Rosemount 4081FG 2-Wire In Situ O2 Analyzer (550° to 1600°C) with FOUNDATION Fieldbus Communications-Orig. Issue Manuals & Guides

MODEL 4081FG TWO-WIRE
IN SITU OXYGEN ANALYZER
(550°°°° to 1600°°°°C) WITH
FOUNDATION FIELDBUS
COMMUNICATIONS

Instruction Bulletin IB-106-4081 Original Issue

Two-Wire In Situ Oxygen Analyzer

Part no.
Serial no.
Order no.

%

29760018

ROSEMOUNT WARRANTY

The oxygen probe is designed for industrial applications. Treat with care to
avoid physical damage. The probe contains components made from ceramic,
which are susceptible to shock when mishandled. THE WARRANTY DOES
NOT COVER DAMAGE FROM MISHANDLING. WARRANTY IS VOID
IF OUTER PROTECTION TUBE IS BROKEN.

Rosemount warrants that the equipment manufactured and sold by it will, upon
shipment, be free of defects in workmanship or material. Should any failure to conform to
this warranty become apparent during a period of one year after the date of shipment,
Rosemount shall, upon prompt written notice from the purchaser, correct such
nonconformity by repair or replacement, F.O.B. factory of the defective part or parts.
Correction in the ma nner provided above shall constitute a f ulfillment of all liabilities of
Rosemount with re spect to the q uality of the equipm ent.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHER WARRANTIES OF QUAL ITY WHETHER WRITTEN, ORAL,
OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY
OF FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure
of Rosemount to comply with the warranty provisions, whether claims by the purchaser are
based in contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deterioration due to
environment. Factors such as corrosive gases and solid particulates can be detrimental and
can create the need for repair or replacement as part o f normal wear and tear during the
warranty period.

Equipment supplied by Rosemount Analytical Inc. but not manu factured by it will be
subject to the same warranty as is extended to Rosemount by the original manufacturer.

At the time of installatio n it is impor tant that the req uired services are supplied to the
system. This will ensure, that should there be a delay between installation and full
commissioning that the sensor being supplied with ac power and reference air will not be
subjected to component deterioration.

IB-106-4081

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PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the Two-Wire In Situ

Oxygen Analyzer components, functions, installation, and maintenance.

This manual is designed to provide information about the Oxygen Analyzer. We recommend that you
thoroughly familiarize yourself with the Description and Installation sections before installing your
transmitter.

The description presents the basic principles of the transmitter along with its performance characteristics
and components. The remaining sections contain detailed procedures and information neces sary to install and
service the transmitter.

Before contacting Rosemount concerning any questions, first consult this manual. It describes most
situations encountered in your equipment’s operation and details necessary action.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this
publication.

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

Highlights an essential operating procedure,
condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

NOTE

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

.

The number in the l ow e r right corne r of each illu s t r ation in this public ation is a man u al illustratio n
number. It is not a part number, and is not related to the illustration in any technical manner.

IB-106-4081

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IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING AND

INSTALLATION OF THIS APPARATUS

The following safety instructions apply specifically
to all EU member states. They should be strictly
adhered to in order to assure compliance with the
Low Voltage Directive. Non-EU states should also
comply with the following unless superseded by
local or Nation al S t and a rds .

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

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

3. Mains suppl y cords shou l d comp ly with the requirements of IE C227 or I EC 245.

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

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

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

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

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

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

10. All graphical symbols used in this product are from one or more of the following
standards: EN610 10-1 , IEC417, an d ISO386 4.

IB-106-4081

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BELANGRIJK

Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.

De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier
moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low
Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen
tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften.

1. Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten,
intern en extern.

2. Na installatie of controle moeten alle veiligheidsdeksels en -aardingen terug geplaatst
worden. Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven.

3. Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.

4. Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen, hoger dan
75°C.

5. Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd
is.

6. Om de veilige werking van dit toestel te verzekeren, moet de voeding door een
stroomonderbreker gevoerd worden (min 10A) welke alle draden van de voeding moet
onderbreken. De stroomonderbrek er mag een m echanisch e schak elaa r bevatten. Z oniet m oet
een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook
duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten onderworpen zijn
aan een erkende standaard zoals IEC947.

7. Waar toestellen of deksels aangegeven staan met het symbool is er
meestal hoogspanning aanwezig. Deze deksels mogen enkel verwijderd
worden nadat de voedingsspanning werd afgelegd en enkel door getraind
onderhoudspersoneel.

8. Waar toestellen of deksels aangegeven staan met het symbool is er gevaar
voor hete oppervlakken. Deze deksels mogen enkel verwijderd worden
door getraind onderhoudspersoneel nadat de voeding ssp ann ing verw ijderd
werd. Sommige oppper-vlakken kunnen 45 minuten later nog steeds heet
aanvoelen.

9. Waar toestellen of deksels aangegeven staan met het symbool gelieve het
handboek te raadplegen.

10. Alle grafische symbolen gebruikt in dit produkt, zijn afkomstig uit een of meer van
devolgende standaards: EN61010-1, IEC417 en ISO3864.

IB-106-4081

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VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.

Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne
skal nøje følges for overholdelse af Lavsspænding sdir ek tiv et og bør også følges i ikke EU­lande medmindre andet er specificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse
forefindes.

2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og jordforbindelser reetableres.

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

4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur højere end 75° C.

5. Alle benyttede kabelforskruninger skal have en intern dimension, så passende
kabelaflastning kan etabler es.

6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse mod indirekte berøring
gennem afbryder (min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsitua­tion. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for
afbryder mellem forsyning og udsty r benyt tes og m æ rk es so m sådan. Afbrydere eller
kontakter skal overholde en kendt standard som IEC947.

7. Hvor udstyr eller dæksler er mærket med dette symbol, er farlige spændinger
normalt forekom-mende bagved. Disse dæksler bør kun afmonteres, når
forsyningsspændingen er frakoblet - og da kun af instrueret servicepersonale.

8. Hvor udstyr eller dæksler er mærket med dette symbol, forefindes meget
varme overflader bagv ed. Disse dæksle r bør kun afmonte res af ins tr uer et
servicepersonale, når forsy ning sspændi ng er frakoble t. Visse ov erf lader vil
stadig være for varme at berøre i op til 45 minutter efter frakobling.

9. Hvor udstyr eller dæksler er mærket med dette symbol, se da i
betjeningsmanual for instruktion.

10. Alle benyttede grafiske symboler i dette udstyr findes i én eller flere af følgende standarder:­EN61010-1, IEC417 & ISO3864.

IB-106-4081

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BELANGRIJK

Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.

Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de
geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden.
Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving
anders voorschrijft.

1. Alle voorziene interne- en externe aardaansluitingen dienen op adequate wijze aangesloten te
worden.

2. Na installatie,onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels /kappen
en aardingen om reden van veiligheid weer aangebracht te worden.

3. Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of IEC 245.

4. Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven
75°C.

5. Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een
adequate verankering van de kabel wordt verkregen.

6. Om een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats
te vinden via een meerpolige automatische zekering (min.10A) die

alle

spanningvoerende
geleiders verbreekt indien een foutconditie optreedt. Deze automatische zekering mag ook
voorzien zijn van een mechanisch bediende schakelaar. Bij het ontbreken van deze
voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te
zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars dienen te
voldoen aan een erkende standaard zoals IEC 947.

7. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het
volgende symbool, kunnen zich hieronder spanning voerende delen bevinden
die gevaar op kunnen leveren. Deze beschermdeksels/kappen mogen
uitsluitend verwijderd worden door getraind personeel als de spanning is
afgeschakeld.

8. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het
volgende symbool, kunnen zich hieronder hete oppervlakken of onderdelen
bevinden. Bepaalde delen kunnen mogelijk na 45 min. nog te heet zijn om aan
te raken.

9. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het
volgende symbool, dient men de bedieningshandleiding te raadplegen.

10. Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende
standaarden: EN 61010-1, IEC 417 & ISO 3864.

IB-106-4081

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TÄRKEÄÄ

Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa.
Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti

noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive)
yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta,
elleivät kansalliset standardit estä sitä.

1. Riittävät maadoituskytkennät on tehtävä kaikkiin maadoituspisteisiin, sisäisiin ja ulkoisiin.

2. Asennuksen ja vianetsinnän jälkeen on kaikki suojat ja suojamaat asennettava takaisin pai­koilleen. Maadoitusliittimen kunnollinen toiminta täytyy aina ylläpitää.

3. Jännitesyöttöjohtimien täytyy täyttää IEC227 ja IEC245 vaatimukset.

4. Kaikkien johdotuksien tulee toimia >75°C lämpötiloissa.

5. Kaikkien läpivientiholkkien sisähalkais ijan täytyy olla sellainen että kaapeli lukkiutuu kun­nolla kiinni.

6. Turvallisen to iminnan varmistamisek si täy ty y jännitesyöttö varustaa turvak y tk im ellä (m in
10A), joka kytkee irti kaikki jännitesyöttöjohtimet vikatilanteessa. Suojaan täytyy myös
sisältyä mekaaninen erotuskytkin. Jos ei, niin jännitesyöttö on pystyttävä katkaisemaan
muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi. Turvakytkimien tai kat­kaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä.

7. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän
takana tai alla hengenvaarallisen suuruinen jännite. Suojaa ei saa poistaa
jänniteen ollessa kytkettynä laitteeseen ja poistamisen saa suorittaa vain
alan asian-tuntija.

8. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän
takana tai alla kuuma pinta. Suojan saa poistaa vain alan asiantuntija kun
jännite-syöttö on katkaistu. Tällainen pinta voi säilyä kosketuskuumana
jopa 45 mi-nuuttia.

9. Mikäli laite tai kosketussuoja on merkitty tällä merkillä katso lisäohjeita
käyt-töohjekirjasta

10. Kaikki tässä tuotteessa käytetyt graafiset symbolit ovat yhdestä tai useammasta seuraavis-ta
standardeista: EN61010-1, IEC417 & ISO3864.

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IMPORTANT

Consignes de sécurité concernant le raccordement et l’installation de cet appareil.
Les consignes de sécurité ci-dessous s’adressent particulièrement à tous les états membres

de la communauté européenne. Elles doivent être strictement appliquées afin de satisfaire
aux directives concernant la basse tension. Les états non membres de la communauté
européenne doivent également appliquer ces consignes sauf si elles sont en contradiction
avec les standards locaux ou nationaux.

1. Un raccordement adéquat à la terre doit être effectuée à chaque borne de mise à la terre,
interne et externe.

2. Après installation ou dépannage, tous les capots de protection et toutes les prises de terre
doivent être remis en place, toutes les prises de terre doivent être respectées en permanence.

3. Les câbles d’alimentation électrique doivent être conformes aux normes IEC227 ou IEC245

4. Tous les raccordements doivent pouvoir supporter une température ambiante supérieure à
75°C.

5. Tous les presse-étoupes utilisés doivent avoir un diamètre interne en rapport avec les câbles
afin d’assurer un serrage correct sur ces derniers.

6. Afin de garantir la sécurité du fonctionnement de cet appareil, le raccordement à
l’alimentation électrique doit être réalisé exclusivement au travers d’un disjoncteur
(minimum 10A.) isolant tous les conducteurs en cas d’anomalie. Ce disjoncteur doit
également pouvoir être actionné m anuell ement, de façon mécanique. Dans le cas contraire,
un autre système doit être mis en place afin de pouvoir isoler l’appareil et doit être signalisé
comme tel. Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telle
IEC947.

7. Lorsque les équipements ou les capots affich ent le sy mbole suivant, cela
signifie que des tensions dangereuses sont présentes. Ces capots ne doivent
être démontés que lorsque l’alimentat ion est coupée, et uniquem ent par un
personnel compétent.

8. Lorsque les équipements ou les capots affich ent le sy mbole suivant, cela
signifie que des surfaces dangereusement chaudes sont présentes. Ces capots
ne doivent être démontés que lorsque l’alimentation est coupée, et uniquement
par un personnel compétent. Certaines surfaces peuvent rester chaudes jusqu’à
45 mn.

9. Lorsque les équipements ou les capots affichent le sy mbole suivant, se reporter
au manuel d’instructions.

10. Tous les symboles graphiques utilisés dans ce produit sont conformes à un ou plusieurs des
standards suivants: EN61010-1, IEC417 & ISO3864.

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WICHTIG

Sicherheitshinweise für den Anschluß und die Installation dieser Geräte.

Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen
Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der
Niederspannungsrichtlinie zu genügen. Nichtmitgliedsstaaten der europäischen
Gemeinschaft sollten die national gültige n Normen und Richtlinien einhalten.

1. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden.

2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerät müssen alle
Sicherheitsabdeckungen und Erdungen wieder installiert werden. Die Funktion aller
Erdverbindungen darf zu keinem Zeitpunkt gestört sein.

3. Die Netzspannungsversorgung muß den Anforderungen der IEC227 oder IEC245 genügen.

4. Alle Verdrahtungen sollten mindestens bis 75 °C ihre Funktion dauerhaft erfüllen.

5. Alle Kabeldurchführungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so
gewählt werden, daß diese eine sichere Verkabelung des Gerätes ermöglichen.

6. Um eine sichere Funktion des Gerätes zu gewährleisten, muß die Spannungsversorgung über
mindestens 10 A abgesichert sein. Im Fehlerfall muß dadurch gewährleistet sein, daß die
Spannungsversorgung zum Gerät bzw. zu den Geräten unterbrochen wird. Ein mechanischer
Schutzschalter kann in dieses System integriert werden. Falls eine derartige Vorrichtung
nicht vorhanden ist, muß eine andere Möglichkeit zur Unterbrechung der Spannungszufuhr
gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden. Ein solcher
Mechanismus zur Spannungsunterbrechung muß mit den Normen und Richtlinien für die
allgemeine Installation von Elektrogeräten, wie zum Beispiel der IEC947, übereinstimmen.

7. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, die eine
gefährliche (Netzspannung) Spannung führen. Die Abdeckungen dürfen
nur entfernt werden, wenn die Versorgungsspannung unterbr ochen wurde .
Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen.

8. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, in bzw.
unter denen heiße Teile vorhanden sind. Die Abdeckungen dürfen nur
entfernt werden, wenn die Versorgungsspannung unterbrochen wurde.
Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen. Bis
45 Minuten nach dem Unterbrechen der Netzzufuhr können derartig Teile
noch über eine erhöhte Temperatur verfügen.

9. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, bei
denen vor dem Eingriff die entsprechenden Kapitel im Handbuch
sorgfältig durchgelesen werden müssen.

10. Alle in diesem Gerät verwendeten graphischen Symbole entspringen einem oder mehreren
der nachfolgend aufgeführten Standards: EN61010-1, IEC417 & ISO3864.

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IMPORTANTE

Norme di sicurezza per il cablaggio e l’installazione dello strumento.
Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione

Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del
Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all’Unione Europea,
salvo quanto disposto dalle vigenti normative locali o nazionali

1. Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra interni ed
esterni, dove previsti.

2. Dopo l’installazione o la localizzazione dei guasti, assicurarsi che tutti i coperchi di
protezione siano stati collocati e le messa a terra si ano col leg ate. L ’integrità di ciscun
morsetto di terra deve essere costantemente garantita.

3. I cavi di alimentazione della rete devono essere secondo disposizioni IEC227 o IEC245.

4. L’intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore
a 75°C.

5. Le dimensioni di tutti i connettori dei cavi utilizzati devono essere tali da consentire un
adeguato ancoraggio al cavo.

.

6. Per garantire un sicuro funzionamento dello strumento il collegamento alla rete di
alimentazione principale dovrà essere eseguita tramite interruttore automa tico (min.10A), in
grado di disattivare tutti i conduttori di circuito in caso di guasto. Tale interruttore dovrà
inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione
dell’alimentazione, chiaramente identificabile. Gli interruttori dovranno essere conformi agli
standard riconosciuti, qual i IEC947.

7. Il simbolo riportato sullo strumento o sui coperchi di protezione indica
probabile presenza di elevati voltaggi. Tali coperchi di protezione devono
essere rimossi esclusivamente da personale qualificato, dopo aver tolto
alimentazione allo strumento.

8. Il simbolo riportato sullo strumento o sui coperchi di protezione indica rischio
di contatto con superfici ad alta temperatura. Tali coperchi di protezione
devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto
alimentazione allo st rum ento. Alcune supe rf ic i possono manten er e tem p eratu re
elevate per oltre 45 minuti.

9. Se lo strumento o il coperchio di protezione riportano il simbolo, fare
riferimento alle istruzioni del manuale Operatore.

10. Tutti i simboli grafici utilizzati in questo prodotto sono previsti da uno o più dei seguenti
standard: EN61010-1, IEC417 e ISO3864.

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VIKTIG

Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret.

Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS­avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til
lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert
av lokale- eller nasjonale standarder.

1. Passende jordforbindel ser må tilk oble s alle jord ingspunkter, interne og eksterne hvor diss e
forefinnes.

2. Etter installasjon eller feilsøking skal alle sikkerhetsdeksler og jordforbindelser reetableres.
Jordingsforbindelsene må alltid holdes i god stand.

3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.

4. Alle ledningsforbindelser skal være konstruert for en omgivelsestemperatur høyere en 750C.

5. Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig
avlastning oppnåes.

6. For å oppnå sikker drift og betjening skal forbind el sen til spenning sforsyningen bare skje
gjennom en strømbryter (minimum 10A) som vil bryte spenningsforsyningen til alle
elektriske kretser ved en feilsituasjon. Strømbryteren kan også inneholde en mekanisk
operert bryter for å isolere instrumentet fra spenningsforsyningen. Dersom det ikke er en
mekanisk operert bryter installert, må det være en annen måte å isolere utstyret fra
spenningsforsyningen, og denne måten må være tydelig merket. Kretsbrytere eller
kontakter skal oppfylle kravene i en annerk jent sta ndard av ty pen I E C947 eller tilsv arend e.

7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det
sannsynlig at disse er tilste de bak deksle t. Disse dekslene må bare fjærnes når
spenningsforsyning er frak oble t utsty ret, og da b are av tre net se rvicepersonell.

8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate,
er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare
fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet
servicepersonell. Noen overflater kan være for varme til å berøres i opp til 45
minutter etter spenningsforsy ning f rak oble t.

9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til
instruksjonsmanualen fo r inst ruk ser.

10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av følgende standarder:
EN61010-1, IEC417 & ISO3864.

IB-106-4081

xi

IMPORTANTE

Instruções de segurança para ligação e instalação deste aparelho.
As seguintes instruções de segurança aplicam-se especificamente a todos os estados

membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento
da Directiva sobre Baixa Tensão. Relativamente aos estados que não pertençam à UE,
deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação
local a tiver substituído.

1. Devem ser feitas ligações de terra apropriadas a todos os pontos de terra, in ternos ou externos.

2. Após a instalação ou eventual reparação, devem ser recolocadas todas as ta mpas de se gurança
e terras de protecção. Deve manter- se sem pre a integridade de todos os terminais de terra.

3. Os cabos de alimentação eléctrica devem obedecer às exigências das normas IEC227 ou
IEC245.

4. Os cabos e fios utilizados nas ligações eléctricas devem ser adequados para utilização a uma
temperatura ambiente at é 75º C.

5. As dimensões internas dos bucins dos cabos devem ser adequadas a uma boa fixação dos
cabos.

6. Para assegurar um funcionamento seguro deste equipamento, a ligação ao cabo de
alimentação eléctrica deve ser feita através de um disjuntor (min. 10A) que desligará todos
os condutores de circuitos durante um a avaria. O disjuntor poderá também conter um
interruptor de isolamento accionado manualmente. Caso contrário, deverá ser instalado
qualquer outro meio para desligar o equipamento da energia eléctrica, devendo ser
assinalado convenientemente. Os disjuntores ou interruptores devem obedecer a uma norma
reconhecida, tipo IEC947.

7. Sempre que o equipamento ou as tampas contiverem o símbolo, é provável a
existência de tensões perigosas. Estas tampas só devem ser retiradas quando a
energia eléctrica tiver sido deslig ada e por Pes soa l da Assis tên cia dev idam ente
treinado.

8. Sempre que o equipamento ou as tampas contiverem o símbolo, há perigo de
existência de superfícies quentes. Estas tampas só devem ser retiradas por
Pessoal da Assistência devidamente treinado e depois de a energia eléctrica ter
sido desligada. Algumas superfícies permanecem quentes até 45 minutos
depois.

9. Sempre que o equipamento ou as tampas contiverem o símbolo, o Manual de
Funcionamento deve ser consultado para obtenção das necessárias instruções.

10. Todos os símbolos gráficos utilizados neste produto baseiam-se em uma ou mais das
seguintes normas: EN61010-1, IEC417 e ISO3864.

