Rosemount 5081FG 2-Wire In Situ O2 Analyzer (550° to 1600°C) Manuals & Guides

Reference Manual

00809-0100-4882, Rev AB

June 2019

Rosemount

TM

5081FG

Two-Wire In-Situ Oxygen Analyzer (550 °C to 1600 °C)

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SECTION i
Introduction

SECTION 1
Description and
Specifications

SECTION 2
Installation

Table of Contents

Preface .................................................................................................... iv

Definitions ................................................................................................ iv

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

Technical Support Hotline: ................................................................. iv

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

System Overview .................................................................................. 1-3

Scope .............................................................................................. 1-3

System Description ......................................................................... 1-3

System Configuration ...................................................................... 1-4

System Features ............................................................................. 1-4

Handling the Analyzer ..................................................................... 1-6

System Considerations ................................................................... 1-6

Specifications ....................................................................................... 1-7

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

Inspect ............................................................................................. 2-2

Packing List ..................................................................................... 2-2

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

Locating Oxygen Probe ................................................................... 2-2

Installing Oxygen Probe .................................................................. 2-4

Locating Rosemount 5081 Transmitter ........................................... 2-7

Installing Rosemount 5081 Transmitter .......................................... 2-8

Electrical Installation ........................................................................... 2-11

General .......................................................................................... 2-11

Oxygen Probe Signal Connections ............................................... 2-12

Rosemount 5081 Transmitter 4-20 mA and Signal Connections . 2-13

Pneumatic Installation ........................................................................ 2-14

General .......................................................................................... 2-14

Reference Air Package ................................................................. 2-14

Instrument Air (Reference Air) ....................................................... 2-14

Calibration Gas .............................................................................. 2-15

SECTION 3
Startup and
Operation

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

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

Establishing Proper Calibration Gas Flow Rate ................................... 3-3

Operation .............................................................................................. 3-4

Overview ......................................................................................... 3-4

Display ............................................................................................. 3-4

Menu Tree ....................................................................................... 3-4

Navigation ....................................................................................... 3-6

Program Menu ...................................................................................... 3-7

Operator Adjustable Parameters ..................................................... 3-7

Code ................................................................................................ 3-8

Display Code ................................................................................... 3-9

Fault Val .......................................................................................... 3-9

Upper Range Val ........................................................................... 3-10

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Cell T Hi ......................................................................................... 3-10

Reset Max Cell T ........................................................................... 3-11

Set O2 Filter Time .......................................................................... 3-11

Trim 4mA ....................................................................................... 3-12

Trim 20mA ..................................................................................... 3-13

Set Hi Bottle O
Set Lo Bottle O
Set O

Set Code ........................................................................................ 3-15

Diagnostics Menu ............................................................................... 3-16

Show Fault ..................................................................................... 3-16

T/C mV ........................................................................................... 3-17

O

Cell Impedance .............................................................................. 3-18

Current Slope ................................................................................. 3-18

Current Constant ........................................................................... 3-19

Previous Slope ............................................................................... 3-19

Previous Constant ......................................................................... 3-20

Max Cell T ...................................................................................... 3-20

SW Ver (SOFt) ............................................................................... 3-21

Unit Ser # (SEr) .............................................................................. 3-21

SW Build Number (bLdn) ............................................................... 3-21

SW Build Date (bd) ........................................................................ 3-21

Cal Check Menu .................................................................................. 3-21

In Manual ....................................................................................... 3-21

Accept High O
Accept Low O

Slope .............................................................................................. 3-23

Constant ......................................................................................... 3-23

Tracking .............................................................................. 3-15

2

CELL mV .................................................................................. 3-17

2

.............................................................................. 3-14

2

............................................................................. 3-14

2

.............................................................................. 3-22

2

............................................................................... 3-22

2

SECTION 4 HART/AMS

SECTION 5
Troubleshooting

SECTION 6
Maintenance and Service

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

Field Communicator Signal Line Connections ...................................... 4-2

Field Communicator PC Connections ................................................... 4-4

Off-Line and On-Line Operations .......................................................... 4-4

HART/AMS Menu Tree ......................................................................... 4-4

Field Communicator Start Cal Check Method ...................................... 4-8

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

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

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

Identifying And Correcting Fault Indications ........................................

Calibration Passes, But Still Reads Incorrectly ..................................... 5-8

Probe Passes
Calibration, O2 Still

Reads High ...................................................................................... 5-8

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

Electronics

Replacement ......................................................................................... 6-1

Display Board Replacement ............................................................ 6-1

Spare Board Stack Replacement .................................................... 6-3

Oxygen Probe Replacement ................................................................. 6-3

5-4

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SECTION 7
Replacement Parts

APPENDIX A
Safety Data

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . A-3

APPENDIX B
Return of Material

Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

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ESSENTIAL INSTRUCTIONS

Oxygen Analyzers

READ THIS PAGE BEFORE PROCEEDING!

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

•

Read all instructions prior to installing, operatin g, and servicing the
product.

•

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

•

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

•

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

•

Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes. Connect all products to the proper electrical and

pressure sources.

•

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

•

When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson. Unauthorized parts and
procedures can affect the product's performance, place the safe
operation of your process at risk, and VOID YOUR WARRANTY.
Look-alike substitutions may result in fire, electrical hazards, or
improper operation.

•

Ensure that all equipment doors are closed and protectiv e cov ers
are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subje ct to change without
notice.

If a Model 275/375 Universal HART® Communicator is used with this unit, the software
within the Model 275/375 may require modification. If a software modification is required,
please contact your local Emerson Service Group or National Response Center at
1-800-433-6076 or 1-888-433-6829.

