laws applicable to safety.

Working Area

WARNING! Auxiliary equipment may have both manual and automatic modes of operation. As

equipment can move suddenly and without warning, do not enter the work cell of this equipment during automatic operation, and do not enter the work envelope of this equipment during manual operation. If you do, serious injury can result.

WARNING! Make sure that power to the auxiliary equipment is turned OFF and locked out

before you perform maintenance procedures on the equipment.

XMO2 User’s Manual iii

Preface

Auxiliary Equipment (cont.)

Qualification of Personnel

Make sure that all personnel have manufacturer-approved training applicable to the auxiliary equipment.

Personal Safety Equipment

Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment. Examples include safety glasses, protective headgear, safety shoes, etc.

Unauthorized Operation

Make sure that unauthorized personnel cannot gain access to the operation of the equipment.

Environmental Compliance

Waste Electrical and Electronic Equipment (WEEE) Directive

GE Measurement & Control Solutions is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE) take-back initiative, directive 2002/96/EC.

The equipment that you bought has required the extraction and use of natural resources for its production. It may contain hazardous substances that could impact health and the environment.

In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or recycle most of the materials of your end life equipment in a sound way.

The crossed-out wheeled bin symbol invites you to use those systems.

If you need more information on the collection, reuse and recycling systems, please contact your local or regional waste administration.

Visit http://www.ge-mcs.com/en/about-us/environmental-health-and-safety/1741-weee-req.html take-back instructions and more information about this initiative.

iv XMO2 User’s Manual

for

Contents

Chapter 1. Features and Capabilities

1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Basic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.4 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4.1 The XMO2 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.4.2 The Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.4.3 Long Cables (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.4.4 Power Supply (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.4.5 The TMO2D Display/Controller (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Chapter 2. Installation

2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.2 Installing the XMO2 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.3 Installing the Sample System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.3.1 A Basic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.3.1 Wiring the XMO2 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.3.2 CE Mark Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.3.3 Grounding the XMO2 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.3.4 Cable Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.3.5 Accessing Terminal Blocks TB1 and TB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.3.6 Wiring the Signal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.4 Establishing the RS232 Communication Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.5 Connecting to Other Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.5.1 The PS5R-C24 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.5.2 TMO2D Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.5.3 LDP Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.5.4 XDP Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.5.5 Moisture Image/Monitor Series Analyzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.5.6 System 1 Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Chapter 3. Startup & Operation

3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.2 Powering Up the XMO2 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.3 Establishing a Sample Gas Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.4 Analog Output Calibration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.5 Factory Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.6 Enhancing the Factory Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3.7 Required Calibration Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3.8 Preparing for Field Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3.9 One-Gas Pushbutton Field Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

XMO2 User’s Manual v

Contents

3.10 Two-Gas Pushbutton Field Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3.10.1 Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3.10.2 Zero Gas Pushbutton Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

3.10.3 Span Gas Pushbutton Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

3.11 IDM Digital Communication Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

3.12 The Edit Functions Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.13 The Field Cal Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

3.13.1 Perform Cal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

3.13.2 Configure Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

3.13.3 Calibration Drifts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

3.13.4 Clear Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

3.13.5 Hold Last Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.14 Changing the 4-20 mA Analog Output Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

3.14.1 4-20mA Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

3.14.2 4mA Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

3.14.3 20 mA Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

3.14.4 4-20mA Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

3.14.5 %O2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Chapter 4. Programming with Instrument Data Manager

4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

4.2 The Edit Functions Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.2.1 The Error Handler Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

4.2.2 Total Drift Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

4.2.3 All Other Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

4.3 The Factory Cal Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

4.3.1 Background Gas Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

4.3.2 Pressure Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

4.4 The Advanced Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.4.1 Fast Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.4.2 Language. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

4.4.3 Meter ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Chapter 5. Specifications

5.1 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

5.2 Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

5.3 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

5.4 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

5.5 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

5.6 Calibration Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

5.7 A Calibration Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

vi XMO2 User’s Manual

Contents

Appendix A. Two Typical Applications

A.1 Blanketing Gases in Hydrocarbon Liquid Storage Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

A.1.1 The Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

A.1.2 Equipment Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

A.1.3 Basic Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

A.1.4 Previous Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

A.2 Reactor Feed Gases in Formaldehyde Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

A.2.1 The Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

A.2.2 Equipment Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

A.2.3 Basic Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

A.2.4 Previous Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Appendix B. Outline and Installation Drawings

Appendix C. IDM Menu Maps

Appendix D. Programming with PanaView

D.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

D.2 Wiring the RS232 Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

D.3 Setting Up the Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

D.4 Adding the XMO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

D.5 Changing Meter Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Appendix E. CE Mark Compliance

E.1 CE Mark Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

E.2 EMI Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

E.3 Wiring the Signal Connections for the Weatherproof Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

E.4 Wiring the Signal Connections for the Explosion/Flameproof Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Appendix F. Certifications

F.1 EC-Type Examination Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

F.2 IECEx Certificate of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

XMO2 User’s Manual vii

Contents

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viii XMO2 User’s Manual

Chapter 1. Features and Capabilities

1.1 Introduction

This chapter introduces you to the features and capabilities of the GE XMO2 Thermoparamagnetic Oxygen Transmitter. The following specific topics are discussed:

• Basic Features - a brief discussion of the XMO2 Transmitter’s basic features and capabilities

• Theory of Operation - details on the sensor’s construction and how the measurements are made

• System Components - a description of the available XMO2 options and the required sample system

Note: The XMO2 technical specifications and ordering information can be found in Chapter 5, Specifications.

1.2 Basic Features

The XMO2 Transmitter measures the concentration of oxygen in the 0-100% range in a variety of gas mixtures, and it provides a 4-20 mA analog output signal that is proportional to the oxygen concentration. In performing these measurements, the microprocessor-based XMO2 provides automatic oxygen signal compensation for background gas composition and/or pressure variations. In addition, the XMO2 is equipped with Fast-Response software, real-time error detection, and push-button field calibration.

The XMO2 Transmitter offers several unique design features:

• Ultra-stable thermistors and a measuring cell that is temperature-controlled at 45°C (113°F) provide excellent

zero and span stability, as well as a high tolerance to ambient temperature variations. Optional measurement cell operating temperatures of 60°C (140°F) and 70°C (158°F) are available for special applications.

• The measurement cell design is resistant to contamination and relatively tolerant of sample gas flow rate

variations. As it has no moving parts, the XMO2 performs reliably under the shock and vibration found in many industrial applications.

• The XMO2’s unique “bridge-within-a-bridge” measurement circuit and microprocessor-based operation

automatically compensate the oxygen signal for variations in the magnetic and thermal properties of the background gas that would otherwise cause measurement errors.

XMO2 User’s Manual 1

Chapter 1. Features and Capabilities

1.2 Basic Features (cont.)

At high oxygen concentrations, changes in atmospheric pressure have significant effects on the measured

•

oxygen level. However, the XMO2 provides automatic microprocessor-based atmospheric pressure compensation of the oxygen signal for these applications.

• The XMO2 modular construction means that the unit can be field-calibrated quickly and easily. Also, the

plug-in measuring cell can be replaced with a pre-calibrated spare in just minutes.

• The XMO2 transmitter, which is available in weatherproof or explosion-proof packaging, is designed to be

installed as close as possible to the process sample point. It can be located up to 450 ft (150 m) from the control system, display, or recorder using standard GE cables.

• An RS232 serial communications interface and a multi-level, menu-driven User Pr ogram provide a convenient

means for calibrating and programming the XMO2

• Internal software algorithms along with user-programmed calibration data provide compensation of the oxygen

signal for background gas composition, atmospheric pressure, or both background gas composition and atmospheric pressure.

• GE proprietary Fast-Response software provides enhanced response times to track rapidly changing processes.

• Sophisticated error-checking software with user-programmable defaults and error limits detects abnormal

measurement conditions.

• Pushbutton adjustment of the 4-20 mA analog output zero and span values is a standard feature with the

XMO2.

• A drift calibration routine provides automatic drift compensation for minor changes in the sensor calibration

setting.

• Programmable recalibration is accomplished in the field via a computer interface, with no potentiometers to

adjust.

2 XMO2 User’s Manual

Chapter 1. Features and Capabilities

Induced Gas Flow

Magnetic Field

Upper Measurement Chamber

Lower

Flow-Through

Chamber

Sample

Inlet

Sample Outlet

Wind

Receiving

(Warmed)

Thermistor

Wind

Generating

(Cooled)

Thermistor

1.3 Theory of Operation

The XMO2 measures the concentration of oxygen in a gas mixture by utilizing the unique paramagnetic properties of oxygen.

As its magnetic susceptibility is approximately 100 times greater than that of most other common gases, oxygen can be easily distinguished from these gases based on its behavior in a magnetic field. Also, oxygen’s magnetic susceptibility varies inversely with temperature. Therefore, by carefully combining a magnetic field gradient and a temperature gradient within the XMO2 measuring cell, an oxygen-containing gas mixture can be made to flow along these gradients. This induced gas flow is known as a magnetic wind. The intensity of this magnetic wind depends on the concentration of oxygen in the gas mixture.

Figure 1 below shows a flow schematic for the XMO2 measuring cell. Permanent magnets within the cell create a magnetic field, while the cell temperature is controlled at 45°C (113°F) to maintain thermal equilibrium. In addition, the cell contains two pairs of highly-stable, glass-coated thermistors. One thermistor of each pair located inside the magnetic field and the other thermistor of each pair located outside the field. Because the thermistors are electrically heated, a temperature gradient is thus created within the magnetic field.

XMO2 User’s Manual 3

Figure 1: Measuring Cell Flow Schematic

Chapter 1. Features and Capabilities

Induced Gas Flow Induced Gas Flow

Wind Receiving

(Warmed)

Thermisters

Wind Generating

(Cooled)

Thermisters

Magnetic Field

1.3 Theory of Operation (cont.)

Figure 2 below shows the arrangement of the two thermistor pairs.

Figure 2: Arrangement of the Thermistor Pairs

A small portion of the sample gas flow is allowed to diffuse from the lower chamber into the upper chamber of the measurement cell. If the sample gas contains a paramagnetic gas such as oxygen, it is attracted to the magnetic field, causing the sample gas pressure to become locally higher in the center of the chamber. At the same time, the sample gas pressure is slightly lower near the thermistors because the high thermistor temperature causes the paramagnetic properties of oxygen to decrease. This slight gradient in sample gas pressure causes the sample gas to flow outward from the center of the magnetic field and over the thermistors. As a result, the inner, wind-generating thermistors decrease in temperature as they lose heat to the magnetic wind. This causes a temperature gradient between the cooler inner thermistors and the warmer outer thermistors.

4 XMO2 User’s Manual

Chapter 1. Features and Capabilities

V02

Vcomp

W1, W2 = Wind Generating (Cooled) Thermistors R1, R2 = Wind Receiving (Warmed) Thermistors

1.3 Theory of Operation (cont.)

Figure 3 below shows how the two thermistor pairs are connected in series in an electronic bridge circuit. The bridge circuit becomes unbalanced as the electrical resistance of the thermistors changes with temperature. This circuit imbalance causes a voltage drop, which is proportional to the oxygen concentration in the gas being measured, to appear across the bridge circuit.

Figure 3: Thermistor Bridge Circuit

As the background gases that comprise the balance of an oxygen-containing gas mixture change, the magnetic and thermal properties of the gas mixture also change. This affects the accuracy and response of any paramagnetic oxygen analyzer. To compensate for such variations, the XMO2 has a unique “bridge-within-a-bridge” design.

The oxygen measuring bridge circuit described on the previous page is itself one arm of another compensation bridge circuit that maintains the oxygen bridge at a constant temperature as background gas composition changes. The electrical power change necessary to keep the oxygen bridge at constant temperature is a function of the thermal properties of the background gas. Therefore, this power fluctuation provides a signal that is related to the thermal conductivity of the background gas. That signal is then used to reduce the effects of the background gas variation on the oxygen span point measurement.

In addition to maintaining a constant oxygen bridge temperature, the XMO2 microprocessor compensates for any zero point shift in the oxygen bridge circuit output caused by background gas changes.

Finally, the bridge circuit voltage is further adjusted for variations in background gas composition and/or atmospheric pressure by internal, microprocessor-based compensation algorithms. The compensated signal is then amplified and converted to a 4-20 mA analog output that is proportional to the concentration of oxygen in the gas mixture.