IB-106-4081

xii

IMPORTANTE

Instrucciones de seguridad para el montaje y cableado de este aparato.

Las siguientes instrucciones de seguridad , son de aplicacion especifica a todos los miembros
de la UE y se adjuntaran para cumplir la normativa europea de baja tension.

1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en
aquellos terminales previstos al efecto.

2. Una vez finalizada las operaciones de mantenimiento del equipo, se deben volver a colocar
las cubiertas de seguridad aasi como los terminal es de ti er ra. Se debe comprob ar la
integridad de cada terminal.

3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245.

4. Todo el cableado sera adecuado para una tempera tura am biental de 75ºC.

5. Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables.

6. Para un manejo seguro del equipo, la alimentacion electrica se realizara a traves de un
interruptor magnetotermico ( min 10 A ), el cual desconectara la alimentacion electrica al
equipo en todas sus fases durante un fallo. Los interruptores estaran de acuerdo a la norma
IEC 947 u otra de reconocido prestigio.

7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica
peligrosa, dicho alojamiento solamente se abrira una vez que se haya
interrumpido la alimentacion electrica al equipo asimismo la intervencion
sera llevada a cabo por personal entrenado para estas labores.

8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con
alta temperatura, por tanto se abrira una vez que se haya interrumpido la
alimentacion electr ica al equipo po r personal ent rena do para est as labo res,
y al menos se esperara unos 45 minutos para enfriar las superficies
calientes.

9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el
manual de instrucciones.

10. Todos los simbolos graficos usados en esta hoja, estan de acuerdo a las siguientes normas
EN61010-1, IEC417 & ISO 3864.

IB-106-4081

xiii

VIKTIGT

Säkerhetsföreskrifter för kablage och installation av denna apparat.
Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall

följas i varje avseende för att överensstämma med Lågsp ännings direktivet. Icke EU
medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala
eller nationella föreskrifter.

1. Tillämplig jordkontakt skall utföras till alla jordade punkter, såväl internt som externt där så
erfordras.

2. Efter installation eller felsökning skall samtliga säkerhetshöljen och säkerhetsjord
återplaceras. Sam tlig a jordterminaler måste hållas obrutna hela tiden.

3. Matningsspänningens kabel måste överensstämma med föreskrifterna i IEC227 eller
IEC245.

4. Allt kablage skall vara lämpligt för användning i en omgivningstemperatur högre än 75ºC.

5. Alla kabelförskruvningar som används skall ha inre dimensioner som motsvarar adekvat
kabelförankring.

6. För att säkerställa säker drift av denna utru stn ing sk all ans lutn ing ti ll huvudst römmen endast
göras genom en säkring (min 10A) som skall frånkoppla alla strömförande kretsar när något
fel uppstår. Säkringen kan även ha en mekanisk frånskiljare. Om så inte är fallet, måste ett
annat förfarande för att frånskilja utrustningen från strömförsörjning tillhandahållas och klart
framgå genom markering. Säkring eller omkopplare måste överensstämma med en gällande
standard såsom t ex IEC947.

7. Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för
livsfarlig spänning i närheten. Dessa höl jen får endas t avlägsnas när st röm men
ej är ansluten till utrustningen - och då endast av utbildad servicepersonal.

8. När utrustning eller hölje är markerad med vidstående symbol föreligger risk
för brännskada vid kontakt med uppvärmd yta. Dessa höljen får endast
avlägsnas av utbildad servicepersonal, när strömmen kopplats från
utrustningen. Vissa ytor kan vara mycket varma att vidröra även upp till 45
minuter efter avstängning av strömmen.

9. När utrustning eller hölje markerats med vidstående symbol bör
instruktionsmanualen studeras för information.

10.

Samtliga grafiska symboler som förekommer i denna produkt finns angivna i en eller flera
av följande föreskrifter:- EN61010-1, IEC417 & ISO3864.

IB-106-4081

xiv

IB-106-4081

xv/xvi

TABLE OF CONTENTS

Section Page

ROSEMOUNT WARRANTY......................................................................................................................i

SECTION I. INTRODUCTION............................................................................................................. 1-1

1-1. Component Checklist of Typical System (Package Contents) ..................................... 1-1

1-2. System Overview........................................................................................................... 1-2

1-3. Specifications.................................................................................................................. 1-6

SECTION II. INSTALLATION............................................................................................................. 2-1

2-1. Pre-Installation................................................................................................................ 2-1

2-2. Mechanical Installation.................................................................................................. 2-1

2-3. Electrical Installation................................................................................................... 2-10

2-4. Pneumatic Installation.................................................................................................. 2-11

SECTION III. STARTUP....................................................................................................................... 3-1

3-1. General............................................................................................................................ 3-1

3-2. Power Up....................................................................................................................... 3-1

3-3. Reestablishing Proper Calibration Check Gas Flow Rate......................................... 3-2

SECTION IV. OPERATION.................................................................................................................. 4-1

4-1. General............................................................................................................................ 4-1

4-2. Program Menu ................................................................................................................4-4

4-3. Diagnostics Menu .......................................................................................................... 4-8

4-4. Calcheck Menu ............................................................................................................ 4-10

4-5. Simulate Switch........................................................................................................... 4-12

4-6. Security Switch............................................................................................................4-12

SECTION V. TROUBLESHOOTING .................................................................................................. 5-1

5-1. General............................................................................................................................ 5-1

5-2. Probe Life ....................................................................................................................... 5-1

5-3. Fault Indications............................................................................................................. 5-2

5-4. Identifying and Correcting Fault Indications .............................................................. 5-3

SECTION VI. MAINTENANCE AND SERVICE............................................................................. 6-1

6-1. Model 4081 Elec tr onics Replacem ent............................................................................. 6-1

6-2. Oxygen Probe Replacement.......................................................................................... 6-2

SECTION VII. REPLACEMENT PARTS ..........................................................................................7-1

SECTIO N VIII. RETURNI N G EQUIPMENT TO THE FACTORY............................................ 8-1

INDEX I-1

IB-106-4081

xvii

LIST OF ILLUSTRATIONS

Figure 1-1. Typical System Package ..........................................................................................................1-1

Figure 1-2. Two-Wire In Situ Oxygen Analyzer Fieldbus Connections.....................................................1-5

Figure 1-3. Typical System Installation......................................................................................................1-5

Figure 2-1. Probe Installation Details.........................................................................................................2-2

Figure 2-2. Optional Adapter Plate.............................................................................................................2-3

Figure 2-3. Optional Probe Mounting Flange.............................................................................................2-3

Figure 2-4. Horizontal Probe Installation ...................................................................................................2-4

Figure 2-5. Adjusting Probe Insertion Depth..............................................................................................2-5

Figure 2-6. Flat Surface Mounting Dimensional Information....................................................................2-7

Figure 2-7. Pipe Mounting Dimensional Information.................................................................................2-8

Figure 2-8. Display Positioning Assembly.................................................................................................2-9

Figure 2-9. Oxygen Probe Terminal Block...............................................................................................2-10

Figure 2-10. Model 4081 Transmitter Terminal Block.............................................................................2-11

Figure 2-11. Oxygen Probe Gas Connections...........................................................................................2-11

Figure 2-12. Air Set, Plant Air Connection ..............................................................................................2-12

Figure 3-1. Normal Operation Display.......................................................................................................3-1

Figure 3-2. Faulted Operation Display .......................................................................................................3-1

Figure 3-3. Proper Calibration Check Gas Flow Rate ................................................................................3-2

Figure 4-1. Normal Operation Display.......................................................................................................4-1

Figure 4-2. Model 4081 Transmitter Menu Tree........................................................................................4-2

Figure 4-3. Infrared Remote Control (IRC)................................................................................................4-3

Figure 4-4. CODE.......................................................................................................................................4-4

Figure 4-5. DISPLAY CODE....................................................................................................................4-4

Figure 4-6. CELL T HI.............................................................................................................................4-5

Figure 4-7. RESET MAX CELL T...........................................................................................................4-5

Figure 4-8. SET O2 FILTER TIME ........................................................................................................4-6

Figure 4-9. SET HI BOTTLE O2............................................................................................................4-6

Figure 4-10. SET LO BOTTLE O2.........................................................................................................4-7

Figure 4-11. SET CODE............................................................................................................................4-7

Figure 4-12. SHOW FAULT.....................................................................................................................4-8

Figure 4-13. T/C mV ..................................................................................................................................4-8

Figure 4-14. O2 CELL mV........................................................................................................................4-8

Figure 4-15. CELL IMPEDANCE ............................................................................................................4-9

Figure 4-16. PREVIOUS SLOPE..............................................................................................................4-9

Figure 4-17. PREVIOUS CONSTANT.....................................................................................................4-9

Figure 4-18. MAX CELL T....................................................................................................................4-10

Figure 4-19. IN MANUAL? ....................................................................................................................4-10

Figure 4-20. ACCEPT HIGH O2............................................................................................................4-11

Figure 4-21. ACCEPT LOW O2............................................................................................................4-11

Figure 4-22. PURGING............................................................................................................................4-11

Figure 4-23. SLOPE .................................................................................................................................4-11

Figure 4-24. CONSTANT ........................................................................................................................4-12

Figure 4-25. Simulate and Security Switch Positions...............................................................................4-12

IB-106-4081

xviii

LIST OF ILLUSTRATIONS (Continued)

Figure 5-1. Slope vs. Impedance ................................................................................................................ 5-1

Figure 5-2. Speed of Response................................................................................................................... 5-2

Figure 5-3. Faulted Operation Display....................................................................................................... 5-2

Figure 5-4. Model 4081 Transmitter Terminal Block................................................................................5-3

Figure 5-5. Fault 1, Open Thermocouple................................................................................................... 5-4

Figure 5-6. Fault 2, Reversed Thermocouple............................................................................................. 5-4

Figure 5-7. Fault 3, Shorted Thermocouple................................................................................................5-5

Figure 5-8. Fault 4, High Probe Temperature.............................................................................................5-5

Figure 5-9. Fault 5, O

Cell Open............................................................................................................... 5-6

2

Figure 5-10. Fault 6, Cell Impedance Too High......................................................................................... 5-6

Figure 5-11. Fault 7, Reversed O

Cell....................................................................................................... 5-7

2

Figure 6-1. Two-Wire In Situ Oxygen Analyzer Exploded View..............................................................6-0

Figure 6-2. Oxygen Probe Terminal Block................................................................................................6-2

LIST OF TABLES

Table 1-1. Product Matrix.................................................................................................................... 1-0

Table 4-1. Model 4081 Transmitter Parameters .................................................................................. 4-7

Table 8-1. Replacement Parts List....................................................................................................... 7-1

IB-106-4081

xix

Table 1-1. Product Matrix

4081FG High Temperature Oxygen Flue Gas Analyz er

High Temperature Analyzer - Instruction Book

Code Sensing Probe Length

1 20 in. (508 mm) probe, 1/4 in. tube fittings
2 26 in. (660 mm) probe, 1/4 in. tube fittings
3 38 in. (965 mm) probe, 1/4 in. tube fittings

Code Probe Outer Tube Mater i al - Ma ximum Operating Temperature

1

Alumina - 2912°F (1600°C) maximum - 1.25 NPT mounting

2

Inconel 600 - 1832°F (1000°C) maximum - 1.25 NPT mounti ng

Code Mounting Adapter - Stack Side

0 No adapter plate required uses 1.25 NPT

(“0” must also be chosen under “Mount i ng Adapter” below)
1 New flanged installation - Square weld plate with studs (matches “Mounting Adapter” below)
2 Model 450 mounting (“4” must also be chosen under “Mounting Adapter” below)
3 Competitor's Mount (“5” must also be chosen under “Mounting Adapter” below)

Code Mounting A dapter - Probe Side

0 No adapter plate
1 ANSI 2 in. 150 lb flange to 1.25 NPT adapter

2 DIN to 1.25 NPT adapter (184 mm flange, 145 mm BC with 4 x 18 mm dia. holes)
3 JIS to 1.25 NPT adapter (155 mm flange , 130 mm B C with 4 x 13 mm dia. holes)
4 Model 450 to 1.25 NPT adapter
5 Competitor’s mounting flange

1

(6 in. dia. Flange, 4.75 in. BC with 4 x 0.75 in. dia. holes)

Code Electronics & Housing - Intrinsically Safe, NEMA 4X, IP65

1 4081 F
2 4081 F
3 4081 F

OUNDATION
OUNDATION
OUNDATION

Fieldbus Electronics - CENELEC EEx ia IIC T5 (pending)
Fieldbus Electronics - CSA Class I, Div. I, Groups B,C,D (pending)
Fieldbus Electronics - FM Class I, Div. I, Groups B,C,D (pending)

Code Housing Mounting

0 Surface or wall mounting
1 1/2 to 2 in. pipe mounting

Code Communications

0 No remote cont rol

Infrared Remote Control (IRC)

1

(LCD display through cover window)

Code Calibration Accessories

1No hardware

Calibration and reference air flowmet ers and refer-

2

ence air pressure reg ulator

Code Armored Cable Length

00 No cable
11 20 ft (6 m)
12 40 ft (12 m)
13 60 ft (18 m)
14 80 ft (24 m)
15 100 ft (30 m)
16 150 ft (45 m)
17 200 ft (61 m)
18 300 ft (91 m)
19 400 ft (122 m)
20 500 ft (152 m)

4081FG2100111211 Example

IB-106-4081

1-0

SECTION I. INTRODUCTION

1-1. COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS)

A typical Rosemount Two-Wire In Situ Oxygen
Analyzer should contain the items shown in Figure
1-1. Record the part number, serial number, and or­der number for each component of your system

7

in the table located on the first page of this manual.
Also, use the product matrix in Table 1-1 to compare
your order number against your unit. The first part of
the matrix defines the model. The last part defines the
various options and features of the analyzer. Ensure
the features and options specified by your order
number are on or included with the unit.

1

2

3

6

5

4

1. Instruction Bulletin 5. Infrared Remote Control (IRC) (Optional)

2. Model 4081 Transmitter 6. Reference Air Set (Optional)

3. Oxygen Probe 7. Pipe Mounting Kit (Optional)

4. Adapter Plate with mo unting hardware
and gasket (Optional)

Figure 1-1. Typical System Package

29760001

IB-106-4081

1-1

1-2. SYSTEM OVERVIEW

a. Scope.

This Instruction Bulletin is designed to
supply details needed to install, start up, opera te,
and maintain the Rosemount Two-Wire In Situ
Oxygen Analyzer. The analyzer consists of an
oxygen probe and Model 4081 Transmitter. Inte­gral signal conditioning electronics outputs a
digital F
an O

OUNDATION

value. An infrared remote control (IRC)

2

allows access to setup, calibration, and diagnos­tics. This same information, plus additional de­tails, can be accessed via fieldbus digital
communications.

OUNDATION

b. F

fieldbus Technology.

fieldbus is an all digital, serial, two-way communi­cation system that inter-connects field equipment
such as sensors, actuators, and controllers. Fieldbus
is a Loc al Area Network (LA N) for instruments used
in both process and manufacturing automation with
built-in c apacity to d istribut e the contro l applic ation
across the network. The fie ldbus environment is the
base level group of digital networks in the hierarchy
of planet networks.

The fieldbus retains the desirable features of the
4-20 mA analog system, including a standardized
physical interface to the wire, bus powered de­vices on a single wire, and intrinsic safety op­tions, and enables additional capabilities, such
as:

Increased capabilities due to full digital com-

•

munications
Reduced wiring and wire terminations due to

•

multiple devices on one set of wires
Increased selection of suppliers due to inter-

•

operability
Reduced loading on control room equipment

•

with the distribution of some control and in­put/ output functions to field devices
Speed options for process control and manu-

•

facturing applications

fieldbus signal representing

OUNDATION

F

The equipment measures oxygen percentage by
reading the voltage developed across an electro­chemical cell, which consists of a small yttria­stabilized, zirconia disc. Both sides of the disc
are coated with porous metal electrodes. The
millivolt output voltage of the cell is given by the
following Nernst equation:

EMF = KT log

10(P1/P2

) + C

Where:

1. P

is the partial pressure of the oxygen in the

2

measured gas on one side o f the cell.

2. P

is the partial pressure of the oxygen in the

1

reference air on the opposite side of the cell.

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

NOTE

For best results, use clean, dry, instrument
air (20.95% oxygen) as the reference air.

NOTE

The probe uses a Type B thermocouple to
measure the cell temperature.

When the cell is at 550°C to 1600°C (1022°F to
2912°F) and there are unequal oxygen concen­trations across the cell, oxygen ions will travel
from the high oxygen partial pressure side to the
low oxygen partial pressure side of the cell. The
resulting logarithmic output voltage is approxi­mately 50 mV per decade.

The output is proportional to the inverse loga­rithm of the oxygen concentration. Therefore, the
output signal increases as the oxygen concentra­tion of the sample gas decreases. This character­istic enables the Rosemount Two-Wire In Situ
Oxygen Analyzer to provide exceptional sensi­tivity and accuracy at low oxygen concentra­tions.

c. System Description.

The Rosemount Two­Wire In Situ Oxygen Analyzer is designed to
measure the net concentration of oxygen in an
industrial process; i.e., the oxygen remaining af­ter all fuels have been oxidized. The oxygen
probe is permanently positioned within an ex­haust duct or stack and performs its task without
the use of a sampling system. The Model 4081
Transmitter is mounted remotely and conditions
the oxygen probe outputs.

Oxygen analyzer equipment measures net oxy­gen concentration in the presence of all the prod­ucts of combustion, including water vapor.
Therefore, it may be considered an analysis on a
“wet” basis. In comparison with older methods,
such as the portable apparatus, which provides an
analysis on a “dry” gas basis, the “wet” analysis
will, in general, indicate a lower percentage of
oxygen. The difference will be proportional to
the water content of the sampled gas stream.

IB-106-4081

1-2

d. System Configuration.

The equipment discus­sed in this manual consists of two major compo­nents: the oxygen probe and the Model 4081
Transmitter.

Oxygen probes are available in three length op­tions, providing in situ penetration appropriate to
the size of the stack or duct. The options on
length are 20 in. (508 mm), 26 in. (660 mm), or
38 in. (965 mm).

Power is supplied to the electronics through

6.

OUNDATION

the F

fieldbus digital signal line

for intrins i c safety (IS) pu rp oses .

Infrared remote control (IRC) allows inter-

7.

facing without exposing the electronics.

An operator can operate and diagnostically

8.

troubleshoot the Two-Wire In Situ Oxygen
Analyzer in one of two ways:

The Model 4081 Transmitter is a two-wire trans­mitter providing an output proportional to the
measured oxygen concentration. A customer­supplied 24 VDC power source is required to pro­vide power to the electronics. The transmitter ac­cepts millivolt signals generated by the probe and
produces the outputs to be used by other remotely
connected devices. The output is a F

OUNDATION

fieldbus digital communication signal.

e. System Features.

The cell output voltage and sensitivity in-

1.

crease as the oxygen concentration de­creases.

High process temperatures eliminate the

2.

need for external cell heating and increase
cell accuracy.

OUNDATION

F

3.

Easy probe replacement due to the light-

4.

fieldbus is standard.

weight, compact probe design.

Remote location of the Model 4081 Trans-

5.

mitter removes the electronics from high
temperature or corrosive environments.

(a) Infrared Remote Control. The IRC

allows access to fault indication
menus on the Model 4081 Transmitter
LCD display. Calibration can be per­formed from the IRC keypad.

OUNDATION

(b) F

Fieldbus Interface. The
transmitter’s output carries a signal
containing the oxygen level encoded in
digital format. This digital output can
also be used to communicate with the
oxygen analyzer and access all of the
oxygen an aly z er st atu s in f orm at ion .

Selected Distributed Control Systems - The

9.

use of distributed control systems requires
input/output (I/O) hardware and AMS
Security codes are provided (by infrared
remote control) to prevent unintended
changes to analyzers adjacent to the one
being accessed.

10. A calibration check procedure is provided
to determine if the Rosemount Two-Wire In
Situ Oxygen Analyzer is correctly measur­ing the net oxygen c oncentration in t he in­dustrial process.

IB-106-4081

1-3

f. Handling the Analyzer.

The probe was spe­cially packaged to prevent breakage due to han­dling. Do not remove the padding material fro m
the probe until immediately before installation.

It is important that printed circuit
boards and integrated circuits are han­dled only when adequate antistatic pre­cautions have been taken to prevent
possible equipment damage.

The oxygen probe is designed for indus­trial applications. Treat with care to
avoid physical damage. The probe con­tains components made from ceramic,
whic h are su sce ptib le to s hock w he n mis­handled. THE WARRANTY DOES
NOT COVER DAMAGE FROM
MISHANDLING.

able line voltage, ambient temperatures, envi­ronmental considerations, convenience, and
serviceability. Figure 1-2 shows a typical system
wiring. A typical system installation is illustrated
in Figure 1-3.

A source of instrument air is required at the oxy­gen probe for reference air use. Since the Two­Wire In Situ Oxygen Analyzer is equipped with
an in-place calibration feature, provisions should
be made for connecting calibration check gas
tanks to the oxygen probe during calibration.

If the calibration check gas bottles are to be per­manently connected, a check valve is required
next to the calibration fittings on the integral
electronics.

This check valve is to prevent breathing of cali­bration check gas line and subsequent flue gas
condensation and corrosion. The check valve is
in addition to the stop valve in the calibration
check gas kit.

NOTE

g. System Considerations.

Prior to installing your
Rosemount T wo-Wire In Situ Oxyge n Analyzer,
make sure you have all the components neces­sary to make the system installation. Ensure all
the components are properly integrated to make
the system functional.

After verifyin g that yo u have all t he c ompo ne nts,
select mounting locations and determine how
each component will be placed in terms of avail-

The electronics of the Model 4081 Trans­mitter is rated NEMA 4X (IP65) and is
capable of operating at temperatures up to
65°C (149°F).

Retain the packaging in which the Rose­mount Two-Wire In Situ Oxygen Analyzer
arrived from the factory in case any com­ponents are to be shipped to another site.
This packaging has been designed to pro­tect the product.

IB-106-4081

1-4

TWO-WIRE IN SITU

OXYGEN ANALYZER

OmV

2

SIGNAL

MODEL 4081

TRANSMITTER

FIELDBUS

DIGITAL OUTPUT

(TWISTED PAIR)

CALIBRATION CHECK

GAS LINE

Figure 1-2. Two-Wire In Situ Oxygen Analyzer Fieldbus Connections

GASES

STACK

OXYGEN

PROBE

REFERENCE

AIR LINE

TEMPERATURE

mV SIGNAL

DUCT

OPTIONAL
ADAPTER
PLATE

INTRINSIC

SAFETY

BARRIER

(OPTIONAL)

FIELDBUS

COMPUTER TERMINAL

29760002

MODEL 4081

TRANSMITTER

FLOWMETER

PRESSURE

REGULATOR

FIELDBUS

DIGITAL SIGNAL

Figure 1-3. Typical System Installation

INSTRUMENT
AIR SUPPLY
(REFERENCE AIR)

29760003

IB-106-4081

1-5

1-3. SPECIFICATIONS

Net O2 Range ......................................................................... 0 to 25% O

Fully Field Selectable via the F

OUNDATION

Fieldbus Interface

Lowest Limit................................................................... 0.05% O

Highest Limit.................................................................. 25.00% O

2

2

2

Accuracy................................................................................ ±1.5% of reading or 0.05% O2, whichever is gre ater

System Response to Calibration Check Gas .......................... Initial response in less than 3 seconds

T90 in less than 10 seconds

PROBE

Lengths ................................................................................. 20 in. (508 mm)

26 in. (660 mm)
38 in. (965 mm)

Temperature Limits

Process............................................................................ 550° to 1600°C (1022° to 2912°F)

Ambient .......................................................................... -40° to 149°C (-40° to 300°F) Ambient

Mounting and Mounting Position .......................................... Vertical or Horizontal

Materials of Construction

Process Wetted Parts

Inner Probe .............................................................. Zirconia

Outer Protection Tube.............................................. Alumina [1600°C (2912°F) limit]

Inconel 600 [1000°C (1832°F) limit]

Probe Junction Box.................................................. Cast aluminum

Speed of Installation/Withdrawal........................................... 1 in. (25.4 mm) per minute

Hazardous Area Certification................................................. Intrinsically safe per EN50 014 (1977), clause 1.3

(1)

pending

Reference Air Requirement.................................................... 100 ml per minute (0.2 scfh) of clean, dry instrument air;

1/4 in. tube fittings

Calibration Check Gas Fittings.............................................. 1/4 in. tube fittings

Cabling ................................................................................. Two twisted pairs, shielded

ELECTRONICS

Enclosure.................................................................................. IP65 (NEMA 4X), weatherproof, and corrosion-resistant

Materials of Construction......................................................... Low copper aluminum

Ambient Temperature Limits................................................... -20° to 65°C (-4° to 149°F)

Relative Humidity.................................................................... 95% with covers sealed

Inputs (from O

Probe)............................................................. Two wires - O2 signal

2

Two wires - type B thermocouple

Output ................................................................................... F

OUNDATION

fieldbus digital signal

Fieldbus Logic Function Blocks

Two AI Blocks: Execution Rate ...................................... 75mS

PID Block: Execution Rate .............................................. 150mS

Fieldbus Segment Power Consumption .................................. 30mA max, 30VDC max

Hazardous Area Certification................................................... Cenelec EEx ia IIC T4 or T5

(2)

(pending)

NEC Class I Div. I Group B,C,D (pending)

Fisher-Rosemount has satisfied all obligations
coming from the European legislation to harmo­nize the product requirements in Europe.

Power Transient Protection...................................................... IEC 801-4

Shipping Weight ...................................................................... 10 lbs (4.5 kg)

INFRARED REMOTE CONTROL

Power Requirements................................................................ Three AAA batteries

Hazardous Area Certification................................................... Cenelec EEx ia IIC Class I, Div. I, Group A, B, C, D

(1)

Thermocouple and O2 probe cell are both unpowered, developing a millivolt emf, and are considered a “simple apparatus” by certifying
agencies.

(2)

Dependent on ambient temperature limits.

IB-106-4081

1-6

2

SECTION II. INSTALLATION

2-1. PRE-INSTALLATION

a. Inspect.

for any evidence of damage. If the container is
damage d, n oti fy th e car ri er i m me diately .

b. Packing List.

the packing list are present. Notify Rosemount
Analytical immediately if items are missing.

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

2-2. MECHANICAL INSTALLATION

Avoid installation locations near steam
soot blowers.

Carefully inspect the shipping container

Confirm that all items shown on

selected so the process ga s temperature falls
within a range of 550° to 1600°C (1022° to
2912°F). Figur e 2-1 provides mechanical in­stallation references.

Check the flue or stack for holes and air

2.

leakage. The presence of this condition will
substantially affect the accuracy of the oxy­gen reading. Therefore, either make the
necessary repairs or install the probe up­stream of any leakage.

Ensure the area is clear of internal and exter-

3.

nal obstructions that will interfere with in­stallation and maintenance access to the
probe. Allow adequate clearance for probe
rem o val (Figure 2-1).

b. Installing Oxygen Probe.

The probe was specially packaged to
prevent breakage due to handling. Do
not remove the padding material from
the probe until immediately before in­stallation.

a. Locating Oxygen Probe.

The location of the o xygen probe i n the stack

1.

or flue is important for maximum accuracy in
the oxygen analyzing process. The probe
must be positioned so the gas it measures is
representative of the process. Best results are
normally obtained if the probe is positioned
near the center of the duct (40-60% insertion).
Longer ducts may require several analyzers
since the O2 can vary due to stratification. A
point too near the wall of the duct, or the in­side radius of a bend, may not provide a rep­resentative sample because of the very low
flow conditions. The sensing point should be

Ensure all components are available to in-

1.

stall the probe.

NOTE

Leave the probe inner protective cover in
place until installation. This is required to
protect the ceramic cell during movement.

If using an optional adapter plate (Figure

2.

2-2) or an op tio nal moun ting fla n ge ( Fi gur e
2-3), weld or bolt the component onto the
duct. The through hole in the stack or duct
wall and refractory material must be 2 in.
(50.8 mm) diameter, minimum.

IB-106-4081

2-1

1/4 TUBE FITTING
(REFERENCE
AIR PORT)

1/4 TUBE FITTING

(CALIBRATION

CHECK GAS PORT)

REFERENCE
AIR VENT

FRONT VIEW

(REMOVAL ENVELOPE)

1.1

O

(29)

DIM “A”

1.25 NPT PROCESS
CONNECTION

7.1 (180)

DIM “B”

O

4.1

(109)

SIDE VIEW

1.8

(49)

TABLE 1. INSTALLATION (REMOVAL)

PROBE

20 IN.

26 IN.

38 IN.

DIM “A”

20 (508)

26 (660)

38 (965)

DIM “B”

31 (787)

37 (940)

49 (1245)

Figure 2-1. Probe Installation Details

BOTTOM VIEW

INSTALL WITH PORT AT

THE BOTTOM

3.0

(77)

NOTE: DIMENSIONS ARE IN INCHES WITH

MILLIMETERS IN PARENTHESES.

3/4 NPT

CONDUIT

PORT

29750001

IB-106-4081

2-2

MET AL WALL

STACK OR DUCT

MASONRY WALL

ST ACK

A

B

C

NOTE: DIMENSIONS ARE

IN INCHES WITH
MILLIMETERS IN
PARENTHESES.

DIMENSION

“B” THREAD 0.625-11 M-16x2 M-12x1.75

“C” DIA. 4.75 (121) 5.71 (145) 5.12 (130)

A

WELD OR BOLT ADAPTER
PLATE TO STACK OR DUCT.
JOINT MUS T BE AIR TIGHT.

PLA TE DIMENSIONS

ANSI

4512C34G01

“A” 6.00 (153) 7.5 (191) 6.50 (165)

2.50 (63.5)
MIN. DIA.

4512C36G01

JOINT MUS T

BE AIR TIGHT

DIN

3.00 SCHEDULE 40
PIPE SLEEVE

SUPPLIED BY CUSTOMER

JIS

4512C35G01

Figure 2-2. Optional Adapter Plate

WELD PIPE TO

ADAPTER PLATE

3.50 (89)

O.D. REF

29750002

GASES

STACK

OXYGEN

PROBE

MODEL 4081

TRANSMITTER

DUCT

OPTIONAL
ADAPTER
PLATE

FLOWMETER

FIELDBUS

DIGITAL SIGNAL

PRESSURE

REGULATOR

Figure 2-3. Optional Probe Mounting Flange

INSTRUMENT
AIR SUPPLY
(REFERENCE AIR)

29760003

IB-106-4081

2-3

STACK OR DUCT

METAL WALL

WELD PIPE TO

METAL WALL

2.0 IN. (51 mm)
MIN. DIA.

REFRACTORY

SCHEDULE 40

STACK OR DUCT
METAL W ALL

ADAPTER

2 IN. NPT

PIPE

1.25 NPT

CUSTOMER

SUPPLIED
ADAPTER

INSULATE IF EXPOSED

TO AMBIENTWEATHER

CONDITIONS

2 IN. NPT

SCHEDULE 40

PIPE

CALIBRA TION

GAS LINE

Figure 2-4. Horizontal Probe Installation

If the optional adapter plates are not used, a

3.

2 in. NPT, schedule 40, pipe nipple (Figure
2-4) should be welded to the stack or duct
wall.

When a 2 in. NPT to 1.25 NPT adapter is
threaded to the welded pipe nipple, the
adapter provides the pipe threads needed
for the probe’s process fit ting .

CHECK

REFERENCE

AIR LINE

SYSTEM

CABLE

29750004

Where high particulate or slag is in the flue

4.

gas stream, it may be desirable to inset the
probe in the refractory as shown in Figure
2-5. Use pipe couplings and nipples to ad­just the probe insertion dept h.

Use rags or other material to seal around

5.

the probe during insertion. This prevents
hot gases from escaping or cold air from
entering the stack or duct.

IB-106-4081

2-4

REFRACTORY

STACK OR

DUCT METAL

PROBE LENGTH

A

WALL

1.5 + A

DIMENSION A -- 1-5/8, 2-1/2, 3, OR
4 IN. 1.25 NPT SCHEDULE 40
PIPE NIPPLE

2 IN., 1.25 NPT
PIPE COUPLING

Figure 2-5. Adjusting Probe Insertion Depth

29750005

IB-106-4081

2-5

Initially insert the probe to a depth of 3 in.

6.

(76.2 mm) or 1/2 the depth of the stack or
duct refractory, whichever is greater.

After initial insertion, do not insert the
probe at a rate exceeding 1 in. per min­ute (25.4 mm per minute) or damage to
the probe may result due to thermal
shock.

After initial insertion, insert the probe at a

7.

rate of 1 in. (25.4 mm) per minute until the
probe is fully inserted.

Install anti-seize compound on the pipe

8.

threads and screw the probe into the proc­ess flange or adapter.

the insulation is replaced afterward. See
Figure 2-4.

If the ducts will be washed dow n during
outage, MAKE SURE to power down
the probes and remove them from the
wash area.

c. Locating Model 4081 Transmitter.

Ensure the Model 4081 Transmitter is eas-

1.

ily accessible for maintenance and service
and for using the infrared remote control (if
applicable).

NOTE

Use anti-seize compound on threads to ease
future removal of probe.

The electrical conduit port should be facing
down for a horizontal probe installation. See
Figure 2-4. In vertical probe installations,
orient the probe so the system cable drops
vertically from the probe. Ensure the elec­trical conduit is routed below the level of
the terminal block housing. This drip lo op
minimizes the possibility that moi sture will
accumulate in the housing.

If insulation was removed to access the

9.

duct work for probe mounting, make sure

Do not allow the temperature of the
Model 4081 Transmitter to exceed 65°C
(149°F) or damage to the unit may
result.

The ambient temperature of the transmitter

2.

housing must not exceed 65°C (149°F). Lo­cate the electronics in an area where tem­perature extremes, vibration, and electro­magnetic and radio frequency interference
are minimal.

Locate the Model 4081 Transmitter within

3.

150 ft (45.7 m) of the oxygen probe due to
wiring and signal considerations.

IB-106-4081

2-6

d. Installing Model 4081 Tra nsmitter.

Ensure all components are available to in-

1.

stall the Model 4081 Transmitter.

Choose a method or location to mount the

2.

transmitter.

(a) Flat Surface Mounting. The trans-

mitter may be mounted on a flat

surface using the threaded mounting
holes located on the bottom of the
transmitter housing. Refer to Figure
2-6 for installation references.

(b) Pipe Mounting. An optional pipe

mounting bracket is available for this
type of installation. Refer to Figure
2-7 for installation references.

COVER

LOCK

CIRCUIT

END

6.32

(160.5)

1.32

(33.5)

O-RING

(2 PLACES)

NOTE: DIMENSIONS ARE IN INCHES

WITH MILLIMETERS IN
PARENTHESES.

3.68

(93.5)

6.35

(161.3)

TERMINAL
END

3/4-14 NPT
(2 PLACES)

THREADED CAP
(2 PLACES)

0.839

(21.31)

SURFACE

BY OTHERS

TERMINAL BLOCK (TB)

TERMINAL END

CAP OMITTED

FOR CLARITY

(THIS VIEW)

1/4-20 THREADS
(4 PLACES)

0.839
(21.31)

FLAT SURFACE MOUNTING

PAD HOLE PATTERN

Figure 2-6. Flat Surface Mounting Dimensional Information

IB-106-4081

2-7

26020003

6.35

(161.3)

COVER LOCK

6.9

(175.3)

TERMINAL
BLOCK (TB)

CIRCUIT

6.32

(160.5)

1.00

(25.4)

0.375 (9.525) DIA.
(4 MOUNTING

HOLES)

1.405

(35.687)

2.81

(71.374)

END

1.32
(33.5)

C

TERMINAL
END

3/4 -14 NPT
2 PLACES

3.87

(98.3)

7.5

(190.5)

6.5

(165.1)

3.25

(82.55)

L

C

L

3/4-14 FNPT

(2 PLACES)

5/16-18 NUT

4.00

(101.6)

TERMINAL END CAP
OMITTED FOR CLARITY
IN THIS VIEW.

2 IN. PIPE/WALL
MOUNTING BRACKET
(OPTION)

U-BOLT
(2 PLACES)

%

1/4-20 THREADS

BRACKET HOLE PATTERN

FOR WALL MOUNTING

NOTE:

DIMENSIONS ARE IN INCHES WITH
MILLIMETERS IN PARENTHESES.

*SCREWS FURNISHED WITH

Figure 2-7. Pipe Mounting Dimensional Information

5/16 WASHER

U-BOLT

MOUNTING KIT ONLY. NOT
FURNISHED WITH
ANALYZER/TRANSMITTER.

BOTTOM VIEW

1/4-20 SCREW*

29760016

IB-106-4081

2-8

For correc t viewing orienta tion, the disp lay

3.

may be changed 90 degrees, using the fol­lowing procedure:

(d) Lift and rotate the display board 90

degrees either way.

(a) Refer to Figure 2-8. Loosen the cover

lock screw until the cover lock is dis­engaged from the knurled surface on

the threaded circuit end cap.
(b) Remove the circuit end cap.
(c) Remove the three screws retaining the

display board in place.

(e) Reposition the display board on the

standoffs. Install and tighten all three
screws.

(f) Install the circuit end cap and tighten

the cover lock screw to secure the
cover lock in place.

CIRCUIT

END CAP

SCREW

COVER LOCK

SCREW

DISPLAY

BOARD

O

90

Figure 2-8. Display Positioning Assembly

90

O

HOUSING

29760004

IB-106-4081

2-9

2-3. ELECTRICAL INSTALLATION

All wiring must conform to local and national codes.

Disconnect and lock out power before
connecting the unit to the power supply.

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

It is necessary to prevent moisture from entering
the Model 4081 Transmitter housing. The use of
weather-tight cable glands is required. If conduit
is used, plug and seal connections on the trans­mitter housing to prevent moisture accumulation
in the terminal side of the housing.

Moisture accumulation in the transmit­ter housing can affect its performance
and may void its warranty.

b. Oxygen Probe Signal Connections.

To meet the Safety Requirements of IEC
1010 (EC requirement), and ensure safe
operation of this equipment, connection
to the main electrical power supply must
be made through a circuit breaker (min
10 A) which will disconnect all current­carrying conductors during a fault
situation. This circuit breaker should
also include a mechanically operated
isolating switch. If not, then another ex­ternal means of disconnecting the supply
from the equipment should be located
close by. Circuit breakers or switches
must comply with a recognized standard
such as IEC 947.

a. General.

The power supply and signal wiring
should be shielded. Also, make sure the signal
wiring is grounded at the Model 4081 Transmitter
end only. Do not ground the signal loop at more
than one point. Twisted pairs are recommended.
Ground t he trans mitter ho using to an earth ground
to prevent unwanted electromagnetic interference
(EMI) or rad io fr equ en cy in t erf er en ce (R FI ).

Two signals represent the O

1.

value and the

2

cell temperature. The probe provides these
values to the Model 4081 Transmitter for
processing and signal conditioning.

Wiring connections for the probe are shown

2.

in Figure 2-9.

TERMINAL
BLOCK

CONDUIT

NOTE

For optimum EMI/RFI immunity, shield the

OUNDATION

F

fieldbus signal cable and enclose

in an earth grounded metal conduit .
Never run signal or sensor wiring in the same

conduit, or open tray, with power cables.
Keep signal or sensor wiring at least 12 in.
(0.3 m) away from other electrical equipment
and 6.5 ft (2 m) from heavy electrical equip­ment.

IB-106-4081

2-10

THERMOCOUPLE + (GY)

THERMOCOUPLE - (RD)

CELL - (WH)

CELL + (BK)

Figure 2-9. Oxygen Probe Terminal Block

26020004

c. Model 4081 Transmitter and F

Fie l d b u s S ignal Connections.

Two signals representing the O

1.

the cell temperature are supplied to the
Model 4081 Transmitter from the oxygen
probe.

OUNDATION

value and

2

2-4. PNEUMATIC INSTALLATION

a. General.

Reference air is required for O
lation, and calibration check gas is required dur­ing a calibration check. Refer to Figure 2-11 for
the gas connections on th e oxygen probe.

calcu-

2

Wiring connections for the Model 4081

2.

Transmitter are shown in Figure 2-10.

NOTE

The ground arrangement shown in Figure
2-10 limits the amount of noise introduced
into the electronics.

Connect wire shields to terminal 1. Connect

3.

earth ground as shown.

CELL - (WH)

THERMOCOUPLE - (RD)

FACTORY-INSTALLED

JUMPER

TERMINAL

BLOCK (TB1)

PROBE

CABLE

SHIELD

GROUND

4

3

12

CELL + (BK)

7

6

5

THERMOCOUPLE + (GY)

EARTH

GROUND

11

12

13

14

TERMINALS

FIELDBUS
DIGITAL (-)

15

FIELDBUS

16

DIGITAL (+)

8

9

10

b. Reference Air Package.