XMO2 User’s Manual 5

Chapter 1. Features and Capabilities

1.4 System Components

The basic XMO2 measurement system consists of an XMO2 Transmitter mounted in a Sample System. The sample system is mandatory, and can either be provided by GE or constructed according to our recommendations.

1.4.1 The XMO2 Transmitter

The XMO2 transmitter is self-contained, consisting of the oxygen sensor and associated electronics. It requires a 24 VDC power input @1.2 A maximum at power-up, and it provides a 4-20 mA analog output signal that is proportional to the oxygen concentration of the sample gas and has fully programmable zero and span points. Also provided is an RS232 digital output for oxygen concentration, background gas, and atmospheric pressure signals. Programming, and calibration of the unit may also be performed via this interface.

All XMO2 transmitters include a 10 ft (3 m), 4-conductor cable for connecting the power input and the 4-20 mA analog output. Optional XMO2 accessories available from GE include:

• Power/analog output cable lengths of up to 450 ft (150 m)

• 24 VDC power supply (Model PS5R-C24)

• 3-conductor cable with a DB9 (male or female) or DB25 (male or female) connector for connecting the XMO2

RS232 digital output to external devices

The XMO2 is designed to be installed in a sample system as close as possible to the process sample point. It is available in two environmental packages:

• Weatherproof

• Explosion-proof/Flameproof (with gas inlet and outlet flame arrestors)

The XMO2 transmitter, which is shown in Figure 4 on page 7, can be configured for the following standard oxygen ranges:

0 to 1% 0 to 25% 0 to 2% 0 to 50% 0 to 5% 0 to 100% 0 to 10% 80 to 100% 0 to 21% 90 to 100%

*Pressure compensation is required

* *

6 XMO2 User’s Manual

1.4.1 The XMO2 Transmitter (cont.)

Inlet

Flame Arrestor

Outlet

Flame Arrestor

Chapter 1. Features and Capabilities

The standard XMO2 transmitter maintains the measurement cell at an operating temperature of 45°C (113°F). An optional 60° (140°F) or 70°C (158°F) cell operating temperature is available upon request.

Note: The 60° (140°F) or 70°C (158°F) cell operating temperatures should be selected only when necessary, as the

higher cell operating temperature results in reduced sensitivity.

XMO2 User’s Manual 7

Figure 4: The XMO2 Transmitter

Chapter 1. Features and Capabilities

1.4.2 The Sample System

A sample system is mandatory for use with the XMO2 transmitter. The specific design of the sample system depends on the conditions of the sample gas and the requirements of the application. At a minimum, the sample system should include a sample gas flowmeter and a gas flow regulator valve.

In general, the sample system must deliver a clean, representative sample of the gas mixture to the XMO2 transmitter at a temperature, pressure, and flow rate that are within acceptable limits. The standard XMO2 transmitter sample gas conditions are as follows:

• -20° to +40°C (-4° to +104°F), at the standard measurement cell operating temperature of 45°C (113°F)

• Atmospheric pressure

• 1.0 SCFH (500 cc/min) flow rate

GE offers sample systems for a wide variety of applications. A typical sample system for use with the XMO2 transmitter is shown in Chapter 2, Installation. For assistance in designing your own sample system, please consult the factory.

IMPORTANT: ATEX compliance requires both:

• Fast Response calibration of the XMO2 transmitter

• Pressure Compensation of the XMO2 or constant control of the sample system pressure.

1.4.3 Long Cables (optional)

GE provides a standard 10 ft (3 m), 4-conductor, col or -coded cable with each XMO2 to connect to the power input and the analog output. Optional cables are available in lengths up to 450 ft (150 m) as P/N X4(*), where * specifies the length in feet. For longer cables or to use your own cable, refer to Chapter 2, Installation, for recommendations.

1.4.4 Power Supply (optional)

The XMO2 requires 24 VDC input power at a maximum start-up current of 1.2 A. The GE PS5R-C24 power supply may be used to convert 100-240 VAC to the required 24 VDC.

1.4.5 The TMO2D Display/Controller (optional)

The GE TMO2D Display/Controller provides a two-line x 24-character back-lit LCD display for the XMO2’ s 4-20 mA analog output signal. It also permits display and option programming via its keyboard. Additional features include: recorder outputs, a real time clock, alarm relays, and relays for driving sample system solenoids for automatic zero and span calibration. For more information on the TMO2D, please contact GE.

8 XMO2 User’s Manual

Chapter 2. Installation

2.1 Introduction

This chapter describes how to install the XMO2 transmitter and its sample system. It also contains information on connecting optional system components. Installation of the XMO2 system consists of three basic steps:

1. Installing the XMO2 transmit ter in the sample system (if you purchased your sample system from GE, this step

has already been done for you)

2. Mounting, plumbing, and wiring the sample system

3. Making wiring connections for power input, 4-20 mA analog output, RS232 digital output, and optional

external devices

2.2 Installing the XMO2 Transmitter

Note: This section applies only if the XMO2 transmitter has not already been installed in the sample system by GE.

The sample system must deliver a clean, representative gas sample to the XMO2 at the proper temperature, pressure and flow rate. This usually means a clean, dry gas sample that is free of solid and liquid particulates and is delivered at atmospheric pressure, a temperature no greater than 40°C (104°F), and a flow rate of approximately 1.0 SCFH (500 cc/min). A typical sample system fo r the XMO2 might include an inlet gas flow regulating needle valve, a sample gas flow meter, and a pressure gauge.

Note: Because factory calibration of the XMO2 is done at atmospheric pressure and at a flow rate of 1.0 SCFH,

operation of the XMO2 at other pressures and/or flow rates requires a field recalibration to ensure optimum accuracy.

To install the XMO2 transmitter in the sample system, complete the following steps:

1. Select a location in the sample system that provides at least 9 in. (230 mm) of clearance above the top cover of

the XMO2 for access to the interior of the transmitter enclosure.

2. Mount the XMO2 transmitter in the sample system via its two mounting holes. Be sure that the transmitter is

upright and is level to within ±15°.

3. Use 1/4” stainless steel tubing to connect the sample system Inlet and Outlet fittings to the corresponding

XMO2 ports.

WARNING! For explosion-proof units, be sure to conform to all safety and electrical code

requirements.

XMO2 User’s Manual 9

Chapter 2. Installation

0.875 (22.2)

(685.8)

27.00

25.25

(641.3)

4 places

Ø1/2"

SPAN GAS INLET

ZERO GAS INLET

INLET

SAMPLE

OUTLET

SAMPLE

19.25 (488.9)

21.00 (533.4)

9.00

(229.5)

(MIN)

TRANSMITTER

XMO2

0.875 (22.2)

2.3 Installing the Sample System

You can order a complete sample system from GE that is mounted on a steel panel and includes the XMO2 transmitter and all necessary components and plumbing. Several standard sample systems are available, and custom-designed sample systems can be built to your exact specifications.

2.3.1 A Basic System

Figure 5 below shows a basic sample system (dwg #732-164) that has been designed for use with the XMO2 transmitter.

Figure 5: Basic XMO2 Sample System (ref. dwg #732-164)

10 XMO2 User’s Manual

Chapter 2. Installation

2.3 A Basic System (cont.)

The sample system shown in Figure 5 on page 10 consists of a painted steel plate with the following components mounted on it:

• Inlet needle valves for sample, zero, and span gas flow regulation

• Ball valves for flow selection

• An XMO2 transmitter

• A sample gas outlet pressure gauge

• A sample gas flowmeter

Other components, such as a pump, a filter/coalescer, or a pressure regulator could be added to the system if needed.

2.3.0a Mounting the Sample System

To mount the sample system, complete the following steps:

1. Select a location that is as close as possible to the process sampling point. The ambient temperature at this

location should be in the range of -20° to +40°C (-4° to +104°F).

IMPORTANT: For locations where the ambient temperature falls below -20°C (-4°F), install the sample system in a

heated enclosure.

2. Using the mounting holes provided, fasten the sample system to a convenient vertical surface. The system must

be installed in an orientation that keeps the XMO2 transmitter upright and level to within ±15°.

3. After the sample system has been mounted, use 1/4” stainless steel tubing to connect all inlet and outlet lines to

the 1/4” tube fittings on the sample system. The sample line leading from the process to the sample system should be as short as possible in order to decrease system lag time and to prevent condensation in the line.

Proceed to the next section to begin wiring the system.

CAUTION! Always apply power to the XMO2 transmitter immediately after installation,

especially if it is mounted outdoors or in a humid area.

XMO2 User’s Manual 11

Chapter 2. Installation

Cover

Set Screw

Internal Ground

Screw

External

Ground

2.3.1 Wiring the XMO2 Transmitter

This section describes how to make all necessary electrical connections to the XMO2 system.

2.3.2 CE Mark Requirements

CAUTION! To meet CE Mark requirements, all electrical cables must be grounded and shielde d

as described in Appendix E.

2.3.3 Grounding the XMO2 Enclosure

WARNING! The XMO2 transmitter enclosure must be properly grounded.

Connect the external ground screw on the XMO2 enclosure (see Figure 6 below) to a suitable earth ground.

Figure 6: XMO2 Ground Screw Locations

12 XMO2 User’s Manual

Chapter 2. Installation

2.3.4 Cable Specifications

Table 1 below shows the transmitter wiring connections using the standard GE XMO2 4-wire cable [P/N X4(L), where L = length in ft]. This cable can be used for distances up to 450 ft (150 m).

Table 1: GE 4-Wire XMO2 Cable

Lead Color AWG Terminal

+24 VDC Line Red 22 TB1-1

24 VDC Return Black 22 TB1-2

4-20 mA (+) White 22 TB1-3

4-20 mA (-) Green 22 TB1-4

If you are using your own cable to wire the XMO2, refer to Table 2 below for cable requirements.

Table 2: Non-GE Cable Requirements

MAX. CABLE LENGTH WIRE SIZE

ft m AWG mm

450 130 22 0.35

700 200 20 0.60 1,050 320 18 1.00 1,700 500 16 1.20 2,800 850 14 2.00 4,000 1,200 12 3.00

Table 3 below shows the connections for the GE standard 3-wire RS232 cable (P/N 704-667, -668, -669, or -670-L, where L = length in ft), which is available with a DB-9 or a DB-25 connector (male or female). This cable is available in standard lengths of 6 ft and 12 ft.

Table 3: GE 3-Wire RS232 Cable

Lead Color AWG Terminal

RX Red 22 TB2-1

TX White 22 TB2-2

GND Green 22 TB2-3

See EIA-RS Serial Communications (GE document #916-054) for a more detailed discussion of RS232 wiring.

Note: See Figure 64 on page 74 for detailed drawings of the standard GE cables described above.

XMO2 User’s Manual 13

Chapter 2. Installation

+24VDC Line (red)

1 2 3 4

2 3

–24VDC Return (black)

+4 to 20mA (white)

–4 to 20 mA (green)

RS232 TX (white)

RS232 GND (green)

2 3 4 1

External Ground Screw

Cover

Internal Ground Screw

Set Screw

RS232 RX (red)

2.3.5 Accessing Terminal Blocks TB1 and TB2

The 24 VDC power input, 4-20 mA analog output, and RS232 digital output wiring connections are made to terminal blocks TB1 and TB2 inside the XMO2 enclosure (see Figure 7 below). To access this terminal block, loosen the locking set screw and remove the cover from the transmitter. Then, refer to Figure 7 below for the location and pin designations of terminal blocks TB1 and TB2.

CAUTION! Do not make any connections to any unused pins on terminal blocks TB1 or TB2.

Figure 7: TB1 and TB2 Terminal Block Connections

Proceed to the next section to begin making connections to terminal blocks TB1 and TB2.

14 XMO2 User’s Manual

Chapter 2. Installation

2.3.6 Wiring the Signal Connections

Complete the following steps to make the signal connections to terminal blocks TB1 and TB2:

1. Install a cable clamp or gland in one of the 3/4” conduit holes.

CAUTION! Be sure to plug the unused conduit hole to maintain the designated weatherproof or

explosion-proof rating.

2. Route the 4-wire and 3-wire (if used) cables through the cable clamp. Then, tighten the clamp to secure the

cable(s).

3. Unplug the TB1 and TB2 connectors by pulling them straight off the printed circuit board, and loosen the

screws on the side of the connectors.