After the oxygen probe
is installed, connect the reference air set. Install
the reference air set according to Figure 2-12.

c. Instrument Air (Reference Air).

Instrument air
is required for reference. Use 10 psig (68.95 kPa
gage) minimum, 225 psig (1551.38 kPa gage) at

0.2 scfh (100 ml/min.); less than 40
parts-per-million total hydrocarbons. Regulator
outlet pressure should be set at 5 psi (35 kPa).

d. Calibration Check Gas.

Two calibration check
gas concentrations are used with the Two-Wire
In Situ Oxygen Analyzer: Low Gas - 0.4% O
and High Gas - 8% O2, each with the balance in
nitrogen. Do not use 100% nitrogen. See Figure
2-11 for the probe connections. Set both calibra­tion check gases at the same flow rate: 5 scfh
(2.5 L/min).

1/4 TUBE FITTING

(REFERENCE AIR PORT)

2

CELL AND
THERMOCOUPLE

CONDUITS

NOTE:

RUN CELL AND THERMOCOUPLE SIGNALS IN
SEPARATE CONDUIT FROM .FIELDBUS

FIELDBUS
DIGITAL

29760005

Figure 2-10. Model 4081 Transmitter Terminal Block

IB-106-4081

2-11

1/4 TUBE FITTING

(CALIBRATION CHECK

GAS PORT)

REFERENCE

AIR VENT

Figure 2-11. Oxygen Probe Gas Connections

26020006

0.125-27 NPT FEMALE

OUTLET CONNECTION

1

2

OUTLET

3.12 (79.25) MAX

3

2.250 (57.15)

NOTE: DIMENSIONS ARE IN INCHES WITH

MILLIMETERS IN PARENTHESES.

4.81 (122.17)

FLOW SET

POINT KNOB

0.25-18 NPT FEMALE
INLET CONNECTION

1.19
(30.22)

DRAIN VALVE

10.0

(254)

REF

(SUPPLIED BY CUSTOMER)

SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYGEN PROBE.

1/4” TUBE

(38.10)

2.0

(50.80)

1.50

1 FLOWMETER 0.2-2.0 SCFH 771B635H08

2 2" PRESSURE GAGE 0-15 PSIG 275431-006

3 COMBINATION FILTER-REG. 0-30 PSIG 4505C21G01

TO PROBE

2 MOUNTING HOLES

3.19 (81.03) LG

THROUGH BODY FOR

0.312 (7.92) DIA BOLTS

REF AIR SET

263C152G05

8.50

(215.90)

MAX

INSTRUMENT
AIR SUPPLY
10-225 PSIG
MAX PRESSURE

26020034

Figure 2-12. Air Set, Plant Air Connection

IB-106-4081

2-12

3

SECTION III. STARTUP

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

3-1. GENERAL

a. Verify Mechanical Installation.

Two-Wire In Situ Oxygen Analyzer is installed
correctly. See paragraph 2-2 for mechanical in­stallation information.

b. Verify Terminal Block Wiring.

wiring of both the oxygen probe terminal block
and Model 4081 Transmitter terminal block is
correct. Refer to paragraph 2-3 for electrical in­stallation and wiring information.

3-2. POWER UP

a. General.

The Two-Wire In Situ Oxygen Ana­lyzer displays the current oxygen reading on the
LCD face of the Model 4081 Transmitter. The
O

concentration and cell temperature are dis-

2

played as shown in Figure 3-1. T his and other in­formation may also be accessed using the

OUNDATION

F

fieldbus.

Ensure the

Ensure the

Figure 3-1. The display will now track the O
concentration and cell temperature.

CELL

TEMPERATURE

Figure 3-1. Normal Operation Display

O CONCENTRATION

2

%

29760006

2

b. Startup Display.

When the probe is first in­serted into the stack, some time is required until
minimum operating temperatures [550°C
(1022°F)] are reached. Some time is also re­quired for the electronics to reach an operating
state. Therefore, when the unit is first powered
up, a faulted operation display as shown in
Figure 3-2 may be displayed by the transmitter
until the probe operating temperatures are
reached and the electronics are working properly
(approximately 5 minut es ).

c. Operating Display.

After the probe has
reached operating temperatures, the Model
4081 Transmitter display should look similar to

%

29760007

Figure 3-2. Faulted Operation Display

IB-106-4081

3-1

3-3. REESTABLISHIN G PROPER CALIB RATION

CHECK GAS FLOW RATE

The calibration check gas flow must be enough to en­sure no comb ustion flue gases mix with the cali bra­tion check gases and only clean, good calibration
check gas surrounds the cell without expending ex­cess gas (Figure 3-3). Monitor the O
using an IRC or F

OUNDATION

fieldbus. Set the cali-

concentration

2

bration check gas flow rate as follows:

NOTE

Only set the calibration check gas flow rate
at startup. It is not necessary to perform
this procedure for each calibration check.

Adjust the calibration check gas flow to 5 scfh

a.

(2.5 L/min) to ensure the cell is surrounded by
calibration check gas. Due to the cooling effect
of the gas, the cell temperature will decrease
slightly, causing the O

concentration to drop.

2

Once the electronics compensates for this effect,
the O

concentration will stabilize.

2

Next, slowly reduce the calibration check gas

b.

flow until the O

concentration changes, which

2

indicates that the calibration check and flue gases
are mixing. Increase the flow rate until this effect
is eliminated.

FLUE GAS

CALIBRATION

GAS

STACK OR DUCT
METAL WALL

PROTECTIVE

TUBE

CELL

REFRACTORY

CALIBRATION

CHECK GAS LINE

REFERENCE

Figure 3-3. Proper Calibration Check Gas Flow Rate

AIR LINE

26020062

IB-106-4081

3-2

4

SECTION IV. OPERATION

4-1. GENERAL

a. Overview.

controls and displays of the Two-Wire In Situ
Oxygen Analyzer. The use of the Infrared Re­mote Control (IRC) and the Model 4081 Trans­mitter Liquid Crystal Display (LCD) are
described in detail.

This section explains the operator

CIRCUIT

END

b. Display.

The Model 4081 Transmitter LCD dis­plays the O2 concentration and cell temp-erature
during normal operation (see Figure 4-1). The
LCD will also display fault conditions when the y
occur. To interact with the transmitter, use the
IRC and navigate through a series of menus dis­played on the LCD.

TERMINAL

END

MODEL 4081 TRANSMITTER

ELECTRONICS HOUSING

%

Figure 4-1. Normal Operation Display

29760008

IB-106-4081

4-1

ON STARTUP

RESET

OR ON

FROM ANY

SCREEN

PROCESS DISPLAY

NORMAL

OPERATION

EXIT

ON FROM

ANY SCREEN

EXIT

WITHOUT

EXPLICITY

STATED

1 - USER ENTERS DISPLAY

ANALYZER CODE

2 - USER ENTERS ANALYZER

ACCESS CODE

CAL

NEXT

PROG

2

CODE

1

DISPLAY

CODE

CELL T HI

RESET MAX

CELL T

SET O2 FILTER

TIME

SET HI BOTTLE

O2

SET LO BOTTLE

O2

555 ENTER

NEXT

NEXT

NEXT

NEXT

NEXT

PROCESS DISPLAY

FAULTED

OPERATION

EXIT

PROGRAM

MENU

DIAG

SHOW FAULT IN MANUAL?

T/C mV ACCEPT HIGH O2

O2 CELL mV ACCEPT LOW O2

CELL

IMPEDANCE

PREVIOUS

SLOPE

PREVIOUS

CONSTANT

MAX CELL T

ENTER

NEXT ENTER

NEXT NEXT

NEXT NEXT

NEXT

NEXT

EXIT

EXIT

DIAGNOSTICS

NEXT

NEXT

FAULT

(IF PRESENT)

FAULT

(IF PRESENT)

MENU

PURGING

NEXT

SLOPE

NEXT

CONSTANT

RESET OR EXIT

CALCHECK

MENU

SET CODE

SW VER

NEXT

UNIT SER #

NEXT

SW BUILD

NUMBER

NEXT

NEXT

SW BUILD DATE

Figure 4-2. Model 4081 Transmitter Menu Tree

29760009

IB-106-4081

4-2

c. Menu Tree.

The screens that can be displayed
are shown in the menu tree of Figure 4-2. These
screens are displayed on the LCD and are ac­cessed using the IRC keypad.

d. Navigation.

The IRC in Figure 4-3 is used to
interact with the Model 4081 Transmitter and
navigate thr ough the screens on the LCD.

Hold the IRC within 6 ft (1.8 m) of the

1.

Model 4081 Transmitter and within 15 de­grees from the centerline of the transmitter
LCD. The amount of ambient light may
also affect IRC performance.

NOTE

The LCD may react slowly to IRC com­mands. Allow sufficient time between key
presses to avoid undesired or repeated
commands from accumulating in the com­mand queue.

Use the keys on the IRC to navigate

2.

through the menu screens. Refer to Figure
4-3. General usage is as follows:

(h) ENTER. Initiates the editing process

and causes the most significant digit
of the edited item to start flashing.
Also processes the e ntry so the pre vi­ous value updates to the new value
entered usin g the arrow keys. Fail ure
to press ENTER before exiting a
screen will cancel the input value and
revert to the previous value.

(i) NEXT. Accesses the next user screen

as shown in the menu tree. Any non­entered number in the exited state will
be ignored, and the previous data will
be used.

(j) EXIT. Exits from sub-branches of the

menu tree where an exit option is ex­plicitly shown. Otherwise, returns to
the PROCESS DISPLAY screen at
the top of the menu tree. Any non­entered number in the exited state will
be ignored, and the previous data will
be used.

(a) RESET. Returns to the PROCESS

DISPLAY screen at the top of the
menu tree. Any non-entered number
in the exited state will be ignored, and
the previous data will be used.

(b) HOLD. Not used.

(c) Left/Right Arrow. Moves left and

right among editable digits on the dis­play.

(d) Up/Down Arrow. Increases or de-

creases the value of the currently se­lected digit on the display.

(e) CAL. Accesses the CALCHECK

MENU branch of the menu tree. Only
works from the PROCESS DISPLAY
screen.

(f) PROG. Accesses the PROGRAM

MENU branch of the menu tree. Only
works from the PROCESS DISP LAY
screen.

RESET HOLD

ENTERCAL

PROG

DIAG EXIT

REMOTE CONTROL

ROSEMOUNT

NEXT

MODEL 3081

FISHER-ROSEMOUNT

(g) DIAG. Accesses the DIAGNOSTICS

MENU branch of the menu tree. Only
works from the PROCESS DISPLAY
screen.

IB-106-4081

29760010

Figure 4-3. Infrared Remote Control (IRC)

4-3

4-2. PROGRAM MENU

The PROGRAM MENU branch of the menu tree
allows you to program and edit some process pa­rameters, faults, outputs, and security codes. To ac­cess this branch of the menu tree, press the PROG
key on the IRC when in the PROCESS DISPLAY
screen (Normal or Faulted). You must enter the ana­lyzer code to gain further access to the screens in this
branch. Each screen in this branch is accessed se­quentially usi ng the NEXT key. Re fer to Figure 4-2
during the following menu and screen descriptions.

NOTE

O CONCENTRATION

2

%

To edit a screen value, press ENTER to ac­cess the data field. Use the left and right ar­row keys to move among the digits in the
data field. Note that the editable position
will be flashing. To change the value of a
digit, use the up and down arrow keys to
increase or decrease the value. When fin­ished editing, press ENTER to accept the
value. To go to the next screen in the menu,
press NEXT.

a. CODE.

Refer to Figure 4-4. After pressing the
PROG key, this screen will display. Use this
screen to identify a specific analyzer in a process
to prevent accessing an adjacent analyzer when
using the IRC.

Press ENTER to begin edit ing. At this point , you
can either specify the analyzer by its access code
or view its code if it is unknown.

1.

To gain further access to the screens in the
PROGRAM MENU branch, enter the cor­rect three-digit analyzer access code using
the arrow keys and press ENTER. If secu­rity is disabled, this screen does not appear
and the system displays the FAULT VAL
screen.

ANALYZER

ACCESS CODE

OR SECURITY

ACCESS CODE

Figure 4-4. CODE

b. DISPLAY CODE.

Refer to Figure 4-5. This
screen is accessible from the CODE screen by
entering 555 and pressing ENTER. The DIS­PLAY CODE screen identifies the analyzer ac­cess code so you can return to the CODE screen
and enter the code as described in paragraph
4-2.a. To return to the Process Display screen,
press EXIT.

O CONCENTRATION

2

%

26020009

2.

If the analyzer access code is unknown,
enter 555 and press ENTER to access the
DISPLAY CODE screen. In that screen,
you will be able to view the analyzer access
code.

ANALYZER

ACCESS CODE

26020047

Figure 4-5. DISPLAY CODE

IB-106-4081

4-4

c. CELL T HI.

Refer to Figure 4-6. Use this
screen to set the value of the upper cell tem­perature fault condition. This value i s the maxi­mum allowed cell temperature before a fault
condition is indicated. Press ENTER to begin
editing. Use the arrow keys to select and change
the value. The value must be between 550° and
1600°C. Press ENTER to accept the value.
Pressing NEXT displays the RESET MAX
CELL T screen.

O CONCENTRATION

2

d. RESET MAX CELL T.

Refer to Figure 4-7.
The transmitter tracks the maximum cell tem­perature obtained. Use this screen to reset the
maximum cell temperature attained value to the
current cell temperature. Press ENTER to begin
editing. Use the arrow keys to select and change
the value (Y/N). Then, press ENTER to accept
the value. Pressing NEXT displays the SET O2
FILTER TIME screen.

O CONCENTRATION

2

Figure 4-6. CELL T HI

%

UPPER CELL

TEMPERATURE

FAULT VALUE

26020012

%

Y/N (TO RESET
MAXIMUM CELL
TEMPERATURE)

26020013

Figure 4-7. R ESET MAX CELL T

IB-106-4081

4-5

e. SET O2 FILTER TIME.

Refer to Figure 4-8.
In some applications, it is beneficial to dampen
the raw O

signal coming from the cell. Use this

2

screen to enter the amount of time it will take the
O

to reach 90% of the new reading. Press EN-

2

TER to begin e diting. Use the ar row keys to se­lect and change the screen value to the O
value (in seconds). Enter a value between 0 and
300 seconds and press ENTER to accept the
value. Press NEXT to access the SET HI BOT­TLE O2 screen.

O CONCENTRATION

2

filter

2

f. SET HI BOTTLE O 2.

Refer to Figure 4-9.
Use this screen to identify, within the electronics,
the percentage of O

used as the high calibration

2

check gas. Press ENTER to begin editing. Use
the arrow keys to select and change the screen
value to the O

percentage of the high calibration

2

check gas. Press ENTER to accept the value.
Press NEXT to display the SET LO BOTTLE
O2 screen.

O CONCENTRATION

2

%

O FILTER

2

VALUE (IN SECONDS)

Figure 4-8. SET O2 FILTER TIME

26020048

%

HIGH CALIBRATION

CHECK GAS O

PERCENTAGE

Figure 4-9. SET HI BOTTLE O2

2

26020049

IB-106-4081

4-6

g. SET LO BOTTLE O2 .

Refer to Figure 4-10.
Use this screen to identify, within the electronics,
the percentage of O

used as the low calibration

2

check gas. Press ENTER to begin editing. Use
the arrow keys to select and change the screen
value to the O

percentage of the low calibration

2

check gas. Press ENTER to accept the value.
Press NEXT to display the SET CODE screen.

O CONCENTRATION

2

%

O CONCENTRATION

Figure 4-11. SET CODE

2

%

26020016

LOW CALIBRATION

CHECK GAS O

PERCENTAGE

Figure 4-10. SET LO BOTTLE O2

h. SET CODE.

Refer to Figure 4-11. Use this
screen to set the security code for the
Model 4 081 Transmitter. Press ENTER to begin
editing. Use the arrow keys to select and change
the value. Select any value between 000 and 999,
excluding 000 and 555. Code 000 indicates that
no code is set. Code 555 accesses the DISPLAY
CODE screen. Press ENTER to accept the value.
Pressing NEXT re turns to the CEL L T HI scree n
at the beginning of the PROGRAM MENU.

2

26020050

i. Model 4081 Transmitter Parameters.

4-1 lists the range and default value of operator­adjustable variables used by the Model 4081
Transmitter. These variables may all be changed
from the PROGRAM MENU screens.

Table 4-1. Model 4081 Transmitter Parameters

Parameter Range Default

Upp e r Range L i mit 2.0-25.0% 10.0%
Upper Cell Temp.

650-1600°C 1600°C

Fault Value
Analyzer Access

Code

000-999 (excluding
000 and 555)

000 (no
code)

Table

IB-106-4081

4-7

%

%

THERMOCOUPLE mV

26020018

26020017

Figure 4-13. T/C mV

Figure 4-12. SHOW FAULT

4-3. DIAGNOSTICS MENU

The DIAGNOSTIC S MENU branch o f the menu tree
allows you to examine outputs, current faults, and unit
information. None of the ite ms in the DIAGNOSTICS
MENU are editable. T his branch of the me nu tree may
be accessed by pressing DIAG on the IR C when in t he
PROCESS DISPLAY screen (Normal or Faulted).
Each screen in this branch is accessed sequentially by
pressing NEXT. Refer to Fig ur e 4 -2 during the follow­ing menu and screen descriptions.

a. SHOW FAULT.

Refer to Figure 4-12. After
pressing DIAG, this screen displays. Pressing EN­TER accesses a scree n displaying the current fa ult
(if any). If more than one fault exists, and you are in
the FAULT screen, the display cycles through all
existing faults. Information on the fault screens can
be found in Section V, TROUBLESHOOTING.
Press EXIT to return from this fault sub-menu and
press NEXT to access the T/C mV screen.

b. T/C mV.

Refer to F igur e 4-1 3. Use this screen to
examine the cell thermocouple mV output. Three
decimal places are displayed. Pressing NEXT ac­cesses the O2 CELL mV screen.

c. O2 CELL mV.

Refer to Fig ure 4 -14. Use this
screen to examine the O2 CELL mV output.
Pressing NEXT accesses the CELL I MP EDAN CE
screen.

%

O CELL mV

2

Figure 4-14. O2 CELL mV

26020019

IB-106-4081

4-8

O CONCENTRATION

2

O CONCENTRATION

2

%

O CELL

2

IMPEDANCE STATUS

26020020

Figure 4-15. CELL IMPEDANCE

d. CELL IMPEDANCE.

Refer to Figure 4-15.
Use this screen to examine the O2 CELL IM­PEDANCE status. GOOD indicates the cell i s op­erating normally. WARN indicates the cell has
degraded but is still operational. HI indicates that
the cell has de graded but is still operational; how­ever, failure will occur soon. Pressing NEXT ac­cesses the PREVIOUS SLOPE screen .

%

CALCHECK CELL

SLOPE VALUE

Figure 4-16. PREVIOUS SLOPE

f. PREVIOUS CONSTANT.

Refer to Figure
4-17. Use this screen to examine the cell zero
constant calculated from the most recent calibra­tion check. The constant represents the voltage
generated by the cell when no difference exists
between the amount of O

on the reference and

2

process sides of the cell. Press NEXT to access
the MAX CELL T screen.

O CONCENTRATION

2

26020052

NOTE

Temperature influences cell impedance.
Wait until the cell is at operating te mpera­ture before checking cell impedance. If
checked before the cell reaches operating
temperature [550°C (1022°F)], this screen
displays a fail indication.

e. PREVIOUS SLOPE.

Refer to Figure 4-16. Use
this screen to examine the slope calculated from the
most recent calibration check. The slope is the
amount of cell voltage generated for a given O
value. For each calibration check, record the slope
over the life of the probe. Tracking t he slope will
indicate if the probe is degrading. Press NEXT to
access the PREVIOUS CONSTANT screen.

%

2

CALCHECK CELL

CONSTANT VALUE

26020053

Figure 4-17. PREVIOUS CONSTANT

IB-106-4081

4-9

of the analyzer. Before performing a calibratio n check,
ensure the high calibration check gas and low calib­ration check gas O

percentages are entered into the

2

electronics via the PROGRAM MENU. To set these
values, refer to paragraphs 4-2.f and 4-2.g.

%

Once these values are set, access the CALCHECK
MENU branch by pr ess in g CAL on the IRC when in the
PROCESS DISPLAY screen (Normal or Faulted).
Each screen in this branch identifies a process step in
the calibration check procedure. The first screen in the
sequenc e is the IN MA NUAL? screen.

CELL

TEMPERATURE

MAXIMUM

Figure 4-18. MAX CELL T

g. MAX CELL T.

Refer to Figure 4-18. Use this
screen to examine the maximum temperature at­tained by the O

cell. This value can be reset un-

2

der the PROGRAM MENU. Pressing NEXT
accesses the SW VER screen.

h. SW VER.

Use this screen to see the software
version number for the Model 4081 Transmitter.
Pressing NEXT accesses the UNIT SER #
screen.

i. UNIT SER #.

Use this screen to see the unit
serial number for the Model 4081 Transmitter.
Pressing NEXT accesses the SW BUILD
NUMBER screen.

26020021

a. IN MANUAL?.

Refer to Figure 4-19.

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

If the O2 output value is used in any automatic
process control loops, the loop must be placed in
manual be fore beginning a calibration check.

Once the analyzer is removed from any auto­matic control loops, press ENTER to edit the
screen. Use the arrow keys to select Y (yes) and
press ENTER to process the selection and to dis­play the ACCEPT HIGH O2 screen.

O CONCENTRATION

2

j. SW BUILD NUMBER.

Use this screen to see
the software build number for the Model 4081
Transmitter. Pressing NEXT accesses the SW
BUILD DATE screen.

k. SW BUILD DATE.

Use this screen to see the
software build date for the Model 4081 Trans­mitter. Pressing NEXT returns to the beginning
of the DIAGNOSTICS MENU branch (the
SHOW FAULT screen).

4-4. CALCHECK MENU

The CALCHECK MENU branch of the menu tree
(Figure 4-2) allows you to perform a calibration check

%

Y/N (FOR USER

RESPONSE)

26020054

Figure 4-19. IN MANUAL?

IB-106-4081

4-10

O CONCENTRATION

2

O CONCENTRATION

2

%

%

HIGH CALIBRATION

CHECK GAS O VALUE

Figure 4-20. ACCEPT HIGH O2

b. ACCEPT HIGH O2.

Refer to Figure 4-20.
After pressing ENTER to begin the calibration
check, the high calibration check gas starts to flow.
After waiting approximately three minutes for the
displayed O

value to settle, press NEXT to accept

2

the high calibration check gas reading and apply the
low calibratio n check gas. The next s creen to dis­play is the ACCEPT LO W O2 screen.

2

26020055

%

29760017

Figure 4-22. PURGING

d. PURGING.

The PURGING screen provides an
opportunity for the O2 reading to return to the
process gas concentration prior to exiting the
calibration procedure. Once the displayed oxy­gen concentra tio n ha s retur ned to the pro cess gas
value, press the NEXT button to display the
SLOPE screen.

O CONCENTRATION

2

c. ACCEPT LOW O2.

Refer to Figure 4-21.
Once the low calibration check gas is applied,
wait approximately three minutes for the dis­played O

value to settle. Once the value settles,

2

press NEXT to accept the reading and to display
the PURGING screen.

O CONCENTRATION

2

%

%

LOW CALIBRATION

CHECK GAS O VALUE

Figure 4-21. ACCEPT LOW O2

2

26020056

%

CALCHECK CELL

SLOPE VALUE

Figure 4-23. SLOPE

e. SLOPE.

Refer to Figure 4-23. Use this screen
to examine the slope calculated from current
calibration check. The slope is the amount of cell
voltage generated for a given O

value. After

2

each calibration check, record the slope over the
life of the probe. Tracking the slope will indicate
if the probe is degrading. Press NEXT to access
the CONSTANT screen.

26020057

IB-106-4081

4-11

O CONCENTRATION

2

SIMULATE

SWITCH (3)

ON OFF

%

CALCHECK CELL

CONSTANT VALUE

Figure 4-24. CONSTANT

f. CONSTANT.

Refer to Figure 4-24. Use this
screen to examine the cell zero constant calcu­lated from the current calibration check. The
constant repr esents the voltage genera ted by the
cell when no difference exists between the
amount of O

on the reference and process sides

2

of the cell. Note this value for comparison
against future calibration checks. Press RESET
or EXIT to return to the PROCESS DISPLAY
screen.

26020058

E4.000

40

K

123

ON

SECURITY

SWITCH (2)

ON OFF

Figure 4-25. Simulate and Security Switch Positions

This must be done while the instrument is powered
on. The simulate function will not actuate unless it
sees the transition from OFF to ON. To remove the
device from the simulate mode, place the switch in
the OFF position, or cycle power to the analyzer.
Note that this switch does not actually place the ana­lyzer in the simulate mode, it only allows the simu­late mode to be enabled via fieldbus.

4-6. SECURITY SWITCH

29760020

4-5. SIMULATE SWITCH

The Model 4081FG is equipped with a simulate
function. Located on the fieldbus board is a switch
that controls the simulate enable status of the ana­lyzer. Refer to Figure 4-25. To allow the analyzer to
be placed in simulation mode, place the switch in the
ON position.

The Model 4081FG contains a security function
which prevents parameter from being changed via
fieldbus. Refer to Figure 4-25. To enable the security
feature, set the security switch located on the fieldbus
board to ON, then enable security in the resource
block.

IB-106-4081

4-12

SECTION V. TROUBLESHOOTING

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

5

Life of the probe is negatively impacted by:

Continued operation at elevated temperatures

•

above 1300°C (2372°F).
Operation in processes that contain high levels of

•

sulfur, SO

, or other acidic compounds.

2

5-1. GENERAL

This troubleshooting section describes how to iden­tify and isolate faults that may develop in the T wo­Wire In Situ Oxygen Analyzer.

5-2. PROBE LIFE

The zirconium oxide technology for measuring oxy­gen is very stable and should provide accurate service
for several years.

50

40

30

20

SLOPE (mV/Dec)

NORMAL
OPERATIONAL
CONDITIONS

DETERIORATED PERFORMANCE,
SLOW RESPONSE,
HIGH MEASUREMENT ERROR

Operating cond itions wit h simult aneousl y high leve ls
of SO

and low levels of O2 are particularly

2

damaging.

The health and accuracy of a given cell is closely re­lated to the resistance, or impedance, of the cell.
Figure 5-1 illustrates that the amount of outp ut from
a cell for a given O

value (represented as slope) will

2

remain very stable to the point where cell impedance
increases to approximately 100 ohms.

DETERIORATED PERFORMANCE,
SLOW RESPONSE,
HIGH MEASUREMENT ERROR.
CONDUCT FREQUENT CALIBRA­TION CHECKS.

10

48.0<S<51 mV/Dec

0

45.0<S<48 mV/Dec

IMPEDANCE,

Ω

S<45 mV/Dec

26020059

Figure 5-1. Slope vs. Impedance

IB-106-4081

5-1

500

400

90

SPEED OF RESPONSE (t ), sec

300

200

100

0

AIR TO 0.4% O

0.4% O TO AIR

2

Figure 5-2. Speed of Response

Frequently conduct calibration checks to look for the
following conditions:

Continued degradation of cell slope.

•

Sluggish response. (Note how long it takes the

•

cell to respond to the application of calibration
check gases.) See Figure 5-2.

2

IMPEDANCE,

Ω

26020060

is present. When the error is corrected, the screen
will return to a normal operation display unless an­other error exists.

The slope will be valid only for the process tem­perature at which the calibration check gases are
flowed, so no adjustments to the electronics are made
as a result of a calibration check.

Note that cells exposed to temperatures above
1300°C (2372°F) may lose the ability to measure ac­curately and respond quickly when returned to the
lowest end of the operating temperature range [550°C
(1022°F)].

5-3. FAULT INDICATIONS

The fault conditions for the Two-Wire In Situ Oxy­gen Analyzer will be indicated by the faulted opera­tion display as shown in Figure 5-3. This screen
displays when a fault that invalidates the O

reading

2

%

29760012

Figure 5-3. Faulted Operation Display

IB-106-4081

5-2

5-4. IDENTIFYING AND CORRECTING FAULT

INDICATIONS

A fault in the operation of the Two-Wire In Situ
Oxygen Analyzer is indicated by the faulted opera­tion display. If no faults exist, the display will indi­cate NONE. Information on the current fault is found
under the DIAGNOSTICS MENU as detailed in
Section IV, OPERATION.

The following paragraphs describe the faults, possi­ble causes, and co r rective actions. Refer to Figure 5-4
as needed for test points and w iring information.

NOTE

Allow adequate time for the oxygen probe
to reach its operating temperature [approx-

imately 500°°°°C (932°°°°F)] before investigating
a fau lt. The SHOW FAULTS screen of the
DIAGNOSTICS menu will indicate a fault
until the unit reaches operating temperature.

NOTE

The probe uses a Type B thermocouple to
measure the cell temperature. A Type B
thermocouple output table may be useful
for troubleshooting.

FACTORY-INSTALLED

JUMPER

TERMINAL

BLOCK (TB1)

PROBE

CABLE

SHIELD

GROUND

CELL AND
THERMOCOUPLE

3

12

CELL + (BK)

7

6

5

4

THERMOCOUPLE

8

9

10

11

+(GY)

EARTH

GROUND

TERMINALS

FIELDBUS

12

13

DIGITAL (- )

14
15

FIELDBUS

16

DIGITAL (+)

FIELDBUS
DIGITAL

29760013

CELL - (WH)

THERMOCOUPLE

- (RD)

Figure 5-4. Model 4081 Transmitter Terminal Block

IB-106-4081

5-3

%

%

26020025

Figure 5-5. Fault 1, Open Thermocouple

a. Fault 1, Open Thermocouple.

The thermocou­ple connection is open. The fault displays as
shown in Figure 5-5.

Refer to Figure 5-4 and check the thermo-

1.

couple wiring connections at terminals 8
and 10. Ensure the wires are properly con­nected.

Remove power. Disconnect the thermocou-

2.

ple wires (gray and red) from terminals 10
and 8. Measure the continuity across the
gray and red thermocouple leads. The
measurement should read approximately
1-2 ohms. Larger values indicate the ther­mocouple is open.

If the thermocouple is open, replace the

3.

oxygen probe per paragraph 6-2.

26020024

Figure 5-6. Fault 2, Reversed Thermocouple

b. Fault 2, Reversed Thermocouple Active.

thermocouple connections are reversed. The fault
displays as shown in Figure 5-6.

Allow adequate time for the oxygen probe

1.

to reach operating temperatures. Probe
temperatures below approximately 500°C
(932°F) may result in this fau lt.

Refer to Figure 5-4. Check the gray (to

2.

terminal 10) and red (to terminal 8) wires
for the proper placement.

Using a multimeter, measure between ter-

3.

minals 8(-) and 10(+). If the reading is
negative, the thermocouple wiring is re­versed. Rewire as necessary.

If the wiring is correct and the probe is at

4.

operating temperature, then the transmitter
electronics are bad. Replace the PC board
stack assembly per paragraph 6-1.

The

IB-106-4081

5-4

%

%

26020026

Figure 5-7. Fault 3, Shorted Thermocouple

c. Fault 3, Shorted Thermocouple.

The thermo­couple connections are shorted. The fault dis­plays as shown in Figure 5-7.

Allow adequate time for the oxygen probe

1.

to reach operating temperatures. Probe
temperatures below approximately 500°C
(932°F) may result in this fau lt.

Refer to Figure 5-4. Using a multimeter,

2.

measure between terminals 8(-) and 10(+).

If the multimeter reading, in voltage mode,

3.

is between -0.5 and +0.5 mV, the thermo­couple is shorted.

If the thermocouple is shorted, replace the

4.

oxygen probe per paragraph 6-2.

If the thermocouple is not shorted, then re-

5.

place the PC board stack assembly per
paragrap h 6-1.

26020027

Figure 5-8. Fault 4, High Probe Temperature

d. Fault 4, High Probe Temperature.

The probe’s
temperature has exceeded the maximum cell
temperature setpoint. The fault displays as shown
in Figure 5-8.

If the probe temperature exceeds the maxi-

1.

mum cell temperature setpoint, the

OUNDATION

F
questionable O

Verify that the upper cell temperature set-

2.

fieldbus signal willl indicate a

level.

2

point is configured as desired under the
PROGRAM MENU (see Section IV, OP­ERATION).

IB-106-4081

5-5

%

%

26020028

Figure 5-9. Fault 5, O2 Cell Open

e. Fault 5, O

2

Cell Open.

The O

2

cell connection
is open. The fault displays as shown in Figure
5-9.

Allow adequate time for the oxygen probe

1.

to reach operating temperatures. Probe
temperatures below approximately 500°C
(932°F) may result in this fau lt.

Refer to Figure 5-4 and check the O

2.

wiring connections at terminals 7 and 8.
Ensure the wires are properly connected.

NOTE

Check the cell output voltage at the probe
terminals -- not at the electronics.

Apply low calibration check gas (0.4% O

3.

Measure the cell output from the O
wires at the probe terminal block. The cell
output s hould be 100 ±20 mV. If no voltage
can be measured, the cell is open.

cell

2

cell

2

26020029

Figure 5-10. Fault 6, Cell Impedance Too High

f. Fault 6, Cell Impedance Too High.

The O

2

cell impedance has exceeded 100 ohms. The
fault displays as shown in Figure 5-10.

This fault is usually indicated in conjunc-

1.

tion with Fault 5, Cell Open. Correcting
Fault 5 should correct Fault 6.

If Fault 6 appears independently, the cell

2.

has degraded beyond specification.

If the O

3.

cell has become too old, replace

2

the oxygen probe per paragraph 6-2.

).

2

If the O

4.

cell is open, replace the oxygen

2

probe per paragraph 6-2.

IB-106-4081

5-6

%

Figure 5-11. Fault 7, Reversed O2 Cell

26020030

g. Fault 7, Reversed O

Cell.

The O

cell connec-

2

2

tions are reversed. The fault displays as shown in
Figure 5-11.

Refer to Figure 5-4. Check the black (to

1.

terminal 7) and white (to terminal 8) wires
for the proper placement. Rewire if
necessary.

Apply the low calibration check gas

2.

(0.4% O

Using a multimeter, measure between ter-

3.

).

2

minals 7(+) and 8(-). If the cell output
reading is nega tive, the O

cell wiring is re-

2

versed.

If the wiring is correct, check if the multi-

4.

meter reading is the same as the reading
shown on the O

CELL mV diagnostics

2

screen (see Section IV, OPERATION).

If the reading is different, the transmitter

5.

electronics are faulty. Replace the PC board
stack assembly per paragraph 6-1.

IB-106-4081

5-7

6

1. Housing 9. O-ring

2. O-ring 10. PC Board Stack (CPU, Analog,

3. Lockwasher and F

OUNDATION

Fieldbus Boards)

4. Screw 11. Display Board

5. Terminal End Cap 12. Screw

6. Terminal Block 13. Circuit End Cap

7. Ground Screw 14. Screw

8. Washer 15. Cover Lock

2

1

7

8

4

3

5

6

9

10

15

13

14

STANDOFF

11

12

RIBBON

CABLE

Figure 6-1. Two-Wire In Situ Oxygen Analyzer Exploded View

OUNDATION

F

FIELDBUS

BOARD

STANDOFF

ANALOG
BOARD

CPU BOARD

29760014

IB-106-4081

6-0

SECTION VI. MAINTENANCE AND SERVICE

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

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

6-1. MODEL 4081 ELECTRONICS REPLACEMENT

Before replacing any electronic components, verify
that the power to the Model 4081 Transmitter is
removed. Refer to Table 8-1 for replacement part
numbers.

a. Display Board Replacement.

lowing procedure to replace display board (11,
Figure 6-1).

Loosen screw (14) until cover lock (15)

1.

disengages from the knurled surface of cir­cuit end cap (13).

Remove circuit end cap (13).

2.

Remove three screws (12) retaining the

3.

electronics in place.

Lift display board (11) and disconnect the

4.

ribbon cable connector between the display
board and the CPU board of PC board stack
(10).

Using a replacement display board, connect

5.

the ribbon cable connector between the dis­play board and the CPU board of PC board
stack (10). Ensure the cable connector is
fully seated.

Reposition display board (11) on the stand-

6.

offs. Rotate the display board 90 degrees
either way as desired.

Install and tighten all three screws (12).

7.

Install circuit end cap (13).

8.

Use the fol-

Tighten cover lock screw (14) until cover

9.

lock (15) engages knurled surface of circuit
end cap (13).

b. PC Board Stack Replacement.

(10, Figure 6-1) is composed of the CPU board
and the analog board. Use the following proce­dure to replace these boards as a set.

Loosen cover lock screw (14) until cover

1.

lock (15) disengages from the knurled sur­face of circuit end cap (13).

Remove circuit end cap (13). Remove three

2.

screws (12).

Lift display board (11) and disconnect the

3.

ribbon cable connector between the display
board and the CPU board of PC board stack
(10).

Lift the CPU board from housing (1) by the

4.

standoffs.

Remove two screws (4) and lockwashers

5.

(3). Lift terminal block (6) until the analog
board is unplugged from the terminal
board.

Reinstall terminal block (6), lockwashers

6.

(3), and screws (4).

Lift the analog board from housing (1) by

7.

the standoffs.

Install replacement PC board stack (10) into

8.

housing (1). Carefully seat the analog board
onto housing pins. Press firmly o n the CP U
board standoffs to ensure good contact.

Connect the ribbon cable connector be-

9.

tween display board (11) and the CPU
board of PC board stack (10). Ensure the
cable connector is fully seated.

10. Reposition display board (11) on the stand­offs. Rotate the display board 90 degrees
either way as desired.

11. Install and tighten all three screws (1 2) and
circuit end cap (13).

12. Tighten cover lock screw (14) until cover
lock (15) engages knurled surface of circuit
end cap (13).

PC board stack

IB-106-4081

6-1

Use heat resistant gloves and clothing
when removing the probe. The probe
can be as hot as 1600°°°°C (2912°°°°F). This
can cause severe burns.

6-2. OXYGEN PROBE REPLACEMENT

The oxygen p rob e is de signed wit h c era mic mate ria ls
to provide maximum life at elevated temperatures
and is not rebuildable. The condition of the sensing
cell can be determined periodically by two methods:

Note the cell impedance at the electronics. Whe n the

•

impedance displays a warning indication (WARN),
increase the frequency of impedance readings. A cell
with a sustained high impedance indication (HI) indi­cates a probe that is beyond its useful life.

Conduct a calibration check. Follow the prompts

•

provided by the electronics through the process of
flowing two calibration check gases of known val­ues. Record the generated slope and constant val­ues.

Refer to Table 8-1 for replacement probe part num­bers. Before replacing the probe, verify that the refer­ence air and calibration check gas lines are turned off
and disconnected from the probe.

Remove the end cap of the probe to expose the

a.

terminal block.

Refer to Figure 6-2. Disconnect the four wires

b.

(two oxygen signal wires and two thermocouple
wires) from the terminal block.

Disconnect the reference air and the calibration

c.

check gas lines.

Unscrew the probe from the stack and remove.

d.

Using a replacement probe, refer to paragraph

e.

2-2.c for mechanical installation instructions.

Refer to paragraph 2-3.b for electrical installa-

f.

tion instructions.

Probe replacement may be conducted online as long
as the process in which the probe is mounted is oper­ating at a negative, or slightly positive, pressure. Re­fer to Section V, TROUBLESHOOTING, for more
information.

Do not install or remove probes from a
process where pressures are more than a
few inches of H2O positive pressure. Ho t
gases may escape from the stack and
cause severe personal injury.

Do not insert or withdraw a probe into
or out of a hot process faster than 1 in.
(25.4 mm) per minute or instrument
damage from thermal shock may occur.

Also, ash, slag, or other materials can
build up on the probe body in some ap­plications. If this buildup is cau sing dif­ficulty when withdrawing the probe, DO
NOT FORCE. Rotate the probe back
and forth to attempt to loosen the mate­rial on the probe body. Or, wait until the
process cools down and access the
buildup from inside the furnace.

Refer to paragraph 2-4 for reference air and cali-

g.

bration check gas installation instructions.

TERMINAL
BLOCK

CONDUIT

THERMOCOUPLE + (GY)

THERMOCOUPLE - (RD)

CELL - (WH)

CELL + (BK)

Figure 6-2. Oxygen Probe Terminal Block

26020004

IB-106-4081

6-2

7

SECTION VII. REPLACEMENT PARTS

Table 7-1. Replacement Parts List

Figure and

Index No. Part Number Description

1-1, 2 1A99372H01 Model 4081 Transmitter CENELEC
1-1, 2 1A99372H02 Model 4081 Transmitter CSA
1-1, 2 1A99372H03 Model 4081 Transmitter FM
1-1, 3 5R10092G01 20” Replacement Oxygen Probe, with Alumina Outer Protection Tube
1-1, 3 5R10092G02 26” Replacement Oxygen Probe, with Alumina Outer Protection Tube
1-1, 3 5R10092G03 38” Replacement Oxygen Probe, with Alumina Outer Protection Tube
1-1, 3 5R10092G09 20” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube
1-1, 3 5R10092G010 26” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube
1-1, 3 5R10092G011 38” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube
6-1, 10 23811-03 PC Board Stack Assembly (CPU and Analog Boards) - F
6-1, 11 23652-01 Display Board
6-1, 6 23581-00 Terminal Block
6-1, 13 23593-01 Circuit End Cap (with Glass)

OUNDATION

fieldbus

IB-106-4081

7-1/7-2

8

SECTION VIII. RETURNING EQUIPMENT TO THE FACTORY

If factory repair of defective equipment is required,

8-1.

proceed as follows:

Secure a return authorization number from a

a.