4. Connect the 24 VDC input power leads as follows:

CAUTION! Connecting the +24 VDC (red) lead to any terminal except TB1-1 will damage the

XMO2.

a. Insert the 4-wire cable +24 VDC line (red) lead into pin TB1-1 and tighten the screw. b. Insert the 4-wire cable 24 VDC return (black) lead into pin TB1-2 and tighten the screw.

5. Connect the 4-20 mA analog output leads as follows: a. Insert the 4-wire cable + 4-20 mA (white) lead into pin TB1-3 and tighten the screw. b. Insert the 4-wire cable – 4-20 mA (green) lead into pin TB1-4 and tighten the screw.

6. Connect the option al RS 232 digital output leads as follows: a. Insert the 3-wire cable RX (red) lead into pin TB2-1 and tighten the screw. b. Insert the 3-wire cable TX (white) lead into pin TB2-2 and tighten the screw. c. Insert the 3-wire cable GND (green) lead into pin TB2-3 and tighten the screw.

7. Carefully plug the TB1 and TB2 connectors back onto the printed circuit board, and reinstall the cover on the

XMO2.

8. Connect the other ends of the cables to the 24 VDC power supply, the 4-20 mA input of the display/control device, and the serial port of the computer or terminal (see the instruction manuals for those devices for details).

XMO2 User’s Manual 15

Chapter 2. Installation

2.4 Establishing the RS232 Communication Link

Before the XMO2 can be programmed, a link between the built-in RS232 digital output and a computer terminal must be established. To accomplish this, proceed as follows:

Note: See GE document EIA-RS Serial Communications (916-054) for a details of the RS232 standard.

1. Verify that either Com 1 or Com 2 on the computer is unused.

IMPORTANT: Do not use a virtual Com port, such as Com 3 or Com 4, for communicating with the XMO2.

2. With both the XMO2 and the computer turned OFF, connect a serial cable from the XMO2 to the PC. See

Chapter 2, Installation, for detailed instructions.

CAUTION! Never make any connections to a computer while it is powered up. Damage to the

system may result.

3. Power up the PC and launch the IDM software.

Note: See the IDM User’s Manual (910-185) for information on installing and launching your program.

4. In the Global menu of IDM, select the Preferences option to specify the com port to which your XMO2 has

been connected.

5. For proper communications with the XMO2, the following com port settings must be specified:

• Baud Rate = 9600

• Data Bits = 8

• Parity = None

• Stop Bits = 1

• Flow Control = Xon/Xoff

6. Select the Connect to a New Instrument option, enter the XMO2 ID number (1 to 254), and select OK.

16 XMO2 User’s Manual

Chapter 2. Installation

2.5 Connecting to Other Devices

This section discusses interconnection of the XMO2 transmitter with other GE devices. The following devices are included:

• PS5R-C24 power supply

• TMO2D display

• LDP display

• XDP display

• Moisture Image/Monitor Series analyzers

• System 1 moisture analyzer

2.5.1 The PS5R-C24 Power Supply

The GE PS5R-C24 power supply converts a 100-240 VAC input to the required 24 VDC output. Figure 8 below shows the PS5R-C24 connections. As indicated, the AC input Line, Neutral and Ground connections are made to the terminals along the bottom of the panel, while the DC output +24V line and 24V return connections are made to the terminals along the top of the panel. See the instructions provided with the power supply for more details.

Figure 8: PS5R-C24 Power Supply Connections

XMO2 User’s Manual 17

Chapter 2. Installation

2.5.2 TMO2D Display

The GE TMO2D Display provides a two-line x 24 character back-lit LCD. It features display and option programming via the keyboard and it offers recorder outputs, alarm relays, and optional relays for driving sample system solenoids for automatic zero and span calibration of the XMO2. See Figure 74 on page 84 for an interconnection diagram, and refer to the TMO2D User’s Manual (910-084) for details on its operation.

2.5.3 LDP Display

The LDP Display provides an integral, regulated 24 VDC power supply, an adjustable 3-digit display to program the 4-20 mA analog input range, two programmable SPDT alarm relays rated for 1A @250 VAC, and an isolated, independently-adjustable 4-20 mA analog output. The LDP is supplied in an explo sion-proof enclosure t hat is rated for Cenelec EEx d IIC T6 and IP66 (with an optional gasket). See Figure 74 on page 84 for an interconnection diagram, and refer to the LDP User’s Manual (910-225) for details on its operation.

2.5.4 XDP Display

The XDP Explosion-proof Display Package provides an integral, regulated 24 VDC power supply, a 3-digit display with an adjustable 4-20 mA analog input range, two SPDT alarm relays rated for 1A @250 VAC, and an isolated, independently-adjustable 4-20 mA analog output. See Figure 74 on page 84 for an interconnection diagram, and refer to the XDP User’s Manual (910-204) for details on its operation and specifications.

2.5.5 Moisture Image/Monitor Series Analyzers

These GE instruments include the Moisture Image Series 1 and Moisture Monitor Series 3 analyzers. These analyzers accept inputs from a variety of sensors (including the XMO2) and offer graphical and digital interfaces. See Figure 74 on page 84 for interconnection diagrams, and refer to the User’s Manual (910-108 or 110) for details on its operation.

Note: An external 24 VDC power supply (such as the PS5R-C24) is required to use the XMO2 with these analyzers.

2.5.6 System 1 Analyzer

The GE System 1 is a versatile multi-channel analyzer which accepts inputs from any combination of GE moisture, temperature, oxygen, and thermal conductivity transmitters. See Figure 74 on page 84 for an interconnection diagram, and refer to the System 1 User’s Manual (900-019) for details on its operation.

Note: An external 24 VDC power supply (such as the PS5R-C24) is required to use the XMO2 with the System 1

analyzer.

18 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.1 Introduction

This chapter provides instructions for starting up and operating the XMO2 system. The following specific topics discussed:

• Powering up the XMO2 transmitter

• Establishing a sample gas flow

• Calibration of the analog output signal

If you have not already done so, read Chapter 2, Installation, for details on mounting and wiring the XMO2 transmitter , the sample system, and any other optional equipment.

3.2 Powering Up the XMO2 Transmitter

The XMO2 transmitter does not have a power switch. It begins taking measurements and generating an analog output signal in the 0-25 mA range as soon as it is connected to a 24 VDC power source. To power up the system, simply energize the 24 VDC power supply.

Because the standard XMO2 measurement cell is controlled at a constant 45°C (113°F) operating temperature, allow at least 30 minutes for the unit to warm up and reach temperature stability before taking any measurements. During this time, you can establish a sample gas flow through the system, as described in the next section.

3.3 Establishing a Sample Gas Flow

Usually, the XMO2 transmitter is factory-calibrated at a sample gas flow rate of 1.0 SCFH (500 cc/min) and at atmospheric pressure. Unless otherwise specified on your XMO2 calibration sheet, optional sample system tagging, or optional sample system instructions, your XMO2 should be operated at atmospheric pressure and at the flow rate listed in Table 4 below.

Table 4: Recommended Sample Gas Flow Rates

XMO2 Type Flow Rate in SCFH (cc/min)

Weatherproof 1.0 ± 0.5 (500 ± 250)

Explosion-proof 1.0 ± 0.2 (500 ± 100)

Pressure-compensated 0.5 ± 0.5 (250 ± 50)

Note: For optimum performance, operating the XMO2 at conditions other than those used for the factory calibration

requires that the unit be recalibrated at the actual field conditions.

XMO2 User’s Manual 19

Chapter 3. Startup & Operation

3.3 Establishing a Sample Gas Flow (cont.)

To establish a flow of sample gas through the system, complete the following steps (see Figure 5 on page 10 as an example):

1. Set the sample system ball valves to direct only the sample inlet stream to the inlet port of the XMO2

transmitter.

2. Use the sample inlet needle valve to regulate the flow of sample gas until the flowmeter reads the same flow

rate listed for your unit in Ta ble 4 on page 19.

3. Read the resulting system pressure on the pressure gauge. Make sure that there are no unnecessary flow

restrictions downstream of the sample system.

IMPORTANT: For atmospheric pressure-compensated units, the XMO2 outlet port must be vented directly to

atmosphere with no restrictions, by installing all sample system components and tubing upstream of the XMO2 transmitter.

4. Take a reading of the XMO2 4-20 mA analog output.

In some applications, pressure changes due to flow rate changes can cause noticeable errors in the oxygen measurement. In such cases, consider the following corrective measures:

• Reducing the flow rate to the minimum recommended value minimizes flow rate sensitivity. A bypass flow

type sample system (speed loop) allows minimum flow through the XMO2 yet maintains a fast transport of the sample gas to the XMO2.

• For the fastest transport, minimize the sample line length from the process.

• If you cannot shorten the sample line length, reduce the sample line pressure to les s than 5 psig.

Proceed to the next section to complete the initial XMO2 startup.

20 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.4 Analog Output Calibration Options

The XMO2 4-20 mA analog output has been calibrated at the factory for the oxygen range indicated on the XMO2 Calibration Sheet shipped with the unit. (Figure 9 on page 22 shows a typical calibration sheet.) Upon initial startup, field verification and/or calibration of the 4-20 mA analog output is required. To perform this task, either of the following procedures may be used:

• Pushbutton calibration (offset gas method)

• IDM digital communication calibration (zero/span gas method)

This section provides information on calibrating the XMO2 in the field using either a one-gas (offset gas) method or a two-gas (zero gas and span gas) method. The following specific topics are discussed:

• Factory calibration procedures

• Updating the factory calibration

• Required calibration materials

• Getting the XMO2 ready and locating the calibration switches

• How to perform a one-gas (Offset Gas) or two-gas (Zero and Span Gas) Pushbutton calibration

• How to perform an IDM digital communication calibration

After the XMO2 is in operation, field calibration is recommended at intervals of about 1-3 months, depending on the application.

3.5 Factory Calibration Procedures

Prior to shipment, your XMO2 was calibrated at the factory for the %O2 range specified at the time of purchase. The following standard %O

• 0 to 1% • 0 to 5% • 0 to 21% • 0 to 50%* • 80 to 100%*

• 0 to 2% • 0 to 10% • 0 to 25% • 0 to 100%* • 90 to 100%*

In addition, your XMO2 was calibrated at the factory for the compensation signal specified at the time of purchase. The following standard compensation signals are provided:

• Background Gas Compensation - the standard factory calibration uses N

ranges are available:

* Pressure compensation is required

and CO2 as the background gases.

• Pressure Compensation - the standard factory calibration is for atmospheric pressure (700-800 mm of Hg).

Note: Compensation signals are available for special background gases and/or special pressure ranges. For

availability, pricing, and delivery, please contact GE.

XMO2 User’s Manual 21

Chapter 3. Startup & Operation

3.5 Factory Calibration Procedures (cont.)

Figure 9: Sample Calibration Sheet

22 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.6 Enhancing the Factory Calibration

When your XMO2 transmitter was calibrated at the factory, the actual factory calibration data points were entered into the XMO2 software. If requested on the original order, calibration data points for expected field background gas composition and/or measurement cell pressure variations may also have been entered. To supplement this factory calibration data, calibration data points generated in the field for these parameters can be added into the XMO2 software.

The factory calibration can be further enhanced by performing periodic recalibrations in the field. The XMO2 then uses the new calibration data to create offset and drift curves that compensate the original factory calibration data for variations that occur in the field.

When making a measurement, the XMO2 uses the Offset Curve or Drift Curve, along with any background gas and/or cell pressure compensation data, entered at the factory or in the field, to update the factory calibration data.

To maintain the integrity of this process, the XMO2 should be recalibrated periodically. This is typically done every 1-3 months with a single (offset) calibration gas, depending on the application. The optimum recalibration interval depends on such factors as %O

gas, etc. In addition, the XMO2 should be recalibrated with the two-gas (zero gas and span gas) method at least once per year. Again, the optimum calibration interval depends on the specific application.

range, required accuracy, components of the gas mixture, the cleanliness of the sample

Using the calibration procedures in this chapter, the XMO2 can be recalibrated for the same %O

range, background

gas mixture, and compensation signals used for the factory calibration. However, if it has been some time since the original factory calibration, or if you want to calibrate the XMO2 for a different %O

range, gas mixture, or

compensation signal, contact the factory for instructions.

CAUTION! The calibration procedures described in this chapter require the use of specialized

apparatus and should be performed only by properly trained service personnel, following all applicable safety practices.