Rosemount Analytical Sales Office or represen­tative before returning the equipment. Equipment
must be returned with complete identification in
accordance with Rosemount instructions or it
will not be accepted.

In no event will Rosemount be responsible for
equipment returned without proper authorization
and identification.

Carefully pack defective unit in a sturdy box

b.

with sufficient shock absorbing material to en­sure that no additional damage will occ ur during
shipping.

In a cover letter, describe completely:

c.

The symptoms from which it was deter-

1.

mined that the equipment is faulty.

The environment in which the equipment

2.

has been operating (housing, weather, vi­bration, dust, etc.).

Site from which equipment was removed.

3.

Whether warr a nt y o r non war r ant y se r vic e i s

4.

requested.

Enclose a cover letter and purchase order and

d.

ship the defective equipment according to in­structions provided in Rosemount Return
Authorization, prepaid, to:

American

Rosemount Analytical Inc.
RMR Department
1201 N. Main Street
Orrville, Ohio 44667

European

Rosemount Ireland
Equipment Return Repair Dept.
151 Shannon Industrial Estate
Co. Clare
Ireland

If warranty service is requested, the defective
unit will be carefully inspected and tested at the
factory. If failure was due to conditions listed in
the standard Rosemount warranty, the defective
unit will be repaired or replaced at Rosemount’s
option, and an operating unit will be re turned to
the customer in accordance with shipping in­structions furnished in the cover letter.

Complete shipping instructions for return of

5.

equipment.

Reference the return authorization number.

6.

For equipment no longer under warranty, the
equipment will be repaired at the factory and re­turned as directed by the purchase order and
shipping instru ct i ons .

IB-106-4081

8-1/8-2

A
B
C
D
E
F
G
H

I

INDEX

This index is an alphabeti zed listing of parts, terms, and procedures related to the Two-Wire In Situ Oxygen Analyzer. Every
item listed in the index refers to a location in the manual by page number or numbers.

A

Absolute Temperature, 1-2
ACCEPT HIGH O2 Screen, 4-11
ACCEPT LOW O2 Screen, 4-11
Accuracy, 1-6
Adapter Plate, 2-3
Ambient Temperature Limits, Electronics, 1-6
Arithmetic Constant, 1-2

C

CAL Key, 4-3
CALCHECK Menu, 4-2, 4-10
Calibration Check Gas, 1-4, 1-6, 2-11
Calibration Check Gas Flow Rate, 3-2
Cell Constant, 1-2
CELL IMPE DANC E Sc ree n, 4-9
Cell Impedance Too High Fault, 5-6
CELL T HI Screen, 4-5
Check Valve, 1-4
Component Checklist, 1-1
CONSTANT Screen, 4-12

D

DIAG Key, 4-3
Diagnostics Menu, 4-2, 4-8
Display Board, 2-9
Display Board Positioning, 2-9
Display Board Replacement, 6-1
DISPLAY CODE Screen, 4-4
Drip Loop, 2-6

E

Earth Ground, 2-11
Electrical Installation, 2-10
Electromagnetic Interference (EMI), 2-10
ENTER Key, 4-3
EXIT Key, 4-3

H

Hazardous Area Certification, 1-6
Hazardous Area Certification, IRC, 1-6
Hazardous Area Certification, Probe, 1-6
High Probe Temperature Fault, 5-5

I

IN MANUAL? Screen, 4-10
Infrared Remote Control (IRC), 1-1, 1-3
Inner Probe, 1-6
Inputs, 1-6
Inspect, 2-1
Instrument Air, 1-4, 2-11
Insulation, 2-6
Intrinsic Safe, 1-5
Intrinsic S afety (IS), 1-3
IP65, 1-4, 1-6
IRC, 4-3
IRC Power Requirements, 1-6

L

Lengths, Probe, 1-3, 1-6
Liquid Crystal Display (LCD), 4-1

M

Materials of Construction, 1-6
Materials of Construction, Electronics, 1-6
MAX CELL T Screen, 4-1 0
Mechanical Installation, Probe, 2-1
Menu Arrows, 4-3
Menu Tree, 4-2
Minimum Operating Temperatures, 3-1
Model 4081 Transmitter, 1-1, 1-3, 2-6, 2-7, 2-11, 4-7
Model 4081 Transmitter, Installation, 2-7
Mounting Bracket, 2-7
Mounting Dimensions, Transmitter, 2-7, 2-8
Mounting Position, Probe, 1-6

F

Fault Indications, 5-2
Faulted Operation Display, 3-1
Fieldbus, 1-2

G

Grounding, 2-11

N

NEMA, 1-4
NEMA 4X, 1-6
Nernst Equation, 1-2
NEXT Key, 4-3
Normal Operation Display, 3-1, 4-1

IB-106-4081

I-1

O

O2 CELL mV Screen, 4-8

Cell Open Fault, 5-6

O

2

Open Thermocouple Fault, 5-4
Outer Protection Tube, 1-6
Output, 1-6
Oxygen probe, 1-3
Oxygen Probe, 1-1, 2-10
Oxygen Probe Gas Connection, 2-11
Oxygen Pro be Re pl a cem en t , 6- 2
Oxygen Probe, Installing, 2-1
Oxygen Probe, Locating, 2-1

P

Packaging, 1-4
Packing List, 2-1
Partial Pressure, 1-2
PC Board Stack Replacement, 6-1
Plant Air Connection, 2-12
Pneumatic Installation, 2-11
PREVIOUS C O NSTANT Scre e n, 4-9
PREVIOUS SLO PE S c re en, 4-9
Probe Insertion Depth, 2-6
Probe Insertion Rate, 2-6
Probe Installation Details, 2-2
Probe Lengths, 1-6
Probe Life, 5-1
Probe Mounting, 1-6
Probe Mounting Flange, 2-3
Product Matrix, 1-0
PROG Key, 4-3
Program Menu, 4-2, 4-4
Protective Cover, 2-1

R

Radio Frequency Interference (RFI), 2-10
Reference Air, 1-2, 1-4, 1-6, 2-11
Reference Air Set, 1-1
Relative Humidity, 1-6
Replacment Parts, 7-1
RESET Key, 4-3
RESET MAX CELL T Screen, 4-5

Returning E qu ipm en t , 8-1
Reversed O
Reversed Thermocouple Fault, 5-4

Cell Fault, 5-7

2

S

Security Switch, 4-12
Selected Distributed Control Systems, 1-3
SET CODE Screen, 4-7
SET HI BOTTLE O2, 4-6
SET HI BOTTLE O2 Screen, 4-6
SET LO B OTTLE O2 Screen, 4-7
SET O2 FILTER TIME Screen, 4-6
Shipping Weight, 1-6
Shorted Thermocouple Fault, 5-5
SHOW FAULT Screen, 4-8
Simulate and Secu r ity Sw it ch Pos it ion s , 4- 12
Simulate Switch, 4-12
SLOPE Scre en , 4- 11
Slope vs. Impedance, 5-1
Specifications, 1-6
Speed of Installation, 1-6
Speed of Response, 5-2
Speed of Withdrawal, 1-6
SW BUILD DATE Screen, 4-10
SW BUILD NUMBER Screen, 4-10
SW VER Screen, 4-10

T

T/C mV Screen, 4-8
Temperature Limits, 1-6
Transmitter LCD, 4-1
Transmitter Terminal Block, 5-3
Troubleshooting, 5-1
Two-Wire In Situ Oxygen Analyzer, 1-1, 6-0
Type B thermocouple, 1-2
Typical System Installation, 1-5

U

UNIT SER # Screen, 4-10

Z

Zirc onia Disc, 1- 2

IB-106-4081

I-2

APPENDIX A. 4081FG TRANSDUCER BLOCK PARAMETER

DESCRIPTIONS

Parameter

Mnemonic Valid Range

ALERT_KEY See FF-891 section 5.3. 4
BLOCK_ALM See FF-891 section 5.3. 8
BLOCK_ERR See FF-891 section 5.3. 6
BUILD_DATE 0 N/A This is the date that the 4081FG software was built. 43
BUILD_NUMBER 0-65445 27 The build number of the 4081FG software. 42
CAL_CONSTANT ±20.0 mV This paramet er represents the constant (offset) value

CAL_MINIMUM_
SPAN

CAL_POINT_HI 0.0-25.0 %O2 See FF-903 section 3.3. In the 4081FG, a calibration

CAL_POINT_LO 0.0-25.0 %O2 See FF-903 section 3.3. In the 4081FG, a calibration

CAL_SLOPE 34.5-57.5 mV/Decade This parameter represents the slope value calculated

CAL_STATE See Table 1 0 Enumera ted This param eter represents the present state the

CAL_STEP 0: No effect

CAL_UNIT See FF-903 section

COLLECTION_
DIRECTORY

DETAILED_STATUS See Table 4 0 Enumerated This is a bit- enumerated va lue used to commun icate

MODE_BLK See FF-891 section 5.3. 5
PRIMARY_VALUE See FF-903 section 3.3. In the 4081FG, this is the

PRIMARY_VALUE_
RANGE

PRIMARY_VALUE_
TYPE

SECONDARY_
VALUE

1: Go to next step
2: Abort procedure

4.10 Units Codes

See section 4.1 in
FF-903

Initial

Value Units Description

calculated in the calibration check procedure.
See FF-903 section 3.3. In the 4081FG, a calibration

is used for checking the analyzer only. The
calculation of the Primary Value is not effected.

is used for checking the analyzer only. The
calculation of the Primary Value is not effected.

is used for checking the analyzer only. The
calculation of the Primary Value is not effected.

during a calibr at ion check proce dur e .

calibration check cycle is in. Refer to table 1 for the
definition of states.

0 Enumerated This parameter is used to step the transmitter through

1342 (%) Enumerated See FF-903 section 3.3. In the 4081FG, a calibration

65535

(other)

Enumerated See FF-903 section 3.3 and 4.1. In the 4081FG, this

a sensor calibration check. Setting this parameter to 1
requests the transmitter to move to the next cycle state
of the calib ration check procedure. The transmitter
will set this parameter value back to 0 when it has
completed processing the step request. Setting this
parameter to a value of 2 will caus e the present
calibration to be aborted.

is used for checking the analyzer only. The
calculation of the Primary Value is not effected.

See FF-891 section 5.3. 12

the status of the 4081FG (This is similar in nature to
the command 48 status bits in HART). See Table 5.

present % O
being applied.

See FF-903 section 3.3. In the 4081FG, this range is
0-40% and the number of displayable units is 2.

parameter is fixed at a value of 1001(°C).
See FF-903 section 3.3. In the 4081FG, this is the

temperature of the O
calculated O2 value is dependent on this temperature
along with the sensor raw mV value.

reading and should reflect any test gas

2

sensor. The value of the

2

Index

Number

21

18

16

17

20

22

23

19

40

14

15

13

38

IB-106-4081

A-1

Parameter
Mnemonic Valid Range

SECONDARY_
VALUE_UNIT

SENSOR_CAL_
DATE

SENSOR_CAL_ LOC See FF-903 section 3.3. 29
SENSOR_CAL_

METHOD
SENSOR_CAL_ WHO See FF-903 section 3.3. 31
SENSOR_FILTER_

VALUE
SENSOR_

IMPEDANCE
SENSOR_RANGE See FF-903 section 3.3. In the 4081FG, this is the O2

SENSOR_RAW_MV_
VALUE

SENSOR_RAW_TC_
MV_VALUE

SENSOR_SN 0-4000000 0 See FF-903 section 3.3. 27
SENSOR_TEMP_

HIGH_ALARM
SENSOR_TEMP_

MAXIMUM
SENSOR_TEMP_

MAXIMUM_RESET
SENSOR_TYPE See FF-903 section

ST_REV See FF-891 section 5.3. 1
STATS_ATTEMPTS 0-16777215 0 Total number of messages sent to the transducer a/d

STATS_FAILURES 0-16777215 0 Total number of fai led a/d board message attempts. 45
STATS_TIMEOUTS 0-16777215 0 Total number of t imed out a/d board message

STRATEGY See FF-891 section 5.3. 3
TAG_DESC See FF-891 section 5.3. 2
TRANSDUCER_

DIRECTORY
TRANSDUCER_

TYPE
UPDATE_EVT See FF-891 section 5.3. 7
VERSION N/A This is the version of the 4081FG software. 41
XD_ERROR See Table 5 and FF-903 section 3.3. 11

See section 4.1 in
FF-903

0-300 0 Sec This is the filter value of the sensor. Valid range is

See Table Enumerated This is the status of the sensor impedance based on

±INF mV This is the raw sign al from the O2 sensor. 33

±INF mV This is the raw sign al from the O2 sensor

0-1600 1600 °C This is the temperature of the sensor where the

-32k-32k °C The maximum temperatur e the sensor has been

0 = Do Not Reset
1 = Reset High

4.2 Transducer
Types

Initial
Value Units Description

01001 (°C) Enumerated See FF-903 section 3.3 and 4.10. In the 4081FG, this

0 Reset Maximum Cell Temp to current temp. 36

65535

(ZrO2)

Enumerated See FF-903 section 3.3 and 4.3. 25

parameter is fixed at a value of 1001 (°C).
See FF-903 section 3.3. 30

See FF-903 sections 3.3 and 4.5. 28

0-300 sec.

the last impedance measurement.

sensor 0-25%.

thermocouple.

temperature too high alarm is set in detailed status.

exposed to.

board.

attempts.

See FF-903 section 3.3. 9

See FF-903 section 3.3. 10

Index

Number

39

32

24

26

34

37

35

44

46

IB-106-4081

A-2

Appendix

B Analog Input (AI)

Function Block

OUT_D

AI

OUT = The block output value and status
OUT_D = Discrete output that signals a selected

alarm condition

OUT

The Analog Input (AI) function block processes field device
measurements and makes them available to other function blocks. The
output value from the AI block is in engineering units and contains a
status indicating the quality of the measurement. The measuring
device may have several measurements or derived values available in
different channels. Use the channel number to define the variable that
the AI block processes.

The AI block supports alarming, signal scaling, signal filtering, signal
status calculation, mode control, and simulation. In Automatic mode,
the block’s output parameter (OUT) reflects the process variable (PV)
value and status. In Manual mode, OUT may be set manually. The
Manual mode is reflected on the output status. A discrete output
(OUT_D) is provided to indicate whether a selected alarm condition is
active. Alarm detection is based on the OUT value and user specified
alarm limits. Figure B-1 on page B-4 illustrates the internal
components of the AI function block, and Table B-1 lists the AI block
parameters and their units of measure, descriptions, and
index numbers.

fieldbus-fbus_31a

TABLE B-1. Definitions of Analog Input
Function Block System Parameters .

Parameter Index

Number

ACK_OPTION 23 None Used to set auto acknowledgment of alarms.
ALARM_HYS 24 Percent The amount the alarm value must return within the alarm limit before the associated active

ALARM_SEL 38 None Used to select the process alarm conditions that will cause the OUT_D parameter to be set.
ALARM_SUM 22 None The summary alarm is used for all process alarms in the block. The cause of the alert is

ALERT_KEY 04 None The identification number of the plant unit. This information may be used in the host for

Units Description

alarm condition clears.

entered in the subcode field. The first alert to become active will set the Active status in the
Status parameter. As soon as the Unreported status is cleared by the alert reporting task,
another block alert may be reported without clearing the Active status, if the subcode
has changed.

sorting alarms, etc.

B-1

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

Parameter Index

Number

BLOCK_ALM 21 None The block alarm is used for all configuration, hardware, connection failure or system

BLOCK_ERR 06 None This parameter reflects the error status associated with the hardware or software

CHANNEL 15 None The CHANNEL value is used to select the measurement value. Refer to the appropriate

FIELD_VAL 19 Percent The value and status from the transducer block or from the simulated input when simulation

GRANT_DENY 12 None Options for controlling access of host computers and local control panels to operating,

HI_ALM 34 None The HI alarm data, which includes a value of the alarm, a timestamp of occurrence and the

HI_HI_ALM 33 None The HI HI alarm data, which includes a value of the alarm, a timestamp of occurrence and

HI_HI_LIM 26 EU of PV_SCALE The setting for the alarm limit used to detect the HI HI alarm condition.
HI_HI_PRI 25 None The priority of the HI HI alarm.

Units Description

problems in the block. The cause of the alert is entered in the subcode field. The first alert
to become active will set the Active status in the Status parameter. As soon as the
Unreported status is cleared by the alert reporting task, another block alert may be reported
without clearing the Active status, if the subcode has changed.

components associated with a block. It is a bit string, so that multiple errors may be shown.

device manual for information about the specific channels available in each device.
You must configure the CHANNEL parameter before you can configure the XD_SCALE

parameter.

is enabled.

tuning, and alarm parameters of the block. Not used by device.

state of the alarm.

the state of the alarm.

HI_LIM 28 EU of PV_SCALE The setting for the alarm limit used to detect the HI alarm condition.
HI_PRI 27 None The priority of the HI alarm.
IO_OPTS 13 None Allows the selection of input/output options used to alter the PV. Low cutoff enabled is the

L_TYPE 16 None Linearization type. Determines whether the field value is used directly (Direct), is converted

LO_ALM 35 None The LO alarm data, which includes a value of the alarm, a timestamp of occurrence and

LO_LIM 30 EU of PV_SCALE The setting for the alarm limit used to detect the LO alarm condition.
LO_LO_ALM 36 None The LO LO alarm data, which includes a value of the alarm, a timestamp of occurrence and

LO_LO_LIM 32 EU of PV_SCALE The setting for the alarm limit used to detect the LO LO alarm condition.
LO_LO_PRI 31 None The priority of the LO LO alarm.
LO_PRI 29 None The priority of the LO alarm.
LOW_CUT 17 % If percentage value of transducer input fails below this, PV = 0.
MODE_BLK 05 None The actual, target, permitted, and normal modes of the block.

only selectable option.

linearly (Indirect), or is converted with the square root (Indirect Square Root).

the state of the alarm.

the state of the alarm.

Target: The mode to “go to”
Actual: The mode the “block is currently in”
Permitted: Allowed modes that target may take on

Normal: Most common mode for target
OUT 08 EU of OUT_SCALE The block output value and status.
OUT_D 37 None Discrete output to indicate a selected alarm condition.
OUT_SCALE 11 None The high and low scale values, engineering units code, and number of digits to the right of

PV 07 EU of XD_SCALE The process variable used in block execution.

the decimal point associated with OUT.

B-2

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

Parameter Index

Number

PV_FTIME 18 Seconds The time constant of the first-order PV filter. It is the time required for a 63% change in the

SIMULATE 09 None A group of data that contains the current transducer value and status, the simulated

STRATEGY 03 None The strategy field can be used to identify grouping of blocks. This data is not checked or

ST_REV 01 None The revision level of the static data associated with the function block. The revision value

TAG_DESC 02 None The user description of the intended application of the block.
UPDATE_EVT 20 None This alert is generated by any change to the static data.
VAR_INDEX 39 % of OUT Range The average absolute error between the PV and its previous mean value over that

VAR_SCAN 40 Seconds The time over which the VAR_INDEX is evaluated.
XD_SCALE 10 None The high and low scale values, engineering units code, and number of digits to the right of

Simulation

Units Description

IN value.

transducer value and status, and the enable/disable bit.

processed by the block.

will be incremented each time a static parameter value in the block is changed.

evaluation time defined by VAR_SCAN.

the decimal point associated with the channel input value.
The XD_SCALE units code must match the units code of the measurement channel in the

transducer block. If the units do not match, the block will not transition to MAN or AUTO

To support testing, you can either change the mode of the block to
manual and adjust the output value, or you can enable simulation
through the configuration tool and manually enter a value for the
measurement value and its status. In both cases, you must first set the
ENABLE jumper on the field device.

NOTE

All fieldbus instruments have a simulation jumper. As a safety measure,
the jumper has to be reset every time there is a power interruption. This
measure is to prevent devices that went through simulation in the
staging process from being installed with simulation enabled.

With simulation enabled, the actual measurement value has no impact
on the OUT value or the status.

B-3

Model 4081FG Oxygen Analyzer with F

FIGURE B-1. Analog Input
Function Block Schematic.

OUNDATION

Analog

Measurement

Access
Analog

SIMULATE

NOTES:
OUT = block output value and status.
OUT_D = discrete output that signals a selected alarm condition.

fieldbus Communications

HI_HI_LIM

Meas.

CHANNEL

OUT_SCALE

XD_SCALE

ALARM_HYS

Convert

FIELD_VAL

HI_LIM

LO_LO_LIM

LO_LIM

LOW_CUT

L_TYPE

Cutoff

IO_OPTS

ALARM_TYPE

Alarm

Detection

Filter

PV_FTIME

STATUS_OPTS

PV

MODE

Status

Calc.

OUT_D

OUT

FIELDBUS-FBUS_02A

FIGURE B-2. Analog Input
Function Block Timing Diagram.

Filtering

OUT (mode in man)

OUT (mode in auto)

PV

63% of Change

FIELD_VAL

Time (seconds)

PV_FTIME

The filtering feature changes the response time of the device to smooth
variations in output readings caused by rapid changes in input. You can
adjust the filter time constant (in seconds) using the PV_FTIME
parameter. Set the filter time constant to zero to disable the
filter feature.

FIELDBUS-FBUS_03A

B-4

Signal Conversion

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

You can set the signal conversion type with the Linearization Type
(L_TYPE) parameter. You can view the converted signal (in percent of
XD_SCALE) through the FIELD_VAL parameter.

FIELD_VAL

100 Channel Value EU*@0%–()×

=

--------------------------------------------------------------------------------------

EU*@100% EU*@0%–()

* XD_SCALE values

You can choose from direct, indirect, or indirect square root signal
conversion with the L_TYPE parameter.

Direct

Direct signal conversion allows the signal to pass through the accessed
channel input value (or the simulated value when simulation is enabled).

PV Channel Value=

Indirect

Indirect signal conversion converts the signal linearly to the accessed
channel input value (or the simulated value when simulation is
enabled) from its specified range (XD_SCALE) to the range and units of
the PV and OUT parameters (OUT_SCALE).

Block Errors

FIELD_VAL



PV

--------------------------------



100

EU**@100% EU**@0%–()EU**@0%+×=

** OUT_SCALE values

Indirect Square Root

Indirect Square Root signal conversion takes the square root of the
value computed with the indirect signal conversion and scales it to the
range and units of the PV and OUT parameters.

FIELD_VAL



PV

--------------------------------



100

EU**@100% EU**@0%–()EU**@0%+×=

** OUT_SCALE values

When the converted input value is below the limit specified by the
LOW_CUT parameter, and the Low Cutoff I/O option (IO_OPTS) is
enabled (True), a value of zero is used for the converted value (PV). This
option is useful to eliminate false readings when the differential
pressure measurement is close to zero, and it may also be useful with
zero-based measurement devices such as flowmeters.

NOTE
Low Cutoff

is the only I/O option supported by the AI block. You can set

the I/O option in Manual or Out of Service mode only.

Table B-2 lists conditions reported in the BLOCK_ERR parameter.
Conditions in italics are inactive for the AI block and are given here
only for your reference.

B-5

Model 4081FG Oxygen Analyzer with F

TABLE B-2. BLOCK_ERR Conditions.

OUNDATION

Condition

Number

0 Other

1 Block Configuration Error: the selected channel carries a measurement that

2 Link Configuration Error

3 Sim ulate Active: Simulation is enabled and the block is using a sim ulated value

4 Local Override
5 Device Fault State Set
6 Device Needs Maintenance Soon

7 Input F ailure/Process V ariable has Bad Status: The hardware is bad, or a bad

8 Output Failure: The output is bad based primarily upon a bad input.

9 Memory Failure
10 Lost Static Data
11 Lost NV Data
12 Readback Check Failed
13 Device Needs Maintenance Now
14 Power Up

15 Out of Service: The actual mode is out of service.

fieldbus Communications

Condition Name and Description

is incompatible with the engineering units selected in XD_SCALE, the L_TYPE
parameter is not configured, or CHANNEL = zero.

in its execution.

status is being simulated.

Modes

Alarm Detection

The AI Function Block supports three modes of operation as defined by
the MODE_BLK parameter:

• Manual (Man) The block output (OUT) may be set manually

• Automatic (Auto) OUT reflects the analog input measurement
or the simulated value when simulation is enabled.

• Out of Service (O/S) The block is not processed. FIELD_VAL
and PV are not updated and the OUT status is set to Bad: Out of
Service. The BLOCK_ERR parameter shows Out of Service. In
this mode, you can make changes to all configurable parameters.
The target mode of a block may be restricted to one or more of the
supported modes.

A block alarm will be generated whenever the BLOCK_ERR has an
error bit set. The types of block error for the AI block are defined above.

Process Alarm detection is based on the OUT value. You can configure
the alarm limits of the following standard alarms:

• High (HI_LIM)

• High high (HI_HI_LIM)

• Low (LO_LIM)

• Low low (LO_LO_LIM)

B-6

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

In order to avoid alarm chattering when the variable is oscillating
around the alarm limit, an alarm hysteresis in percent of the PV span
can be set using the ALARM_HYS parameter. The priority of each
alarm is set in the following parameters:

• HI_PRI

• HI_HI_PRI

• LO_PRI

• LO_LO_PRI

Alarms are grouped into five levels of priority:

Priority

Number

0 The priority of an alarm condition changes to ) after the condition that caused

1 An alarm condition with a priority of 1 is recognized by the system, but is not

2 An alarm condition with a priority of 2 is reported to the operator, but does not

3-7 Alarm conditions of priority 3 to 7 are advisory alarms of increasing priority.

8-15 Alarm conditions of priority 8 to 15 are critical alarms of increasing priority.

Priority Description

the alarm is corrected.

reported to the operator.

require operator attention (such as diagnostics and system alerts).

Status Handling

Normally, the status of the PV reflects the status of the measurement
value, the operating condition of the I/O card, and any active alarm
condition. In Auto mode, OUT reflects the value and status quality of
the PV. In Man mode, the OUT status constant limit is set to indicate
that the value is a constant and the OUT status is Good .

The Uncertain - EU range violation status is always set, and the PV
status is set high- or low-limited if the sensor limits for conversion are
exceeded.

In the STATUS_OPTS parameter, you can select from the following
options to control the status handling:

BAD if Limited – sets the OUT status quality to Bad when the value

is higher or lower than the sensor limits.

Uncertain if Limited – sets the OUT status quality to Uncertain

when the value is higher or lower than the sensor limits.

Uncertain if in Manual mode – The status of the Output is set to

Uncertain when the mode is set to Manual

NOTES

1. The instrument must be in Manual or Out of Service mode to set the
status option.

2. The AI block only supports the BAD if Limited option. Unsupported
options are not grayed out; they appear on the screen in the same
manner as supported options.

B-7

Model 4081FG Oxygen Analyzer with F

Advanced Features

Application Information

The AI function block provided with Fisher -Rosemount fieldbus devices
provides added capability through the addition of the following parameters:

ALARM_TYPE – Allows one or more of the process alarm conditions

detected by the AI function block to be used in setting its OUT_D parameter.

OUT_D – Discrete output of the AI function block based on the

detection of process alarm condition(s). This parameter may be linked
to other function blocks that require a discrete input based on the
detected alarm condition.

VAR_SCAN – Time period in seconds over which the variability index

(VAR_INDEX) is computed.

VAR_INDEX – Process variability index measured as the integral of

average absolute error between PV and its mean value over the
previous evaluation period. This index is calculated as a percent of OUT
span and is updated at the end of the time period defined by
VAR_SCAN.

The configuration of the AI function block and its associated output
channels depends on the specific application. A typical configuration for
the AI block involves the following parameters:

OUNDATION

CHANNEL If the device supports more than one measurement,

L_TYPE

SCALING XD_SCALE provides the range and units of the

fieldbus Communications

verify that the selected channel contains the
appropriate measurement or derived value.

Select Direct when the measurement is already in the
engineering units that you want for the block output.

Select Indirect when you want to convert the
measured variable into another, for example, pressure
into level or flow into energy.

Select Indirect Square Root when the block I/O
parameter value represents a flow measurement made
using differential pressure, and when square root
extraction is not performed by the transducer.

measurement and OUT_SCALE provides the range
and engineering units of the output.

B-8

Application Example:
Temperature T ransmitter

TABLE B-3. Analog Input Function
Block Configuration for a Typical
T emper ature Transmitter.

FIGURE B-3. Analog Input Function
Block Diagram for a Typical
T emper ature Transmitter.

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

Situation

A temperature transmitter with a range of –200 to 450 ˚C.

Solution

Table B-3 lists the appropriate configuration settings, and Figure B-3
illustrates the correct function block configuration.

.

Parameter Configured Values

L_TYPE Direct

XD_SCALE Not Used

OUT_SCALE Not Used

Temperature

Measurement

OUT_D

AI Function Block

OUT

To Another
Function Block

FIELDBUS-FBUS_04A

B-9

Model 4081FG Oxygen Analyzer with F

Application Example: Pressure
Transmitter used to Measure
Level in an Open Tank

Situation #1

The level of an open tank is to be measured using a pressure tap at the
bottom of the tank. The level measurement will be used to control the
level of liquid in the tank. The maximum level at the tank is 16 ft. The
liquid in the tank has a density that makes the level correspond to a
pressure of 7.0 psi at the pressure tap (see Figure B-4).

FIGURE B-4. Situation #1 Diagram.

OUNDATION

16 ft

fieldbus Communications

Full Tank

7.0 psi measured at
the transmitter

TABLE B-4. Analog Input Function
Block Configuration for a Pressure
T ransmitter used in Le vel Measurement
(situation #1).

FIGURE B-5. Function Block Diagram
for a Pressure Transmitter used in Level
Measurement.

Solution to Situation #1

Table B-4 lists the appropriate configuration settings, and Figure B-5
illustrates the correct function block configuration.

Parameter Configured Values

L_TYPE Indirect

XD_SCALE 0 to 7 psi

OUT_SCALE 0 to 16 ft

Analog

Measurement

AI

Function

Block

BKCAL_IN

Function

CAS_IN

PID

Block

OUT_D

OUT

OUT

CAS_IN

BKCAL_OUT

AO

Function

Block

B-10

FIGURE B-6. Situation #2 Diagram.

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

Situation #2

The transmitter in situation #1 is installed below the tank in a position
where the liquid column in the impulse line, when the tank is empty, is
equivalent to 2.0 psi (see Figure B-6).

16 ft

Empty Tank

0 ft

2.0 psi measured at
the transmitter

TABLE B-5. Analog Input Function
Block Configuration for a Pressure
T ransmitter used in Le vel Measurement
(Situation #2).

Solution

Table B-5 lists the appropriate configuration settings.

Parameter Configured Values

L_TYPE Indirect

XD_SCALE 2 to 9 psi

OUT_SCALE 0 to 16 ft

B-11

Model 4081FG Oxygen Analyzer with F

Application Example:
Differential Pressure Transmitter
to Measure Flow

Situation

The liquid flow in a line is to be measured using the differential
pressure across an orifice plate in the line, and the flow measurement
will be used in a flow control loop. Based on the orifice specification
sheet, the differential pressure transmitter was calibrated for 0 to 20
inH
configured to take the square root of the differential pressure.

Solution

Table B-6 lists the appropriate configuration settings, and Figure B-7
illustrates the correct function block configuration.

TABLE B-6. Analog Input Function
Block Configuration for a Differential
Pressure T r ansmitter .

FIGURE B-7. Function Block Diagram
for a Differential Pressure Transmitter
Used in a Flow Measurement.

OUNDATION

0 for a flow of 0 to 800 gal/min, and the transducer was not

2

fieldbus Communications

Parameter Configured Values

L_TYPE Indirect Square Root

XD_SCALE 0 to 20 in.

OUT_SCALE 0 to 800 gal/min.

Analog

Measurement

Function

Block

AI

OUT_D

OUT

BKCAL_IN BKCAL_OUT

PID

Function

Block

IN

AO

Function

Block

B-12

Troubleshooting

TABLE B-7. Troubleshooting.

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

Refer to Table B-7 to troubleshoot any problems that you encounter.

Symptom

Mode will not leave
OOS

Process and/or
block alarms will not
work.

Value of output
does not make
sense

Cannot set
HI_LIMIT,
HI_HI_LIMIT,
LO_LIMIT, or
LO_LO_LIMIT
Values

Possible Causes Corrective Action

1.Target mode not set. 1. Set target mode to something other
than OOS.

2.Configuration error 2.BLOCK_ERR will show the
configuration error bit set. The following
are parameters that must be set before
the block is allowed out of OOS:

a. CHANNEL must be set to a valid

value and cannot be left at initial
value of 0.

b. XD_SCALE.UNITS_INDX must

match the units in the transducer
block channel value.

c. L_TYPE must be set to Direct,

Indirect, or Indirect Square Root and
cannot be left at initial value of 0.

3.Resource block 3.The actual mode of the Resource block
is OOS. See Resource Bloc k Diagnostics
for corrective action.

4.Schedule 4.Block is not scheduled and therefore
cannot execute to go to Target Mode.
Schedule the block to execute.

1.Features 1.FEATURES_SEL does not have Alerts
enabled. Enable the Alerts bit.

2.Notification 2.LIM_NOTIFY is not high enough. Set
equal to MAX_NOTIFY.

3.Status Options 3.STATUS_OPTS has Propagate Fault
Forward bit set. This should be cleared to
cause an alarm to occur.

1.Linearization T ype 1.L_TYPE must be set to Direct, Indirect,
or Indirect Square Root and cannot be left
at initial value of 0.

2.Scaling 2.Scaling parameters are set incorrectly:

a. XD_SCALE.EU0 and EU100 should

match that of the transducer block
channel value.

b. OUT_SCALE.EU0 and EU100 are

not set properly.

1.Scaling 1.Limit values are outside the
OUT_SCALE.EU0 and
OUT_SCALE.EU100 values. Change
OUT_SCALE or set values within range.

B-13

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

B-14

Appendix

C PID Function Block

BKCAL_IN

CAS_IN
FF_VAL

IN

TRK_IN_D

TRK_VAL

BKCAL_IN = The analog input value and status from another

block’s BKCAL_OUT output that is used for
backward output tracking for bumpless transfer
and to pass limit status.

CAS_IN = The remote setpoint value from another function

block.
FF_VAL = The feedforward control input value and status.
IN = The connection for the process variable from

another function block.

The PID function block combines all of the necessary logic to perform
proportional/integral/derivative (PID) control. The block supports mode
control, signal scaling and limiting, feedforward control, override
tracking, alarm limit detection, and signal status propagation.

The block supports two forms of the PID equation: Standard and Series .
You can choose the appropriate equation using the FORM parameter.
The Standard ISA PID equation is the default selection.

BKCAL_OUT

OUT

PID

fieldbus-fbus_34a

TRK_IN_D = Initiates the external tracking function.
TRK_VAL = The value after scaling applied to OUT in

Local Override mode.

BKCAL_OUT = The value and status required by the

BKCAL_IN input of another function block
to prevent reset windup and to provide
bumpless transfer to closed loop control.

OUT = The block output and status.

Standard Out GAIN e 1

Series Out GAIN e× 1

Where

GAIN: proportional gain value

τ

: integral action time constant (RESET parameter) in seconds

r

s: laplace operator

τ

: derivative action time constant (RATE parameter)

d

α: fixed smoothing factor of 0.1 applied to RATE
F: feedforward control contribution from the feedforward input (FF_VAL parameter)
e: error between setpoint and process variable



×





×



1

++

----------------

τ

s 1+

r

1



------ -

+

+



s

τ

r

τ

d

-------------------------- -

ατ

s 1+

τ

d



-------------------------- -



ατ

d

s1+×

d

s
s1+×

F

+×=

F

+=

C-1

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

To further customize the block for use in your application, you can
configure filtering, feedforward inputs, tracking inputs, setpoint and
output limiting, PID equation structures, and block output action.
Table C-1 lists the PID block parameters and their descriptions , units of
measure, and index numbers, and Figure C-1 on page C-5 illustrates
the internal components of the PID function block.

TABLE C-1. PID Function Block System Parameters.

Parameter Index

Number

ACK_OPTION 46 None Used to set auto acknowledgment of alarms.

ALARM_HYS 47 Percent The amount the alarm value must return to within the alarm limit before the associated active

ALARM_SUM 45 None The summary alarm is used for all process alarms in the block. The cause of the alert is

ALERT_KEY 04 None The identification number of the plant unit. This information may be used in the host for

Units Description

alarm condition clears.

entered in the subcode field. The first alert to become active will set the Active status in the
Status parameter. As soon as the Unreported status is cleared by the alert reporting task,
another block alert may be reported without clearing the Active status, if the subcode has
changed.

sorting alarms, etc.

ALG_TYPE 74 None Selects filtering algorithm as Backward or Bilinear.

BAL_TIME 25 Seconds The specified time for the internal working value of bias to return to the operator set bias.

BIAS 66 EU of OUT_SCALE The bias value used to calculate output for a PD type controller.

BKCAL_HYS 30 Percent The amount the output value must change away from the its output limit before limit status

BKCAL_IN 27 EU of OUT_SCALE The analog input value and status from another block’s BKCAL_OUT output that is used for

BKCAL_OUT 31 EU of PV_SCALE The value and status required by the BKCAL_IN input of another block to prevent reset

BLOCK_ALM 44 None The block alarm is used for all configuration, hardware, connection failure, or system

BLOCK_ERR 06 None This parameter reflects the error status associated with the hardware or software

BYPASS 17 None Used to override the calculation of the block. When enabled, the SP is sent directly

CAS_IN 18 EU of PV_SCALE The remote setpoint value from another block.

Also used to specify the time constant at which the integral term will move to obtain balance
when the output is limited and the mode is AUTO, CAS, or RCAS.

is turned off.

backward output tracking for bumpless transfer and to pass limit status.

windup and to provide bumpless transfer of closed loop control.

problems in the block. The cause of the alert is entered in the subcode field. The first alert
to become active will set the active status in the status parameter. As soon as the
Unreported status is cleared by the alert reporting task, and other block alert may be
reported without clearing the Active status, if the subcode has changed.

components associated with a block. It is a bit string so that multiple errors may be shown.

to the output.

CONTROL_OPTS 13 None Allows you to specify control strategy options. The supported control options for the PID

DV_HI_ALM 64 None The DV HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and

DV_HI_LIM 57 EU of PV_SCALE The setting for the alarm limit used to detect the deviation high alarm condition.

DV_HI_PRI 56 None The priority of the deviation high alarm.

block are Track enable, Track in Manual, SP-PV Track in Man, SP-PV Track in LO or IMAN,
Use PV for BKCAL OUT, and Direct Acting

the state of the alarm.

C-2

Model 4081FG Oxygen Analyzer with F

Parameter Index

Number

DV_LO_ALM 65 None The DV LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and

DV_LO_LIM 59 EU of PV_SCALE The setting for the alarm limit use to detect the deviation low alarm condition.

DV_LO_PRI 58 None The priority of the deviation low alarm.

ERROR 67 EU of PV_SCALE The error (SP-PV) used to determine the control action.

FF_ENABLE 70 None Enables the use of feedforward calculations

FF_GAIN 42 None The feedforward gain value. FF_VAL is multiplied by FF_GAIN before it is added to the

FF_SCALE 41 None The high and low scale values, engineering units code, and number of digits to the right of

FF_VAL 40 EU of FF_SCALE The feedforward control input value and status.

GAIN 23 None The proportional gain value. This value cannot = 0.

GRANT_DENY 12 None Options for controlling access of host computers and local control panels to operating,

Units Description

the state of the alarm.

calculated control output.

the decimal point associated with the feedforward value (FF_VAL).

tuning, and alarm parameters of the block. Not used by the device.

OUNDATION

fieldbus Communications

HI_ALM 61 None The HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and the

HI_HI_ALM 60 None The HI HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and

HI_HI-LIM 49 EU of PV_SCALE The setting for the alarm limit used to detect the HI HI alarm condition.

HI_HI_PRI 48 None The priority of the HI HI Alarm.

HI_LIM 51 EU of PV_SCALE The setting for the alarm limit used to detect the HI alarm condition.

HI_PRI 50 None The priority of the HI alarm.

IN 15 EU of PV_SCALE The connection for the PV input from another block.

LO_ALM 62 None The LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the

LO_LIM 53 EU of PV_SCALE The setting for the alarm limit used to detect the LO alarm condition.