XMO2 User’s Manual 23

Chapter 3. Startup & Operation

3.7 Required Calibration Materials

To perform a field calibration, the following materials are required:

• Offset gas - for a one-gas %O

• Zero gas - for a two-gas %O

• Span gas - for a two-gas %O

Note: Suggestions for suitable calibration gases are listed on the XMO2 Calibration Sheet provided with your unit.

Also, the accuracy of the calibration will only be as good as the accuracy of the calibration gas(es) used.

calibration

calibration and/or a 4-20 mA analog output calibration

• GE XMO2 Calibration Sheet

• A sample system or individual components (e.g., flowmeter, needle valve, pressure gauge, etc.) for introducing

the calibration gas(es) to the XMO2 transmitter at the required pressure and flow rate. See Chapter 2, Installation, for specific recommendations.

• A multimeter or ammeter (for a 4-20 mA analog output calibration)

WARNING! Avoid using explosive gas mixtures as your XMO2 calibration gases.

3.8 Preparing for Field Calibration

To prepare the XMO2 for a field calibration, refer to Figur e 10 on page 25 and perform the following preliminary steps:

1. Turn the power on and allow at least 30 minutes for the XMO2 to reach temperature stability.

2. Loosen the set screw that locks the XMO2 cover in place, and unscrew the cover.

IMPORTANT: Remember to replace the cover after the field calibration has been completed.

3. Refer to Figure 11 on page 25, and locate the following items:

• Calibration pushbutton (Switch S3)

• Zero/span selector (Switch S1)

• Terminal block TB1

Note: If you plan to perform the field calibration at a computer terminal via the XMO2 RS232 digital output, you do

not need to access the above items because you will skip steps 1-2 above.

24 XMO2 User’s Manual

3.8 Preparing for Field Calibration (cont.)

Set Screw

Circuit Board

Cover

Switch S1

Switch S3

TB2

TB1

Chapter 3. Startup & Operation

Figure 10: XMO2 Cover, Set Screw, and PCB

Note: The XMO2 digital PCB (see Figure 11 below) is located directly below the cover (see Figure 10 above).

Figure 11: PCB Calibration Switches

CAUTION! Switch S2, jumper P6, potentiometer R24, and potentiometer R25 are also located

on the XMO2 circuit boards. However, these items are not

used for normal field calibration.

Never touch these items unless specifically instructed to do so by GE.

XMO2 User’s Manual 25

Chapter 3. Startup & Operation

3.9 One-Gas Pushbutton Field Calibration

This simplified field calibration procedure uses a single (offset) gas to recalibrate the XMO2. Then, the XMO2 compares the data from this field recalibration to the original factory calibration data, and stores the difference as an Offset Curve.

The XMO2 is usually factory-programmed for the offset gas pushbutton calibration method. The Calibration Sheet shipped with your unit specifies the recommended oxygen level (in %O

offset gas oxygen level that was used for the factory calibration. If no offset gas %O Calibration Sheet, the factory calibration was done with 100% N

same offset gas.

To perform a pushbutton offset gas field calibration, complete the following steps:

1. Verify that your XMO2 is configured for a one-gas calibration. This is the factory default configuration for all

units.

2. Using the sample system controls, stop the flow of sample gas to the XMO2 inlet port and initiate a flow of the

same offset gas specified on the XMO2 Calibration Sheet. Establish the same flow rate and pressure conditions used for the sample gas, and allow the offset gas to flow through the XMO2 for at least three minutes.

) for the offset gas to be used. This is the same

is specified on the XMO2

(0.00 %O2) and the field calibration should use the

3. Using Figure 11 on page 25 as a guide, locate the Calibration Pushbutton (Switch S3). Depress the

Calibration Pushbutton and hold it down for 20 seconds. During this time, the green light below the Calibration Pushbutton will go out.

4. When the Calibration Push Button is released, the green light will come back on and the XMO2 has been

recalibrated.

You may now return the XMO2 to normal operation by using the sample system controls to stop the offset gas flow and restart the flow of sample gas.

26 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.10 Two-Gas Pushbutton Field Calibration

This simplified field calibration procedure uses two (zero and span) gases to recalibrate the XMO2. Then, the XMO2 compares the data from this field recalibration to the original factory calibration data, and stores the difference as a Drift Curve.

Note: If the range of your XMO2 is 0 to 21% O

, you can use air as the span gas.

3.10.1 Setup

Before proceeding, you must be sure that your XMO2 is configured for a two-gas calibration. The required reprogramming must be done via the IDM communication link, as follows:

1. Launch IDM.

2. From the Instrument window, pu ll down the Edit Functions menu, as shown in Figure 12 on page 30.

3. Click on the Field Cal option. In the Field Cal window (shown in Figure 13 on page 31), click on the

Configure Cal button.

4. In the Configure Cal window (shown in Figure 17 on page 33), click on the Field Cal Type button.

5. In the Field Cal Type window (shown in Figure 18 on page 33), click on either the 1-Point or 2-Point button.

Then, click on any button on the right to return to the Configure Cal window.

Note: The zero and span calibrations can be performed in either order. For zero-based calibration ranges

(e.g., 0-25%), we recommend performing the span calibration first. For non-zero-based calibration ranges (e.g., 90-100%), we recommend performing the zero calibration first.

Proceed to the appropriate section to begin the field calibration.

XMO2 User’s Manual 27

Chapter 3. Startup & Operation

3.10.2 Zero Gas Pushbutton Calibration

To perform a zero gas pushbutton field calibration, complete the following steps:

1. Using the sample system controls, stop the flow of sample gas to the XMO2 inlet port and initiate a flow of the

same zero gas specified on the XMO2 Calibration Sheet. Establish the same flow rate and pressure conditions used for the sample gas, and allow the zero gas to flow through the XMO2 for at least three minutes.

2. Using Figure 11 on page 25 as a guide, locate the Zero/Span Selector (Switch S1). Set the Zero/Span Selecto r

(Switch S1) to position “1” (“Zero”).

3. Using Figure 11 on page 25 as a guide, locate the Calibration Pushbutton (Switch S3). Depress the

Calibration Pushbutton and hold it down for 20 seconds. During this time, the green light below the Calibration Pushbutton will go out.

4. When the Calibration Pushbutton is released, the green light will come back on and the XMO2 has been

recalibrated. Verify that the mA reading on the ammeter is now equal to the expected value.

IMPORTANT: If the XMO2 fails to recalibrate to the correct analog output value, contact GE for assistance.

3.10.3 Span Gas Pushbutton Calibration

To perform a span gas pushbutton field calibration, complete the following steps:

1. Using the sample system controls, stop the flow of sample gas to the XMO2 inlet port and initiate a flow of the

same span gas specified on the XMO2 Calibration Sheet. Establish the same flow rate and pressure conditions used for the sample gas, and allow the span gas to flow through the XMO2 for at least three minutes.

2. Using Figure 11 on page 25 as a guide, locate the Zero/Span Selector (Switch S1). Set the Zero/Span Selecto r

(Switch S1) to position “3” (“Span”).

3. Using Figure 11 on page 25 as a guide, locate the Calibration Pushbutton (Switch S3). Depress the

Calibration Pushbutton and hold it down for 20 seconds. During this time, the green light below the Calibration Pushbutton will go out.

4. When the Calibration Pushbutton is released, the green light will come back on and the XMO2 has been

recalibrated.

You may now return the XMO2 to normal operation by using the sample system controls to stop the span gas flow and restart the flow of sample gas.

28 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.11 IDM Digital Communication Calibration

At the initial startup of the XMO2, IDM Digital Communication Calibration is the second method available for field verification/calibration of the 4-20 mA analog output.

Note: IDM can also be used to change the 4-20 mA analog output range. See the next section for details.

To prepare for this calibration method, refer to Figure 10 on page 25 and perform the following preliminary steps:

1. Make sure that the RS232 digital output of the XMO2 has been connected to a computer or terminal in accordance with the instructions given in Chapter 2, Installation.

2. Loosen the set screw that locks the XMO2 cover in place, and unscrew the cover.

IMPORTANT: Remember to replace the cover after the calibration has been completed.

3. Turn the computer or terminal on and launch IDM.

Note: Be sure you have properly installed Instrument Data Manager on your PC before attempting to program the

XMO2.

XMO2 User’s Manual 29

Chapter 3. Startup & Operation

3.12 The Edit Functions Menu

T o access the XMO2 calibration, pull down the Edit Functions menu from the Instrument window. This menu consists of the five commands displayed in Figure 12 below. To access any of the commands, simply select it from the menu.

Note: As a programming aid, the relevant portions of the Edit Functions menu have been mapped in Figure 75 on

page 87 and Figure 76 on page 88.

Figure 12: Edit Functions Menu

The following three buttons appear at the right of all menu windows (see Figure 13 on page 31):

• Previous Item - returns you to the previous window (either the command menu or the previous parameter

entered).

• Next Item/Enter - confirms the selection or data entered, and either opens the next window or returns you to

the command menu (depending on your position in the program).

• Exit Page - returns you to the command menu.

30 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.13 The Field Cal Menu

When you select the Field Cal option, a window similar to the one in Figure 13 below opens.

IMPORTANT: The instructions in this section assume that the factory-programmed 2-Gas calibration method is still

selected. If you have previously changed this to the 1-Gas calibration method, any windows that show Zero and Span calibration gas buttons are replaced with a window that shows just the single Offset calibration gas button.

Figure 13: Field Cal Window

The Field Cal option offers the following five choices:

• Perform Cal - calibrates the XMO2

• Configure Cal - sets the calibration type and parameters

• Calibration Drifts - lists drift percentages for zero and span gases

• Clear Calibration - clears the last calibration

• Hold Last Value - holds the last value calibrated

Note: Clicking on the Next Item/Enter button selects the option listed on the status line above the option buttons

(Perform Cal in Figure 13 above). The option listed on the status line in any window is the option that was chosen the last time that menu was used.

Clicking on any of the above choices opens a new window that allows you to perform that function. Proceed to the appropriate section for a detailed description of each option.

XMO2 User’s Manual 31

Chapter 3. Startup & Operation

3.13.1 Perform Cal

Clicking on the Perform Cal button opens a window similar to Figure 14 below.

Figure 14: Perform Cal Window

Click on the Zero Field Cal button to calibrate the zero point or on the Span Field Cal button to calibrate the span point. In either case, a window similar to Figure 15 below opens.

Figure 15: Zero Cal Window

Click Yes to perform the calibration, or Abort Field Cal to stop the calibration and return to the previous menu. The result of a completed calibration is shown in Figure 16 below.

Figure 16: Zero Cal Results

Click on Previous Item or on Next Item/Enter to return to the previous window, or on Exit Page to return to the Instrument Menu.

32 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.13.2 Configure Cal

The Configure Cal option enables you to change the field calibration type and various calibration parameters. Clickin g on the Configure Cal button opens a window like that shown in Figure 17 below.

Figure 17: Configure Cal Window

Click on the desired option button and proceed to the appropriate section for a discussion of that option.

3.13.2a Field Cal Type

A typical Field Cal Type window is shown in Figure 18 below.

Figure 18: Field Cal Type Window

IMPORTANT: The factory setting is the 2 Point (Zero/Span) calibration type.

Click on the appropriate button to select the desired calibration type. Then, click on any button on the right to return to the Configure Cal window.

XMO2 User’s Manual 33

Chapter 3. Startup & Operation

3.13.2b Field Cal Percent

A typical Field Cal Percent window is shown in Figure 19 below.

Figure 19: Field Cal Percent Window

The above menu is used to specify the oxygen percentages of the zero and span calibration gases that will be used. The recommended gases are listed on the XMO2 Calibration Data Sheet.

Click on the Zero Field Cal button to enter the percentage of oxygen in your zero gas. A window similar to Figure 20 below opens.

Figure 20: %O2 Entry Window

Type the zero gas oxygen percentage in the text box, and click the Next Item/Enter button to confirm the entry (click Previous Item or Exit Page button to leave the window without changing the existing percentage).

IMPORTANT: The factory setting is for a 0.00% zero gas and a 20.93% span gas (air).

Repeat the above procedure to enter your span calibration gas oxygen percentage. Then, click on any button on the right to return to the Configure Cal window.

34 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.13.2c Before Delay Time

Clicking on the Before Delay Time button opens a window similar to Figure 21 below.

Figure 21: Before Delay Time Window

In the above window, click on the Zero Field Cal button to enter the before delay time for the zero calibration point. A window similar to Figure 22 below opens.

Figure 22: Zero Point Delay Time Window

Enter the desired zero point before delay time, in minutes and seconds, in the text box. Then, click on the Next Item/Enter button to confirm the entry (click the Previous Item or Exit Page button to exit the window without

changing the existing value).

Repeat the above procedure to enter the before delay time for the span point.

3.13.2d After Delay Time

Repeat the procedure in the above section to set the after delay time for both the zero and span points.

XMO2 User’s Manual 35

Chapter 3. Startup & Operation

3.13.2e Max Total Drift

Max Total Drift is the maximum total calibration drift allowable, expressed as a percentage of the full-scale reading. Selecting this option opens a window similar to Figure 23 below.

Figure 23: Max Total Drift Entry Window

Enter the desired percentage of the full-scale reading in the text box, and click the Next Item/Enter button to confirm the entry (click the Previous Item or Exit Page button to leave the window without changing the existing percentage).

3.13.2f Max Drift/Cal

Max Drift/Cal is the maximum calibration drift allowable per calibration, expressed as a percentage of the full-scale reading. To enter a value, repeat the procedures in the above section.

3.13.3 Calibration Drifts

The Calibration Drifts option enables you to view the current calibration drift at both the zero and span points since the last calibration was performed. Clicking on this button opens a window similar to Figure 24 below.

Figure 24: Calibration Drifts Window

Click on any button to return to the main Field Cal window.

36 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.13.4 Clear Calibration

The window for the Clear Calibration option is similar to Figure 25 below.

Figure 25: Clear Calibration Window

Click on the Yes button to clear the most recent calibration, or click on the No, Previous Item or Exit Page button to close the window without clearing the most recent calibration. If you click on the Yes button, a confirmation screen similar to Figure 26 below opens.

Figure 26: A Typical Cleared Calibration

Click on the Previous Item button to return to the Clear Calibration window, or click on the Next Item/Enter or Exit Page button to return to the main Field Cal window.

3.13.5 Hold Last Value

In addition to performing a field calibration or configuring the calibration parameters, you can program the XMO2 to hold the last calibrated value. To perform this task, click on the Hold Last Value button. Y ou will notice that the text on the button now reads Disable Hold Last. To cancel the Hold Last Value programming, just click on this new button. You can toggle between the two states for this parameter by clicking on this button (remember that the current state is the one NOT

XMO2 User’s Manual 37

written on the button).

Chapter 3. Startup & Operation

3.14 Changing the 4-20 mA Analog Output Range

The XMO2 Calibration Sheet shipped with the unit lists the 4-20 mA analog output range that was set at the factory. IDM enables you to change this range via the 4-20mA Output option. After you click on the 4-20mA Outpu t button from the Edit Functions menu (Figure 12 on page 30), a window similar to Figure 27 below opens. Clicking on any option opens the window for that option, while clicking on Next Item/Enter opens the menu listed on the status line above the options.

Figure 27: 4-20 mA Output Window

The 4-20mA Output option offers the following five choices:

• 4-20mA Range - specifies the oxygen percentage for bo th the 4 mA and 20 mA analog output points

• 4mA Cal - calibrates the 4 mA point

• 20mA Cal - calibrates the 20 mA point

• 4-20mA Test - tests the analog output at various percent oxygen points

• %O2 Test - tests the analog output at various percent oxygen points

Note: Clicking on the Next Item/Enter button selects the option listed on the status line above the option buttons

(4-20mA Range in Figure 27 above). The option listed on the status line in any window is the option that was chosen the last time that menu was used.

Clicking on any of the above choices opens a new window that allows you to perform that function. Proceed to the appropriate section for a detailed description of each option.

38 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.14.1 4-20mA Range

Selecting the 4-20mA Range option opens a window similar to Figure 28 below.

Figure 28: 4 mA Output %O2 Window

In the text box, enter the oxygen percentage in the sample gas that should generate an analog output of 4 mA. Then, click on the Next Item/Enter button to confirm the entry (click the Pr evious Item or Exit Page button to exit the window without changing the existing value) and open a window similar to Figure 29 below.

Figure 29: 20 mA Output %O2 Window

In the text box, enter the oxygen percentage in the sample gas that should generate an analog output of 20 mA. Then, click on the Next Item/Enter button to confirm the entry (click the Pr evious Item or Exit Page button to exit the window without changing the existing value).

The next window requires you to either Clamp 4-20mA Output or not. Select either No or Yes from the list box and click on the Next Item/Enter button to confirm the entry (click the Previous Item or Exit Page button to exit the window without changing the existing value).

Note: A clamped output cannot display measurements outside the programmed 4-20 mA analog output range, while a

reading that is not clamped can display measurements outside the programmed range.

XMO2 User’s Manual 39

Chapter 3. Startup & Operation

3.14.2 4mA Cal

Click on the 4mA Cal button to open a window similar to Figure 30 below and force the analog output to exactly

4.00 mA. This allows you to calibrate the 4 mA point of the analog output signal.

Figure 30: 4mA Cal Window

Use an ammeter connected to the analog output terminals on the rear panel to monitor the 4-20 mA output signal. Calibrate the 4 mA point by clicking on the UP and/or DOWN buttons until the ammeter reads exactly 4.00 mA. Alternatively, you can click on the Numeric Calibration button to open a window like Figure 31 below.

Figure 31: Numeric Calibration Window

Enter the desired current reading (4.00) in the text box and click on the Next Item/Enter button (click on the Previous Item or Exit Page button to close the window without changing the value).

After you have calibrated the 4 mA signal, click on the 4mA STORE button to save the calibration. However, if the calibration is not satisfactory, click on the 4mA ABORT button to cancel the calibration.

3.14.3 20 mA Cal

Repeat the instructions in the section above to calibrate the 20 mA point of the analog output signal.

40 XMO2 User’s Manual

Chapter 3. Startup & Operation

3.14.4 4-20mA Test

Selecting the 4-20mA Test option opens a window similar to Figure 32 below.

Figure 32: 4-20mA Test Window

Enter a current value in the 4-20 mA range to force the analog output signal to that value. Click on the Next Item/Enter button and verify that the ammeter connected to the output terminals on the rear panel reads the correct value. You may repeat this procedure as many times as desired to test the output at various points in the 4-20 mA range. When you have finished, click the Exit Page button to close the window.

3.14.5 %O2 Test

Selecting the %O2 Test option opens a window similar to Figure 33 below.

Figure 33: %O2 Test Window

Enter an oxygen percentage in the text box. Click on the Next Item/Enter button and verify that the digital display on the front panel reads the correct value. You may repeat this procedure as many times as desired to test the display reading at various oxygen percentages. When you have finished, click the Exit Page button to close the window.

XMO2 User’s Manual 41

Chapter 3. Startup & Operation

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42 XMO2 User’s Manual

Chapter 4. Programming with Instrument Data Manager

4.1 Introduction

The XMO2 is factory-programmed and ready for immediate use. However , you can access its programming with your PC, using the GE Instrument Data Manager (IDM) software. IDM also allows you to upload or download site files, display data, and log and view real-time data and diagnostic data in numeric, bar chart or line chart formats. For further information on the display and logging functions, refer to the Instrument Data Manager User’s Manual (910-185). Since Chapter 3, Startup & Operation, describes the Field Cal and 4-20 mA Output options, this chapter covers the Error Handler, Factory Cal and Advanced options in the Edit Functions menu.

Note: Be sure you have properly installed Instrument Data Manager on your PC before attempting to program the

XMO2.

4.2 The Edit Functions Menu

To access the XMO2 calibration, pull down the Edit Functions menu from the Instrument window.The menu consists of the five commands displayed in Figure 34 below. To access any of the commands, simply select it from the menu.

Note: As a programming aid, the relevant portions of the Edit Functions menu have been mapped in Appendix C.

Figure 34: Edit Functions Menu

The following three buttons appear at the right of all menu windows (see Figure 35 on page 44):

• Previous Item - returns you to the previous window (either the command menu or the previous parameter

entered).

• Next Item/Enter - confirms the selection or data entered, and either opens the next window or returns you to

the command menu (depending on your position in the program).

• Exit Page - returns you to the command menu.

XMO2 User’s Manual 43

Chapter 4. Programming with Instrument Data Manager

4.2.1 The Error Handler Menu

Note: For information on the Field Cal and 4-20 mA Output options, refer to Chapter 3.

The Err or Handler menu allows you to configure the manner in which the XMO2 responds to various error conditions. When you click on the Error Handler button in the Edit Functions menu (Figure 34 on page 43), a window similar to Figure 35 below opens.

Figure 35: Error Handler Window

There is a button in the above window for each of the following error conditions:

• Total Drift Err

• Drift/Cal Err

• O2 mV under range

• O2 mV over range

• O2 % under range

• O2 % over range

• BKGD mV under range

• BKGD mV over range

• BKGD under range

• BKGD over range

• PRES mV under range

• PRES mV over range

• PRES val under range

• PRES val over range

To configure the XMO2’s response to any of the above error conditions, click on the corresponding button in the window above and proceed to the appropriate section for instructions.

44 XMO2 User’s Manual

Chapter 4. Programming with Instrument Data Manager

4.2.2 Total Drift Error

The Total Drift Error option lets you enable or disable error handling for a total calibration drift error and to specify the mA output that will be generated during an error condition (typically 23 mA). Clicking on this button opens a window similar to Figure 36 below.

Figure 36: Total Drift Error mA Window

Click on the appropriate button to either enable or disable error handling for this condition at the XMO2’s analog output. If you clicked on the mA Disable button, skip the next screen. If you clicked on mA Enable, a window similar to Figure 37 below opens.

Figure 37: Error mA Output Entry Window

In the text box at the above screen, enter the mA output that you wish to have generated in the event of a total calibration drift error. Click on the Next Item/Enter button to confirm the entry.

XMO2 User’s Manual 45

Chapter 4. Programming with Instrument Data Manager

4.2.2 Total Drift Error (cont.)

After specifying the analog output response to this error condition, a window similar to Figure 38 below opens.

Figure 38: Total Drift Error IDM Window

Click on the appropriate button to either enable or disable the generation of an error signal for this condition via the XMO2’s IDM link. In either case, you will be returned immediately to the main Error Handler menu.

4.2.3 All Other Error Conditions

The programming for all of the other XMO2 error conditions listed on page 44 is identical to that described in the previous section for the Total Drift Err condition. Therefore, simply refer to the instructions in the previous section to configure the error handling for any of these other conditions. All three windows will be identical to those shown in the previous section, except that the error listed above the Enable/Disable buttons will reflect the specific error currently being programmed.

46 XMO2 User’s Manual

Chapter 4. Programming with Instrument Data Manager

4.3 The Factory Cal Menu

The XMO2 comes from the factory completely programmed for your particular application. Should it become necessary to restore the factory setup, you can use the Factory Cal menu and your Calibration Data Sheet to reenter the factory data.

CAUTION! Always refer to your Calibration Data Sheet for the data to enter in the Factory Cal

menu. Entering incorrect data will result in inaccurate operation of the XMO2.

4.3.1 Background Gas Labels

From the Edit Functions menu (shown in Figure 34 on page 43), click on the Factory Cal button. A screen similar to Figure 39 below opens.

Figure 39: BKGD Comp Window

Note: If background gas compensation is not required for your XMO2, click on the No button in the above window

and proceed directly to the Pressure Compensation section on the next page.

To enter your background gas labels click on the Yes button above. A window similar to Figure 40 below opens.

Figure 40: Edit # Gases Window

XMO2 User’s Manual 47

Chapter 4. Programming with Instrument Data Manager

4.3.1 Background Gas Labels (cont.)

In Figur e 40 on page 47, enter the number of background gases for which you have compensation data. Then, press the Next Item/Enter button to open a window similar to Figure 41 below.

Figure 41: Point Editing Window

In the above window, enter an identifying label for background gas #1, and click on the Next Item/Enter button. The above sequence will repeat until you have entered identifying labels for each of your background gases.

4.3.2 Pressure Compensation

If you did not enter any background gas labels or upon entering your final background gas label, a window similar to Figure 42 below opens.

Figure 42: Pressure Comp Window

Note: If pressure compensation is not required for your XMO2, click on the No button in the above window and

proceed directly to the Entering Data Points section on page 51.