LO_LO_ALM 63 None The LO LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and

LO_LO_LIM 55 EU of PV_SCALE The setting for the alarm limit used to detect the LO LO alarm condition.

LO_LO_PRI 54 None The priority of the LO LO alarm.

LO_PRI 52 None The priority of the LO alarm.

state of the alarm.

the state of the alarm.

state of the alarm.

the state of the alarm.

MATH_FORM 73 None Selects equation form (series or standard).

MODE_BLK 05 None The actual, target, permitted, and normal modes of the block.

Target: The mode to “go to”
Actual: The mode the “block is currently in”
Permitted: Allowed modes that target may take on
Normal: Most common mode for target

OUT 09 EU of OUT SCALE The block input value and status.

OUT_HI_LIM 28 EU of OUT_SCALE The maximum output value allowed.

C-3

Model 4081FG Oxygen Analyzer with F

Parameter Index

Number

OUT-LO_LIM 29 EU of OUT_SCALE The minimum output value allowed

OUT_SCALE 11 None The high and low scale values, engineering units code, and number of digits to the right of

PV 07 EU of PV_SCALE The process variable used in block execution.

PV_FTIME 16 Seconds The time constant of the first-order PV filter. It is the time required for a 63 percent change

PV_SCALE 10 None The high and low scale values, engineering units code, and number of digits to the right of

RATE 26 Seconds The derivative action time constant.

RCAS_IN 32 EU of PV_SCALE Target setpoint and status that is provided by a supervisory host. Used when mode is RCAS.

RCAS_OUT 35 EU of PV_SCALE Block setpoint and status after ramping, filtering, and limiting that is provided to a supervisory

RESET 24 Seconds per repeat The integral action time constant.

ROUT_IN 33 EU of OUT_SCALE Target output and status that is provided by a supervisory host. Used when mode is ROUT.

Units Description

OUNDATION

the decimal point associated with OUT.

in the IN value.

the decimal point associated with PV.

host for back calculation to allow action to be taken under limiting conditions or mode
change. Used when mode is RCAS.

fieldbus Communications

ROUT_OUT 36 EU of OUT_SCALE Block output that is provided to a supervisory host for a back calculation to allow action to

SHED_OPT 34 None Defines action to be taken on remote control device timeout.

SP 08 EU of PV_SCALE The target block setpoint value. It is the result of setpoint limiting and setpoint

SP_FTIME 69 Seconds The time constant of the first-order SP filter. It is the time required for a 63 percent change

SP_HI_LIM 21 EU of PV_SCALE The highest SP value allowed.

SP_LO_LIM 22 EU of PV_SCALE The lowest SP value allowed.

SP_RATE_DN 19 EU of PV_SCALE per

second

SP-RATE_UP 20 EU of PV_SCALE per

second

SP_WORK 68 EU of PV_SCALE The working setpoint of the block after limiting and filtering is applied.

STATUS_OPTS 14 None Allows you to select options for status handling and processing. The supported status option

STRATEGY 03 None The strategy field can be used to identify grouping of blocks. This data is not checked or

ST_REV 01 None The revision level of the static data associated with the function block. The revision value will

be taken under limiting conditions or mode change. Used when mode is RCAS.

rate of change limiting.

in the IN value.

Ramp rate for downward SP changes. When the ramp rate is set to zero, the SP
is used immediately.

Ramp rate for upward SP changes. When the ramp rate is set to zero,
the SP is used immediately.

for the PID block is Target to Manual if Bad IN.

processed by the block.

be incremented each time a static parameter value in the block is changed.

STRUCTURE.
CONFIG

TAG_DESC 02 None The user description of the intended application of the block.

TRK_IN_D 38 None Discrete input that initiates external tracking.

75 None Defines PID equation structure to apply controller action.

C-4

Model 4081FG Oxygen Analyzer with F

Parameter Index

Number

TRK_SCALE 37 None The high and low scale values, engineering units code, and number of digits to the right of

TRK_VAL 39 EU of TRK SCALE The value (after scaling from TRK_SCALE to OUT_SCALE) applied to OUT in LO mode.

UBETA 72 Percent Used to set disturbance rejection vs. tracking response action for a 2.0 degree of

UGAMMA 71 Percent Used to set disturbance rejection vs. tracking response action for a 2.0 degree of

UPDATE_EVT 43 None This alert is generated by any changes to the static data.

Units Description

the decimal point associated with the external tracking value (TRK_VAL).

freedom PID.

freedom PID.

OUNDATION

fieldbus Communications

FIGURE C-1. PID Function Block
Schematic.

FF_GAIN
FF_SCALE

FF_VAL

BKCAL_IN

TRK_IN_D

CAS_IN

IN

TRK_VAL

RCAS_IN

Operator

Setpoint

MODE

RCAS_OUT

Setpoint
Limiting

and

Filtering

SP_HI_LIM
SP_LO_LIM
SP_RATE_DN
SP_RATE_UP
SP_FTIME

Scaling

and

Filtering

PV_SCALE
PV_FTIME

Convert

Feedforward

Calculation

Equation

Detection

HI_HI_LIM
HI_LIM
DV_HI_LIM
DV_LO_LIM
LO_LIM
LO_LO_LIM

PID

GAIN
RATE
RESET

Alarm

ROUT_IN

OUT_HI_LIM
OUT_LO_LIM
OUT_SCALE

Operator
Output

ROUT_OUT

Output

Limiting

BKCAL_OUT

OUT

TRK_SCALE
OUT_SCALE

fieldbus-fbus_13a

C-5

Model 4081FG Oxygen Analyzer with F

Setpoint Selection
and Limiting

The setpoint of the PID block is determined by the mode. You can
configure the SP_HI_LIM and SP_LO_LIM parameters to limit the
setpoint. In Cascade or RemoteCascade mode, the setpoint is adjusted
by another function block or by a host computer, and the output is
computed based on the setpoint.

In Automatic mode, the setpoint is entered manually by the operator,
and the output is computed based on the setpoint. In Auto mode, you
can also adjust the setpoint limit and the setpoint rate of change using
the SP_RATE_UP and SP_RATE_DN parameters.

In Manual mode the output is entered manually by the operator, and is
independent of the setpoint. In RemoteOutput mode, the output is
entered by a host computer, and is independent of the setpoint.

Figure C-2 illustrates the method for setpoint selection.

FIGURE C-2. PID Function
Block Setpoint Selection.

OUNDATION

Operator

Setpoint

Auto

Man

Cas

fieldbus Communications

SP_HI_LIM

SP_LO_LIM

Setpoint

Limiting

SP_RATE_UP
SP_RATE_DN

Limiting

Rate

Auto
Man

Cas

fieldbus-fbus_01a

Filtering

Feedforward Calculation

Tracking

The filtering feature changes the response time of the device to smooth
variations in output readings caused by rapid changes in input. You can
configure the filtering feature with the FILTER_TYPE parameter, and
you can adjust the filter time constant (in seconds) using the
PV_FTIME or SP_FTIME parameters. Set the filter time constant to
zero to disable the filter feature.

The feedforward value (FF_VAL) is scaled (FF_SCALE) to a common
range for compatibility with the output scale (OUT_SCALE). A gain
value (FF_GAIN) is applied to achieve the total
feedforward contribution.

You enable the use of output tracking through the control options. You
can set control options in Manual or Out of Service mode only.

The Track Enable control option must be set to True for the track
function to operate. When the Track in Manual control option is set to

True , tracking can be activated and maintained only when the block is

in Manual mode. When Track in Manual is False , the operator can
override the tracking function when the block is in Manual mode.
Activating the track function causes the block’s actual mode to revert to

Local Override .

The TRK_VAL parameter specifies the value to be converted and
tracked into the output when the track function is operating. The
TRK_SCALE parameter specifies the range of TRK_VAL.

C-6

When the TRK_IN_D parameter is True and the Track Enable control
option is True , the TRK_VAL input is converted to the appropriate
value and output in units of OUT_SCALE.

Output Selection
and Limiting

Bumpless T ransfer and
Setpoint T racking

Model 4081FG Oxygen Analyzer with F

Output selection is determined by the mode and the setpoint. In

Automatic , Cascade , or RemoteCascade mode, the output is computed

by the PID control equation. In Manual and RemoteOutput mode, the
output may be entered manually (see also Setpoint Selection

and Limiting on page C-6). You can limit the output by configuring the

OUT_HI_LIM and OUT_LO_LIM parameters.
You can configure the method for tracking the setpoint by configuring

the following control options (CONTROL_OPTS):

SP-PV Track in Man — Permits the SP to track the PV when the

target mode of the block is Man.

SP-PV Track in LO or IMan — Permits the SP to track the PV when

the actual mode of the block is Local Override (LO) or Initialization
Manual (IMan).

When one of these options is set, the SP value is set to the PV value
while in the specified mode.

You can select the value that a master controller uses for tracking by
configuring the Use PV for BKCAL_OUT control option. The
BKCAL_OUT value tracks the PV value. BKCAL_IN on a master
controller connected to BKCAL_OUT on the PID block in an open
cascade strategy forces its OUT to match BKCAL_IN , thus tracking the
PV from the slave PID block into its cascade input connection
(CAS_IN). If the Use PV for BKCAL_OUT option is not selected, the
working setpoint (SP_WRK) is used for BKCAL_OUT.

OUNDATION

fieldbus Communications

PID Equation Structures

You can set control options in Manual or Out of Service mode only.
When the mode is set to Auto , the SP will remain at the last value (it
will no longer follow the PV.

Configure the STRUCTURE parameter to select the PID equation
structure. You can select one of the following choices:

• PI Action on Error, D Action on PV

• PID Action on Error

• I Action on Error, PD Action on PV

Set RESET to zero to configure the PID block to perform integral only
control regardless of the STRUCTURE parameter selection. When
RESET equals zero, the equation reduces to an integrator equation
with a gain value applied to the error:

GAIN e s()×

-------------------------------

s

Where

GAIN: proportional gain value

e: error

s: laplace operator

Reverse and Direct Action

To configure the block output action, enable the Direct Acting control
option. This option defines the relationship between a change in PV and
the corresponding change in output. W ith Direct Acting enabled (True),
an increase in PV results in an increase in the output.

You can set control options in Manual or Out of Service mode only.

C-7

Model 4081FG Oxygen Analyzer with F

NOTE
Track Enable , Track in Manual , SP-PV Track in Man , SP-PV Track in LO
or IMan , Use PV for BKCAL_OUT , and Direct Acting are the only

control options supported by the PID function block. Unsupported
options are not grayed out; they appear on the screen in the same
manner as supported options.

Reset Limiting

The PID function block provides a modified version of feedback reset
limiting that prevents windup when output or input limits are
encountered, and provides the proper behavior in selector applications.

Block Errors

Table C-2 lists conditions reported in the BLOCK_ERR parameter.
Conditions in italics are inactive for the PID block and are given here
only for your reference.

TABLE C-2. BLOCK_ERR Conditions

.

OUNDATION

Condition

Number

0 Other

1 Block Configuration Error: The BY_PASS parameter is not configured and is

2 Link Configuration Error
3 Simulate Active

4 Local Override : The actual mode is LO.

5 Device Fault State Set
6 Device Needs Maintenance Soon

7 Input F ailure/Process Variable has Bad Status: The parameter linked to IN is

8 Output Failure

9 Memory Failure
10 Lost Static Data
11 Lost NV Data
12 Readback Check Failed
13 Device Needs Maintenance Now
14 Power Up

15 Out of Service: The actual mode is out of service.

fieldbus Communications

Condition Name and Description

set to 0, the SP_HI_LIM is less than the SP_LO_LIM, or the OUT_HI_LIM is less
than the OUT_LO_LIM.

indicating a Bad status.

Modes

C-8

The PID function block supports the following modes:

Manual (Man)—The block output (OUT) may be set manually.
Automatic (Auto)—The SP may be set manually and the block

algorithm calculates OUT.

Cascade (Cas)—The SP is calculated in another block and is provided

to the PID block through the CAS_IN connection.

RemoteCascade (RCas)—The SP is provided by a host computer that

writes to the RCAS_IN parameter.

RemoteOutput (Rout)—The OUT is provided by a host computer that

writes to the ROUT_IN parameter.

Local Override (LO)—The track function is active. OUT is set by

TRK_VAL. The BLOCK_ERR parameter shows Local override.

Alarm Detection

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

Initialization Manual (IMan)—The output path is not complete (for

example, the cascade-to-slave path might not be open). In IMan mode,
OUT tracks BKCAL_IN.

Out of Service (O/S)—The block is not processed. The OUT status is

set to Bad: Out of Service . The BLOCK_ERR parameter shows
Out of service.

You can configure the Man, Auto, Cas, and O/S modes as permitted
modes for operator entry.

A block alarm will be generated whenever the BLOCK_ERR has an
error bit set. The types of block error for the AI block are defined above.

Process alarm detection is based on the PV value. You can configure the
alarm limits of the following standard alarms:

• High (HI_LIM)

• High high (HI_HI_LIM)

• Low (LO_LIM)

• Low low (LO_LO_LIM)

Additional process alarm detection is based on the difference between
SP and PV values and can be configured via the following parameters:

• Deviation high (DV_HI_LIM)

• Deviation low (DV_LO_LIM)

In order to avoid alarm chattering when the variable is oscillating
around the alarm limit, an alarm hysteresis in percent of the PV span
can be set using the ALARM_HYS parameter. The priority of each
alarm is set in the following parameters:

• HI_PRI

• HI_HI_PRI

• LO_PRI

• LO_LO_PRI

• DV_HI_PRI

• DV_LO_PRI

Alarms are grouped into five levels of priority:

Priority

Number

0 The priority of an alarm condition changes to ) after the condition that caused

1 An alarm condition with a priority of 1 is recognized by the system, but is not

2 An alarm condition with a priority of 2 is reported to the operator, but does not

3-7 Alarm conditions of priority 3 to 7 are advisory alarms of increasing priority.

8-15 Alarm conditions of priority 8 to 15 are critical alarms of increasing priority.

Priority Description

the alarm is corrected.

reported to the operator.

require operator attention (such as diagnostics and system alerts).

C-9

Model 4081FG Oxygen Analyzer with F

Status Handling

Application Information

Closed Loop Control

If the input status on the PID block is
reverts to

Bad IN

can set the status option in

NOTE
Target to Manual if Bad IN

PID function block. Unsupported options are not grayed out; they
appear on the screen in the same manner as supported options.

The PID function block is a powerful, flexible control algorithm that is
designed to work in a variety of control strategies. The PID block is
configured differently for different applications. The following examples
describe the use of the PID block for closed-loop control (basic PID loop),
feedforward control, cascade control with master and slave, and
complex cascade control with override.

To implement basic closed loop control, compute the error difference
between the process variable (PV) and setpoint (SP) values and
calculate a control output signal using a PID (Proportional Integral
Derivative) function block.

The proportional control function responds immediately and directly to
a change in the PV or SP. The proportional term
in the loop output based on the current magnitude of the error
multiplied by a gain value.

OUNDATION

fieldbus Communications

Bad

, the mode of the block

Manual

status option to direct the target mode to revert to manual. You

. In addition, you can select the

Manual

is the only status option supported by the

or

Out of Service

Target to Manual if

mode only.

GAIN

applies a change

The integral control function reduces the process error by moving the
output in the appropriate direction. The integral term
correction based on the magnitude and duration of the error. Set the
RESET parameter to zero for integral-only control. To reduce reset
action, configure the RESET parameter to be a large value.

The derivative term
change in error. Derivative control is typically used in temperature
control where large measurement lags exist.

The MODE parameter is a switch that indicates the target and actual
mode of operation. Mode selection has a large impact on the operation
of the PID block:

•

Manual

output signal directly.

•

Automatic

automatic correction of error using the

tuning values.

• Cascade and Remote Cascade modes use a setpoint from
another block in a cascaded configuration.

• Remote Out mode is similar to Manual mode except that the block
output is supplied by an external program rather than by
the operator.

• Initialization Manual is a non-target mode used with cascade
configurations while transitioning from manual operation to
automatic operation.

• Local Override is a non-target mode that instructs the block to
revert to Local Override when the tracking or fail-safe control
options are activated.

• Out of Service mode disables the block for maintenance.

mode allows the operator to set the value of the loop

RA TE

applies a correction based on the anticipated

mode allows the operator to select a setpoint for

GAIN, RESET, and RATE

RESET

applies a

C-10

Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications

Abrupt changes in the quality of the input signal can result in
unexpected loop behavior. To prevent the output from changing
abruptly and upsetting the process, select the SP-PV Track in Man I/O
option. This option automatically sets the loop to Manual if a Bad input
status is detected. While in manual mode, the operator can manage
control manually until a Good input status is reestablished.

Application Example: Basic PID
Block for Steam Heater Control

FIGURE C-3. PID Function Block
Steam Heater Control Example.

Situation

A PID block is used with an AI block and an AO block to control the flow
steam used to heat a process fluid in a heat exchanger. Figure C-3
illustrates the process instrumentation diagram.

TCV

101

Steam Supply

TT

100

Steam Heater

Condensate

TC

101

TT

101

Solution

The PID loop uses TT101 as an input and provides a signal to the
analog output TCV101. The BKCAL_OUT of the AO block and the
BKCAL_IN of the PID block communicate the status and quality of
information being passed between the blocks. The status indication
shows that communications is functioning and the I/O is working
properly. Figure C-4 illustrates the correct function block configuration.

fieldbus-fbus_14a

FIGURE C-4. PID Function
Block Diagram for Steam Heater
Control Example.

Outlet

Temperature

Input

AI

Function

Block

TT101

OUT

BKCAL_IN

IN

PID

Function

Block

TC101

OUT

CAS_IN

AO

Function

Block

TCV101

BKCAL_OUT

OUT

fieldbus-fbus_15a

C-11

Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications

Application Example:
Feedforward Control

FIGURE C-5. PID Function Block
Feedforward Control Example.

Situation

In the previous example, control problems can arise because of a time
delay caused by thermal inertia between the two flow streams (TT100
and TT101). Variations in the inlet temperature (TT100) take an
excessive amount of time to be sensed in the outlet (TT101). This delay
causes the product to be out of the desired temperature range.

Solution

Feedforward control is added to improve the response time of the basic
PID control. The temperature of the inlet process fluid (TT100) is input
to an AI function block and is connected to the FF_VAL connector on
the PID block. Feedforward control is then enabled (FF_ENABLE), the
feedforward value is scaled (FF_SCALE), and a gain (FF_GAIN) is
determined. Figure C-5 illustrates the process instrumentation
diagram, and Figure C-6 illustrates the correct function block
configuration.

TCV

101

Steam Supply

TT

100

FF

TC

101

TT

101

FIGURE C-6. Function Block Diagram
for Feedforward Control.

Outlet

Temperature

Input

AI

Function

Block

TT101

Inlet

Temperature

Input

Steam Heater

BKCAL_IN

OUT OUT

FF_VAL

IN

PID

Function

Block

TC101

Condensate

CAS_IN

AO

Function

Block

TCV101

fieldbus-fbus_16a

BKCAL_OUT

OUT

C-12

AI

Function

Block

TT100

OUT

fieldbus-fbus_17a

Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications

Application Example: Cascade
Control with Master
and Slave Loops

FIGURE C-7. PID Function Block
Cascade Control Example.

Situation

A slave loop is added to a basic PID control configuration to measure
and control steam flow to the steam heater. Variations in the steam
pressure cause the temperature in the heat exchanger to change. The
temperature variation will later be sensed by TT101. The temperature
controller will modify the valve position to compensate for the steam
pressure change. The process is slow and causes variations in the
product temperature. Figure C-7 illustrates the process
instrumentation diagram.

Steam
Supply

FT

101

FC

101

TCV

101

TT

100

Steam Heater

TC

101

TT

101

Condensate

Solution

If the flow is controlled, steam pressure variations will be compensated
before they significantly affect the heat exchanger temperature. The
output from the master temperature loop is used as the setpoint for the
slave steam flow loop. The BKCAL_IN and BKCAL_OUT connections
on the PID blocks are used to prevent controller windup on the master
loop when the slave loop is in Manual or Automatic mode, or it has
reached an output constraint. Figure C-8 illustrates the correct
function block configuration.

fieldbus-fbus_18a

C-13

Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications

FIGURE C-8. PID Function Block
Diagram for Cascade Control Example.

Outlet

Temperature

Input

BKCAL_IN

BKCAL_OUT

Steam

Flow

Input

AI

Function

Block

TT 101

AI

Function

Block

FT 101

OUT

OUT

IN

BKCAL_IN

CAS_IN

IN

PID

Function

Block

TC 101

PID

Function

Block

FC 101

OUT

OUT

BKCAL_OUT

IN

AO

Module

Block

TCV 101

C-14