48 XMO2 User’s Manual

Chapter 4. Programming with Instrument Data Manager

4.3.2a Number of Pressures

When you click on the Yes button in Figure 42 on page 48, a window similar to Figure 43 below opens.

Figure 43: Edit # Pressures Window

To enter your pressure compensation data (be sure to reference your Calibration Data Sheet) click on the Edit # of Pressures button above to open a window similar to Figure 44 below.

Figure 44: Edit # Pressures Window

In Figure 44 above, enter the number of pressures for which you have compensation data. Then, press the Next Item/Enter button to return to the window in Figure 43 above.

XMO2 User’s Manual 49

Chapter 4. Programming with Instrument Data Manager

4.3.2b Pressure #1 Background Gases

Note: If you are not using background gas compensation, this menu does not appear. Proceed directly to the next

section.

T o begin entering your data po ints for each of the pressure compensation curves, click on the PRS1 button in Figure 43 on page 49 to open a window similar to Figure 45 below.

Figure 45: Background Gas Window

In the above window, click on the Edit # of BKGDs button to open a window similar to Figure 46 below.

Figure 46: Edit # of BKGDs Window

In the above window, enter the number of background gases for which you have compensation data at the first compensated pressure. Then, click on the Next Item/Enter button to confirm your entry and return to the window in Figure 45 above.

50 XMO2 User’s Manual

Chapter 4. Programming with Instrument Data Manager

Entering Data Points

In the window shown in Figure 45 on page 50, click on the Background Label 1 button (the actual text on this button will correspond to the label you entered in the previous section) to open a window similar to Figure 47 below.

Figure 47: PRS1 BKGD Points Window

In the above window, click on the Edit # of Points button to open a window similar to Figure 48 below.

Figure 48: PRS1 BKGD Points Window

To begin entering your data, click on the PT 1 button in Figure 47 above to open a window similar to Figure 49 below.

Figure 49: %O2 Data Window

XMO2 User’s Manual 51

Chapter 4. Programming with Instrument Data Manager

4.3.2c Completing the Process

By using the window in Figure 49 on page 51 and clicking on the Next Item/Enter button after each entry, you will be able to enter a value for each of the following parameters:

Note: The following list assumes that you are using both pressure and background gas compensation. If you are not

using pressure compensation, the Pressure and Prs mV parameters do not appear. If you are not using background gas compensation, the BK mV parameter does not appear.

• %O2

• Prssure

• O2 mV

• BK mV

• Prs mV

After entering the last parameter, you will be returned to the screen shown in Figure 49 on page 51. Finish the programming of this section by completing the following steps:

1. Repeat the procedure beginning at Figure 47 on page 51 until you have entered data for each parameter at all

of the points listed.

2. Click on the Exit Page button to return to Figure 45 on page 50.

3. Repeat the procedure beginning at Figure 45 on page 50 until you have entered data for each of the labeled

background gases.

4. Click on the Exit Page button to return to Figure 43 on page 49.

5. Repeat the procedure beginning at Figure 43 on page 49 until you have entered data for each of the listed

pressures.

6. Click on the Exit Page button in Figure 43 on page 49.

You have now completed the programming of the Factory Cal menu and you should be back at the main meter window.

52 XMO2 User’s Manual

Chapter 4. Programming with Instrument Data Manager

4.4 The Advanced Menu

The final option in the Edit Functions menu (refer to Figure 34 on page 43) is Advanced. To select this option, click on the Advanced button, and a window similar to Figure 50 below opens.

IMPORTANT: You cannot enter this menu unless you have a valid password. Your assigned password is listed on the

page at the end of this chapter.

Figure 50: Password Window

Enter your password in the text box above and click on the Next Item/Enter button. Then, a window similar to Figure 51 below opens.

Figure 51: Advanced Main Menu

The following options are available in this menu:

• Fast Response - a software enhancement resulting in faster performance under certain conditions

• Language - change the language used for the XMO2 menus

• Meter ID - change the meter identification number

To select one of the above options, click on the corresponding button in the window above and proceed to the appropriate section for instructions.

XMO2 User’s Manual 53

Chapter 4. Programming with Instrument Data Manager

4.4.1 Fast Response

IMPORTANT: ATEX compliance requires both:

• Fast Response calibration of the XMO2 transmitter

• Pressure Compensation of the XMO2 or constant control of the sample system pressure.

IMPORTANT: The response type has been factory preset for your application requirements. If considering a

response-type change, always contact GE first.

When you select the Fast Response option, a window similar to Figure 52 below opens.

Figure 52: Fast Response Window

Click on the appropriate button to either enable or disable the Fast Response software. If you clicked on the No button to disable Fast Response, you are immediately returned to the Advanced main menu. However, if you clicked on the Yes button to enable Fast Response, you are prompted to enter values for the following three parameters:

CAUTION! Do not change the factory default values for any of these parameters without first

contacting GE.

• Fast Tau up

• Fast Tau down

• Fast Threshold %FS

Enter a value for the first parameter, and click on the Next Item/Enter button to confirm the entry and move to the next parameter. After confirming the final parameter, you are returned to the Advanced main menu.

54 XMO2 User’s Manual

Chapter 4. Programming with Instrument Data Manager

4.4.2 Language

When you click on the Language button, a window similar to Figure 53 below opens.

Figure 53: Language Window

The standard language used for the XMO2 menus is English, and these strings are stored in a meter file called default.txt. If you wish to translate this file into another language, click on the Upload to PC button, and a window similar to Figure 54 below opens.

Figure 54: Creating a Data File

In the above window, specify the directory on your PC where you want to copy the default.txt file and click on the OK button. The file will be saved to your PC and you will be returned to the Language main menu.

Next, open the PC file in any word processor and translate the menu strings into the desired language. Be very careful not to change any of the formatting or punctuation in the file. Finally, save the file with a new name (*.txt).

XMO2 User’s Manual 55

Chapter 4. Programming with Instrument Data Manager

4.4.2 Language (cont.)

To load your translated menu string file into the XMO2, click on the Download from PC button to open a window similar to Figure 55 below.

Figure 55: Downloading a Data File

In the above window, navigate to the location and name of your translated menu string file on the PC and click on the OK button. The new file will be loaded into the XMO2. After you power down the meter and restart i t, all of the menus will be displayed in the new language.

If after loading a new text file in a different language, you wish to return to the original English menus, simply click on the Restore to Defaults button. The XMO2 will reload a copy of the factory default.txt file from its memory and the menus will once again appear in English.

56 XMO2 User’s Manual

Chapter 4. Programming with Instrument Data Manager

4.4.3 Meter ID

When you click on the Meter ID button, a window similar to Figure 56 below opens.

Figure 56: Meter ID Window

At the above window, you may either leave the existing meter ID number without change, or enter a new meter ID number. In either case, click the Next Item/Enter button to confirm the entry (or click the Previous Item or Exit Page button to leave the window without changing the meter ID number).

If you changed the existing meter ID number, a window similar to Figure 57 below opens.

Figure 57: Instructions for New Meter ID Number

Note the instructions above for reconnecting your XMO2 to the PC using the new meter ID number. Then, click on the Next Item/Enter or Exit Page button to return to the Advanced main menu.

IMPORTANT: Once you have entered a new meter ID number, you cannot immediately change the number again. You

must exit the page, close the connection, and r econnect the meter using the new meter ID number. If you wish, you may then repeat the process to enter another meter ID number.

XMO2 User’s Manual 57

Chapter 4. Programming with Instrument Data Manager

Your assigned password is: 2719.

[Please copy this page and keep it in a safe place for future reference.]

58 XMO2 User’s Manual

Chapter 5. Specifications

5.1 Performance

Accuracy 0-1% O2 range: ±2% of span

80-100% and 90-100% O All other ranges: ±1% of spam

Linearity ±0.5% of span Repeatability ±0.2% of span Measurement Resolution 0.01 mA

ranges: ±0.2% O

Chapter 5. Specifications

Stability Zero: ±1.0% of span per month (±2% of 0-1% O

Span: ±0.4% of span per month (±-/9% for 0-1% O

range)

range

Response Time Fast Response enabled: <5 seconds for 63% of step change

Damped Response enabled: 40 seconds for 63% of step change

Measurement Ranges (typical)

0-1% 0-2% 0-5% 0-10% 0-21% 0-25% 0-50%* 0-100%* 80-100%* 90-100%* *Pressure compensation required

Controlled Sensor Temperatures

Standard: 45° (113°F) Optional: 60°C or 70°C (140°F or 158°F)

Atmospheric Pressure Effect Standard: ±0.2% of span per mm of Hg

Optional: Pressure compensation

Required Sample Gas Flow Rate

Range: 0.1 to 2.0 SCFH (50 to 1,000 cc/min) Nominal: 1.0 SCFH (500 cc/min) nominal

Sample Gas Flow Rate Effect <1% of span, with weatherproof enclosure, background gas compensation, and

0.1-2.0 SCFH (50-1,000 cc/Min) flow rate

Warmup Time 30 minutes

XMO2 User’s Manual 59

Chapter 5. Specifications

5.2 Functional Specifications

Analog Output 4-20 mA isolated, 800 Ω max, load, isolated, field-programmable Digital Output RS232, 3-conductor Power Input 24.0 VDC ±4 VDC @ 1.2 A maximum

Cable (Power Input and Analog Output)

Standard: 10 ft (3 m), 4-conductor, shielded, P/N X4(10); lengths up to 4000 ft. Optional: lengths to 450 ft. (137 m) available

Cable (Digital Output) 6 ft (2 m), 3-conductor, shielded, P/N 704-667, 668, 669, or 670

Connector: DB9 male, DB9 female, DB25 male, or DB25 female Lengths: up to 4,000 ft (1,200 m)

Operating Temperature

Standard: +45 Optional: +60° or +70°C (+140°F or +158

C (+113oF)

Ambient Temperature Range Standard 45°C unit: -20° to +40°C (-4° to +104°F)

Optional 60°C unit: -5 to 55°C (23 to 131°F) Optional 70°C unit: 5 to 65°C (41 to 149°F)

Sample Gas Pressure Range: 20 psig maximum

60 XMO2 User’s Manual

Chapter 5. Specifications

5.3 Physical Specifications

Sensor Wetted Materials Standard: 316 SS, glass, and Viton™ o-rings

Optional: Hastelloy, Monel, or Titanium with Chemraz™ o-rings

Dimensions Weatherproof unit: 9.53” (H) x 5.71” (D) (242 x 145 mm)

Explosion-proof unit: 10.47” (H) x 5.71” (D) (266 x 145 mm)

Weight 9.5 lb (4.3 kg) Connections Electrical: 3/4 in. NPTF conduit and 6-terminal, removable connector

Process: 1/4 in. NPTF inlet and outlet

Environmental Weatherproof: Class I Div. 1 Groups A, B, C & D

Class II, III Div. 1 Groups E, F & G Tamb 55°C T6 Type 4X

Flameproof: ITS12ATEX17703X

IECEx ITS 12.0058X II 2 G Ex d IIC T6 Gb IP66 -20°C < Tamb < +55°C All conduit entries 3/4” NPT

CE: EMC 2004/108/EC

PED 97/23/EC

Lloyd’s Registry approval

Note: For CE compliance, the power and I/O cables must be shielded. All cables

must be terminated within the cable gland at the XMO2.

Note: See the Certification Drawings in Appendix B, Outline and Installation

Drawings, for additional details.

5.4 Optional Accessories

GE offers a complete line of optional accessories for use with the XMO2 transmitter. These include:

• PS5R-C24: 24 VDC power supply

• X4(*): 4-conductor cable for power input and analog output connections (* specifies length in feet)

lengths up to 450 ft (137 m) are available

• 704-(667, 668, 669, or 670)-*: 3-conductor cable for digital output connections (* specifies length in feet)

DB9 male, DB9 female, DB25 male, and DB25 female connectors are available

The XMO2 can also be interfaced with other GE displays and analyzers, such as:

• TMO2D, LDP, and XDP display/control modules

• Moisture Image Series 1 and Moisture Monitor Series 3 Analyzers

• System 1 Analyzer

XMO2 User’s Manual 61

Chapter 5. Specifications

5.5 Ordering Information

ABCDE

XMO2 -

A: Transmitter Model

XMO2 -

B: Measurin g Cell Package (requires 24 VDC, 1.2 A power

supply) 1 - Weatherproof Enclosure 2 - Explosion-Proof/Flameproof Enclosure X - Without Enclosure (Spare Cell)

C: CE Compliance

H - Standard C - Compliant

D: Pressure Compensation

1 - Background gas compensation only (standard) 2 - Atmospheric pressure and background gas

compensation (optional)

3 - background gas compensation only, IDM user

program

4 - atmospheric pressure & background gas

compensation, IDM user program.

Note: If Package Option B=5 (Rack Mount) is selected,

Comp/Comm Option D must be either 3 or 4.

E: Wetted Material

1 - 316 stainless steel 2 - Hastelloy C-276 / Chemraz O rings

62 XMO2 User’s Manual

5.6 Calibration Specification

ABC

XMO2 -

A: Transmitter Model

XMO2

B: Ra nge of Oxygen Output

1 - 0-1% 2 - 0-2% 3 - 0-5% 4 - 0-10% 5 - 0-21% 6 - 0-25%

Chapter 5. Specifications

7 - 0-50% (atmospheric pressure compensation

XMO2 hardware required)

8 - 0-100% (atmospheric pressure compensation

XMO2 hardware required)

A - 90-100% (atmospheric pressure compensation

XMO2 hardware required)

B - 80-100% (atmospheric pressure compensation

XMO2 hardware required)

S - Special

C: Compensation Signal

1 - Background gas only (standard gas N 2 - Atmospheric pressure only (standard pressure

range of 700-800 mm of Hg) 3 - Background gas only (spec i al gas) 4 - Atmospheric pressure only (special range) 5 - Background gas and atmospheric pressure

(standard gas N

range of 700-800 mm of Hg) 7 - 0, 2, 10, 21% O

S - Background gas and atmospheric pressure

(special gas and special pressure range)

/CO2)

/CO2 and standard pressure

in N2 and 14% CO2/N

XMO2 User’s Manual 63

Chapter 5. Specifications

5.7 A Calibration Sheet

For reference, a sample Calibration Sheet for the XMO2 transmitter is shown in Figure 58 below.

Figure 58: Sample XMO2 Calibration Sheet

64 XMO2 User’s Manual

Appendix A. Two Typical Applications

(MIN)

(228.6)

9.00

TANK

DRAIN TO

AIR INLET

(11.2)

42.00

24.00

30.00

1.25 TYP (31.7)

.62 TYP

(15.7)

.44 DIA

(11.2)

(762.0)

(609.6)

(76.2)

3.00

.44

2 PLCS

(609.6)

24.00

(1066.8)

INLET

NITROGEN

OXYGEN ANALYZER

INLET

SAMPLE

Appendix A. Two Typical Applications

A.1 Blanketing Gases in Hydrocarbon Liquid Storage Tanks

The XMO2 transmitter and its associated sample system is often used to measure the concentration of oxygen (O2) in the nitrogen (N

A.1.1 The Problem

Air can leak into the vapor space above hydrocarbon liquids stored in tanks or process vessels, forming a potentially explosive gas mixture. To solve this problem, inert gases such as N

above the stored liquid and dispel any O monitor the level of O

A.1.2 Equipment Used

A typical instrumentation package for this application includes an XMO2 transmitter configured for a range of 0-21% O

in N2 or CO2 and operating conditions of ambient temperature and atmospheric pressure. The XMO2 is mounted in

a sample system similar to the one shown in Figure 59 below (ref. dwg. #731-559).

) or carbon dioxide (CO2) gases used to blanket hydrocarbon liquids during storage.

or CO2 are often used to purge the vapor space

that may have leaked into that space. In such a system, one must constantly

in the vapor space to make sure that an explosive gas mixture does not form.

Figure 59: Blanketing Gas Sample System

XMO2 User’s Manual 65

Appendix A. Two Typical Applications

A.1.2 Equipment Used (cont.)

The sample system in Figure 59 on page 65 consists of:

• An eductor to draw the sample from and return it to the vapor space above the liquid in the storage tank

• A liquid separator/dump to remove condensable liquids

• A filter/coalescer for the removal of solid and liquid particulates

• Automatic calibration gas solenoid valves for the automatic calibration of the system on a timed basis

• Flowmeters

• Pressure gauges

All components are mounted on a painted steel plate that is usually housed in a heated enclosure.

Note: An optional TMO2D display/controller (or similar device) is required for automatic calibration of the XMO2.

A.1.3 Basic Operating Procedure

The sample system should be located at or near the top of the storage tank so that condensate can drip back into the tank. The gas used to purge the tank provides the motive force in the eductor to pull a gas sample from the vapor space above the hydrocarbon liquid into the sample system. The sample gas, condensed liquids, and the inert gas are all returned to the tank, making this is a closed-loop system. The XMO2 is recalibrated periodically using the purge gas to zero the instrument and ambient air (20.93% O

atmosphere, so that air is not introduced into the storage tank.

For this application the required calibration gases are:

• Zero Gas: N

• Span Gas: air (20.93% O

or CO2 (at least 99.95% pure)

)

) to span the instrument. The span gas can optionally be vented to

A.1.4 Previous Systems

Electrolytic cells were once commonly used for this application. However, such systems required extensive maintenance and frequent manual calibration. In addition, the cells were easily damaged by condensable liquids, requiring frequent cell replacement. As the XMO2 provides continuous monitoring of the O

maintenance-free operation, it is now the system of choice.

content with

66 XMO2 User’s Manual

Appendix A. Two Typical Applications

SAMPLE

INLET

SAMPLE

CELL

OXYGEN

CELL

24.00

(609.6)

30.00 (762)

36.00

(914.4)

1.25

(31.8)

0.44

(11.2)

0.63

(16.0)

3.00

(76.2)

OUTLET

SAMPLE

A.2 Reactor Feed Gases in Formaldehyde Production

The XMO2 transmitter and its associated sample system is often used to measure the concentration of oxygen (O2) in an air/methanol (CH formaldehyde.

A.2.1 The Problem

In order to maximize the yield of the reaction, while maintaining the O2 concentration at a safe level, the air/CH3OH vapor mixture must be continuously monitored and accurately controlled.

A.2.2 Equipment Used

A typical instrumentation package for this application includes an XMO2 transmitter configured for a range of 0-21% O

in N2 or CO2 and operating conditions of a controlled temperature and atmospheric pressure. The XMO2 is

mounted in a sample system similar to the one shown in Figure 60 belo w (ref. dwg. #731-185).

OH) vapor mixture that is commonly used as a reactor feed gas in the production of

Figure 60: Formaldehyde Feed Gas Sample System

XMO2 User’s Manual 67

Appendix A. Two Typical Applications

A.2.2 Equipment Used (cont.)

The sample system in Figure 60 on page 67 consists of:

• Inlet, outlet, and calibration needle valves

• A filter/coalescer assembly

• Pressure gauges

• Flowmeters

All components are mounted on a painted steel plate in an enclosure that is heated to 75 ±10°F.

A.2.3 Basic Operating Procedure

The sample system should be mounted as close as possible to the reactor inlet in order to minimize lag time. Air (20.93% O

continuously verifies that the optimal amount of O maximized yield. Too low an O

) is used as the source of O2, and the air/CH3OH vapor mixture is sampled at the reactor inlet. The XMO2

(typically 9.8%) is present for the reaction to proceed safely to a

level will decrease the yield, while too high an O2 level will create a safety hazard.

For this application the required calibration gases are:

• Zero Gas: N

• Span Gas: air (20.93% O

Note: Any compatible display device may be specified.

(at least 99.95% pure - 0.0% O2)

)

A.2.4 Previous Systems

Dumbbell-type paramagnetic O2 sensors were once commonly used for this application. However, such systems required extensive maintenance and frequent manual calibration. In addition, the sensors were easily damaged by

condensable liquids, requiring frequent sensor replacement. As the XMO2 provides continuous, accurate monitoring of the reactor feed gas O

of choice.

content with maintenance-free operation and excellent calibration stability, it is now the system

68 XMO2 User’s Manual

Appendix B. Outline and Installation Drawings

This appendix includes the following XMO2 drawings in 11” x 17” fold-out format:

• Figure 61, "Certification Drawing (ref. dwg #752-168, Rev. E, SH1)" on page 71

• Figure 62, "Certification Drawing (ref. dwg #752-168, Rev. E, SH2)" on page 72

• Figure 63, "Certification Drawing (ref. dwg #752-168, Rev. E, SH3)" on page 73

• Figure 64, "RS232 Digital Output Cables" on page 74

• Figure 65, "Digital PCB Assembly (ref. dwg #703-1316, rev. K, sh.1)" on page 75

• Figure 66, "Digital PCB Assembly (ref. dwg #703-1316, rev. K, sh. 2)" on page 76

• Figure 67, "Digital PCB Schematic (ref. dwg #700-1316, rev. H, sh. 1)" on page 77

• Figure 68, "Digital PCB Schematic (ref. dwg #700-1316, rev. H, sh. 2)" on page 78

• Figure 69, "Analog PCB Assembly (ref. dwg #703-1276, rev. H,)" on page 79

• Figure 70, "Analog PCB Schematic (ref. dwg #700-1276, rev. F, sh. 1)" on page 80

• Figure 71, "Analog PCB Schematic (ref. dwg #700-1276, rev. F, sh. 2)" on page 81

• Figure 72, "EMI Filter PCB Assembly (ref. dwg. #703-1550, rev. A)" on page 82

• Figure 73, "EMI Filter PCB Schematic (ref. dwg. #700-1550, rev. A)" on page 83

• Figure 74, “Interconnection Diagrams,” on page 84

XMO2 User’s Manual 69

Appendix B. Outline and Installation Drawings

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70 XMO2 User’s Manual

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6&,5,4,3,2 STEEHS DETADPU

72050

6&,5,4,3 STEEHS DETADPU ,OCE REP DETADPU

40/12/1

FCJ

29150

30/92/8

30/4/9

FWP

40/72/1

FWP

40/1/21

92450

6&,5,4,3 STEEHS DETADPU ,OCE REP DETADPU

JADFWP

40/2/21

21/1/21

SPJGK

SPJ

36480

.ONLEDOM

SNOITPIRCSED

SNOISIVER

OCEVER NWDDKCDVPA

DACOTUA

Appendix B. Outline and Installation Drawings

Figure 61: Certification Drawing (ref. dwg #752-168, Rev. E, SH1)

XMO2 User’s Manual 71

Appendix B. Outline and Installation Drawings

20/31/60GJ

20/81/60FMP20/62/40ALR

861-257

ERIUQERGNIWARDSIHTOTSEGNAHC

.NOITAZIROHTUAYCNEGAROIRP

REENIGNENOITACIFITRECEHTTCATNOC

A-ANOITCES

Figure 62: Certification Drawing (ref. dwg #752-168, Rev. E, SH2)

XMO2 User’s Manual 72

ERIUQERGNIWARDSIHTOTSEGNAHC

.NOITAZIROHTUAYCNEGAROIRP

REENIGNENOITACIFITRECEHTTCATNOC

10-

20-

30-

40-

:etaD .gfM

gnisneS EG

tsaE enoZ eerF

dnalerI ,nonnahS

96.57

52.

PYT

39.4352. PYT

78.7

PYT

99.81

PYT

50.3 SCLP 4

.SCLP 4

38.1 AID

39.1 AID

03.3

SCLP 4

00.76

PYT

06 revo stneibma nI

09 rof detar eriw dleif esu C

.nim C

66PI

55 bmaT

X4 epyT

devorppA

X30771XETA21STI

X8500.21 STI xECEI bG 6T CII d xE G 2 II

02- 66PI

TPN "4/3 SEIRTNE TI

UDNOC LLA

ºº

C55+ <bmaT< C

0811

sttaW 52 CDV 42

0811

sttaW 52 CDV 42

0811

sttaW 52 CDV 42

0811

sttaW 52 CDV 42

rezylanA negyxO 2OMX

D&,C,B,A PG 1 VID I LC

G&,F,E PG ,1 VID III,II LC

X4 epyT 6T C 55 bmaT

devorppA

gnisneS ,erutcurtsarfnI EG .rD kraP ygolonhceT 0011

ASU 12810 AM ,acirelliB

gnisneS ,erutcurtsarfnI

.rD kraP ygolonhceT 0011

ASU 12810 AM ,acirelliB

X30771XETA21STI

X8500.21 STI xECEI bG 6T CII d xE G 2 II

02- 66PI

TPN "4/3 SEIRTNE TIUDNOC LLA

ºº

C55+ <bmaT< C

:etaD .gfM

06 revo stneibma nI

09 rof detar eriw dleif esu C

.nim C

66PI

55 bmaT

X4 epyT

devorppA

gnisneS EG

tsaE enoZ eerF

dnalerI ,nonnahS

:etaD .gfM

X30771XETA21STI

X8500.21 STI xECEI

bG 6T CII d xE G 2 II

02- 66PI

TPN "4/3 SEIRTNE TIUDNOC LLA

ºº

C55+ <bmaT< C

0811

sttaW 52 CDV 42

rezylanA negyxO 2OMX

gnisneS ,erutcurtsarfnI EG .rD kraP ygolonhceT 0011

ASU 12810 AM ,acirelliB

era srotserra emalf fi dioV :noituaC

negyxo rof devorppA .devomer

.tnecrep 52 ot pu snoitartnecnoc tiudnoc eriuqer snoitallatsni ASC

.sehcni 81 nihtiw slaes

NOISREV2OMX

861-257

tneserp si erehpsomta evisolpxe na nehw nepo ton oD

LEBAL NOISREV FOORP NOISOLPXE

LEBAL NOISREV FOORP REHTAEW

HCTIWS LANRETXE HTIW LEBAL NOISREV FOORP NOISOLPXE

LEBAL NOISREV FOORP REHTAEW

NOISREV DNALERI

NOISREV ASU

50-

tneserp si erehpsomta evisolpxe na nehw nepo ton oD

Appendix B. Outline and Installation Drawings

Figure 63: Certification Drawing (ref. dwg #752-168, Rev. E, SH3)

XMO2 User’s Manual 73

Appendix B. Outline and Installation Drawings

Cable 704-668 DB9 Female

Cable 704-669 DB25 Male

Cable 704-670 DB9 Male

Cable 704-667 DB25 Female

XMO2 User’s Manual 74

Figure 64: RS232 Digital Output Cables

Appendix B. Outline and Installation Drawings

Figure 65: Digital PCB Assembly (ref. dwg #703-1316, rev. K, sh.1)

XMO2 User’s Manual 75

Appendix B. Outline and Installation Drawings

Figure 66: Digital PCB Assembly (ref. dwg #703-1316, rev. K, sh. 2)

XMO2 User’s Manual 76

Appendix B. Outline and Installation Drawings

Figure 67: Digital PCB Schematic (ref. dwg #700-1316, rev. H, sh. 1)

XMO2 User’s Manual 77

Appendix B. Outline and Installation Drawings

Figure 68: Digital PCB Schematic (ref. dwg #700-1316, rev. H, sh. 2)

XMO2 User’s Manual 78

Appendix B. Outline and Installation Drawings

Figure 69: Analog PCB Assembly (ref. dwg #703-1276, rev. H,)

XMO2 User’s Manual 79

Appendix B. Outline and Installation Drawings

Figure 70: Analog PCB Schematic (ref. dwg #700-1276, rev. F, sh. 1)

XMO2 User’s Manual 80

Appendix B. Outline and Installation Drawings

Figure 71: Analog PCB Schematic (ref. dwg #700-1276, rev. F, sh. 2)

XMO2 User’s Manual 81

Appendix B. Outline and Installation Drawings

Figure 72: EMI Filter PCB Assembly (ref. dwg. #703-1550, rev. A)

XMO2 User’s Manual 82

Appendix B. Outline and Installation Drawings

Figure 73: EMI Filter PCB Schematic (ref. dwg. #700-1550, rev. A)

XMO2 User’s Manual 83

Appendix B. Outline and Installation Drawings

TMO2D Connections (see User's Manual for details) XDP Connections (see User's Manual for details)

XMO2

PS5R-C24

(or equal)

RTN +24

REC

AUX

+24V

76543

RTN

MIS1/MMS3

387654

REC

+- 1RTN

+24V2

AUX

ine

eut

XMO2

PS5R-C24

RTN

(or equal)

+24

XMO2 XMO2

LDP Connections (see User's Manual for details)

XMO2

Gnd

24V

XMO2

+24

PS5R-C24

(or equal)

RTN

CS1.34 Data Acquisition PCB

678 876

5 4 3 21

TB1 TB2

678

TB3

Same As TB1

Pins 2-4

Same As TB1

Pins 2-4

Same As TB1

Pins 2-4

Same As TB1

Pins 2-4

Same As TB1

1234123

TB2 TB1

1234123

TB2 TB1

1234123

TB2 TB1

1234123

TB2 TB1

1234123

TB2 TB1

1234123

TB2 TB1

RTN 24 V

Input

MIS1/MMS3 Connections (see User's Manual for details) MIS2 Connections (see User's Manual for details)

System 1 Connections (see User's Manual for details)

Figure 74: Interconnection Diagrams

XMO2 User’s Manual 84

Appendix C. IDM Menu Maps

This appendix includes the following IDM menu maps:

• Figure 75, “Field Cal, 4-20mA Output and Error Handler Menu Map,” on page 87

• Figure 76, “Factory Cal and Advanced Menu Map,” on pa ge 88

Appendix C. IDM Menu Maps

XMO2 User’s Manual 85

Appendix C. IDM Menu Maps

[no content intended for this page]

86 XMO2 User’s Manual

Edit Functions

Error Handler

4-20mA Output

Field Cal

Factory Cal

Advanced

Perform Cal

Configure Cal

Hold Last Value

Calibration Drifts Clear Calibration

Disable Hold Last

Span Field Cal

Zero Field Cal

Yes

Abort Field Cal

Yes No

Field Cal Percent

After Delay TimeBefore Delay Time

Max Total Drift Max Drift/Cal

Field Cal Type

Span Field Cal

Zero Field Cal

1 Point (Offset) 2 Point (Ze/Sp)

Zero Field Cal

Span Field Cal

%O2 for 4mA

4-20mA Range

Clamp Output?

%O2 for 20mA

NoYes

4mA Cal 20mA Cal

4-20mA Test %O2 Test

4/20mA UP 4/20mA DOWN Numeric Cal 4/20mA STORE 4/20mA ABORT

O2 mV overTotal Drift Err Drift/Cal Err O2 mV under

O2 % under

BKGD over

O2 % over

BKGD mV under BKGD mV over BKGD under PRES val underPRES mV under PRES mV over PRES val over

mA Enable mA Disable

IDM Enable IDM Disable

[see Figure 88] [see Figure 88]

Appendix C. IDM Menu Maps

Figure 75: Field Cal, 4-20mA Output and Error Handler Menu Map

XMO2 User’s Manual 87

Edit Functions

Error Handler

4-20mA Output

Field Cal

Factory Cal

Advanced

Fast Response

NoYes

Language

Meter ID

Upload to PC

Reset to Defaults

[see Figure 87][see Figure 87][see Figure 87]

Fast Tau up

Fast Tau down

Fast Thresh %FS

Yes No

BKGD Comp

Pressure Comp

Yes No

Edit # of Points PT 1 PT n

Edit # Pressures PRS1 PRSn

Edit # of Points PT 1 PT n

Edit # of Points PT nPT 1

Edit # BKGDs

Bkgd Label 1 Bkgd Label n

Edit # Pressures PRS1 PRSn

Edit # of Points PT 1 PT n

Edit # BKGDs

Bkgd Label n

Bkgd Label 1

Appendix C. IDM Menu Maps

Figure 76: Factory Cal and Advanced Menu Map

XMO2 User’s Manual 88

Appendix D. Programming with PanaView

D.1 Introduction

The PanaView™ graphical user interface offers interactive communications between Windows-based PCs and GE instruments compatible with IDM protocol, such as the XMO2 oxygen transmitter. [Compatible 32-bit Windows operating systems include Windows 98SE, NT 4.0 (with Service Pack 6), 2000, XP and ME.] With PanaView , you can :

• Load and save site file data

• Create and save graph and log files

• Display text output and graphs of live measurement data

• Create custom templates for displaying text, graph and log data

• Interface with multiple GE instruments.

This document focuses on particular applications suitable for the XMO2 transmitter. For general PanaView applications such as creating graph and log files, displaying live measurement data, and creating custom templates, please refer to the general PanaView User’s Manual (910-211).

D.2 Wiring the RS232 Interface

All IDM-protocol instruments utilize an RS232 interface to communicate with a PC. For details on wiring your RS232 interface, refer to Establishing the RS232 Communication Link on page 16, and the GE document EIA-RS Serial Communications (916-054).

D.3 Setting Up the Communications Port

Use the steps below to establish communications with the XMO2.

1. Open the “New Meter Browser” window and expand the network tree. Then, highlight the My Computer

(Name) branch by clicking on it.

2. Pull down the “Edit” menu by clicking on it in the menu bar.

3. Click on the “New” menu option to open a submenu opens with two choices (see Figure 77 below).

Figure 77: Edit Menu

XMO2 User’s Manual 89

Appendix D. Programming with PanaView

D.3 Setting Up the Communications Port (cont.)

4. Click on the “Communications Port” option to select it. The Setup Communications screen appears similar to

Figure 78 below.

Figure 78: Setup Communications Screen

5. Open the Protocol menu (the first of the drop-down menus) and click on IDM.

6. Select any suitable available baud rate. A baud rate of 19200 is appropriate for almost all applications.

However, if you experience periodic communication reliability problems, you may wish to consider lowering the baud rate on your instrument and in PanaView.

IMPORTANT: Be sure all the communications port settings match those made in setting up the meter serial port.

7. Click on [OK] to complete data entry.

90 XMO2 User’s Manual

GE Sensing XMO2 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1. Features and Capabilities

1.1 Introduction

1.2 Basic Features

1.3 Theory of Operation

1.4 System Components

1.4.1 The XMO2 Transmitter

1.4.2 The Sample System

1.4.3 Long Cables (optional)

1.4.4 Power Supply (optional)

1.4.5 The TMO2D Display/Controller (optional)

Chapter 2. Installation

2.1 Introduction

2.2 Installing the XMO2 Transmitter

2.3 Installing the Sample System

2.3.1 A Basic System

2.3.1 Wiring the XMO2 Transmitter

2.3.2 CE Mark Requirements

2.3.3 Grounding the XMO2 Enclosure

2.3.4 Cable Specifications

2.3.5 Accessing Terminal Blocks TB1 and TB2

2.3.6 Wiring the Signal Connections

2.4 Establishing the RS232 Communication Link

2.5 Connecting to Other Devices

2.5.1 The PS5R-C24 Power Supply

2.5.2 TMO2D Display

2.5.3 LDP Display

2.5.4 XDP Display

2.5.5 Moisture Image/Monitor Series Analyzers

2.5.6 System 1 Analyzer

Chapter 3. Startup & Operation

3.1 Introduction

3.2 Powering Up the XMO2 Transmitter

3.3 Establishing a Sample Gas Flow

3.4 Analog Output Calibration Options

3.5 Factory Calibration Procedures

3.6 Enhancing the Factory Calibration

3.7 Required Calibration Materials

3.8 Preparing for Field Calibration

3.9 One-Gas Pushbutton Field Calibration

3.10 Two-Gas Pushbutton Field Calibration

3.10.1 Setup

3.10.2 Zero Gas Pushbutton Calibration

3.10.3 Span Gas Pushbutton Calibration

3.11 IDM Digital Communication Calibration

3.12 The Edit Functions Menu

3.13 The Field Cal Menu

3.13.1 Perform Cal

3.13.2 Configure Cal

3.13.3 Calibration Drifts

3.13.4 Clear Calibration

3.13.5 Hold Last Value

3.14 Changing the 4-20 mA Analog Output Range

3.14.1 4-20mA Range

3.14.2 4mA Cal

3.14.3 20 mA Cal

3.14.4 4-20mA Test

3.14.5 %O2 Test

Chapter 4. Programming with Instrument Data Manager

4.1 Introduction

4.2 The Edit Functions Menu

4.2.1 The Error Handler Menu

4.2.2 Total Drift Error

4.2.3 All Other Error Conditions

4.3 The Factory Cal Menu

4.3.1 Background Gas Labels

4.3.2 Pressure Compensation

4.4 The Advanced Menu

4.4.1 Fast Response

4.4.2 Language

4.4.3 Meter ID

5.1 Performance

Chapter 5. Specifications

5.2 Functional Specifications

5.3 Physical Specifications

5.4 Optional Accessories

5.5 Ordering Information