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WARNING

Physical access

Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’ equipment. This could be intentional or
unintentional and needs to be protected against.

Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access by unauthorized
personnel to protect end users’ assets. This is true for all systems used within the facility.

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Section 1 Introduction

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page i-iv

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page i-iv

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page i-iv

PREFACE The purpose of this manual is to provide information concerning the

components, functions, installation and maintenance of the Rosemount
5081FG Two-Wire In-Situ Oxygen Analyzer (550° to 1600°C).

Some sections may describe equipment not used in your configuration. The
user should become thoroughly familiar with the operation of this module
before operating it. Read this instruction manual c ompletely.

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

found throughout this publication.

SYMBOLS

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

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

NOTE

Highlights an essential operating procedure, co ndition, or statement.

:

EARTH (GROUND) TERMINAL

:

PROTECTIVE CONDUCT OR TERMINAL

:

RISK OF ELECTRICAL SHOCK

:

WARNING: REFER TO INSTRUCTION MANUAL

NOTE TO USERS

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

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Technical Support Hotline:

For assistance with technical problems, please
call the North American Response Center. The
Response Center is staffed 24 hours a day, 7
days a week.

Phone: [phone]-RSMT (1-800-654-7768)
Emerson may also be reached via the Internet

through email and the World Wide Web:
Email: [e-mail]

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Section 1 Description and Specifications

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

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-7

COMPONENT
CHECKLIST

A typical Rosemount Two-Wire In-Situ Oxygen Analyzer should contain the
items shown in Figure 1-1. Record the part number, s erial number, and order
number for each component of your system in the tabl e l ocated on the first
page of this manual.

Also, use the product matrix in Table 1-1 at the end of thi s section to compare
your order number against your unit. The first part of the matrix defines the
model. The last part defines the various options and features of the
Rosemount 5081FG Analyzer. Ensure the feature s and options specified by
your order number are on or included with the unit.

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Figure 1-1. Typical System Package

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1.

Instruction Manual

2.

Rosemount 5081 Transmitter

3.

Oxygen Probe

4.

Adapter Plate with Mounting Hardware and Gasket (Optional)

5.

Infrared Remote Control (IRC)

6.

Reference Air Set (Optional)

7.

Field Communicator Package (Optional)

8.

Pipe Mounting Kit (Optional)

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SYSTEM OVERVIEW
Scope This Instruction Bulletin is designed to supply details needed to install, start

up, operate, and maintain the Rosemount Two-Wire In-Situ Oxygen Analyzer.
The analyzer consists of an oxygen probe and Rosem ount 5081 transmitter.
The signal conditioning electronics of the Rosemount 5081 transmitter
outputs a 4-20 mA signal representing an O
control (IRC) allows access to setup, calibration, and diagnostics. This same
information, plus additional details, can be accessed with the HART field
communicator or Asset Management Solutions (AM S) software.

value. An infrared remote

2

System Description The Rosemount Two-Wire 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. Rosemount 5081 transmitter is
mounted remotely and conditions the oxygen pro be outputs.

The equipment measures oxygen percentage by reading the voltage
developed across a heated electrochemical cel l, which consists of a small
yttria stabilized, zirconia disc. Both sides of the disc are coated with porous
metal electrodes. When operated at the proper tem perature, the millivolt
output voltage of the cell is given by the following Nernst equation:

EMF = KT log10(P1/P2) + C

Where:

1.

P2 is the partial pressure of the oxygen in the measured gas on one
side of the cell.

2.

P1 is the partial pressure of the oxygen in the reference air on the
opposite side of the cell.

3.

T is the absolute temperature.

4.

C is the cell constant.

5.

K is an arithmetic constant.

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 th e cell temperature.

When the cell is at operating temperature and there are unequal oxygen
concentrations across the cell, oxygen ions will t ravel from the high oxygen
partial pressure side to the low oxygen partial pres sure side of the cell. The
resulting logarithmic output voltage is approx im ately 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 at low oxygen concentrations.

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The oxygen analyzer measures net oxygen concentration in the presence of
all the products of combustion, including water vap or. Therefore, it may be
considered an analysis on a “wet” basis. In compa rison 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.

System Configuration The equipment discussed in this manual consists of two major components:

the oxygen probe and the Rosemount 5081 transmit ter.
Oxygen probes are available in three length options, providing In-Situ pene-

tration 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).

Rosemount 5081 transmitter is a two-wire transmitter providing an isolated
output, 4-20 mA, that is proportional to the measured oxygen concentration. A
customer-supplied 24 VDC power source is required to simultaneously pro­vide power to the electronics and a 4-20 mA signal loop. The transmitt er
accepts millivolt signals generated by the probe and produces the outputs to
be used by other remotely connected devices. The ou t put is an isolated 4-20
mA linearized current.

System Features 1. The cell output voltage and sensitivity increase as the oxygen

concentration decreases.

2.

High process temperatures eliminate the need for external cell heating
and increase cell accuracy.

3.

HART communication is standard. To use the HART capability, you
must have either:

(a)

Field Communicator

(b)

Asset Management Solutions (AMS) software f or the PC

4.

Easy probe replacement due to the light-weight, com pact probe design.

5.

Remote location of the Rosemount 5081 transmitter removes the
electronics from high temperature or corrosive environments.

6.

Power is supplied to the electronics through the 4-20 mA line for intrinsic
safety (IS) purposes.

7.

Infrared remote control (IRC) allows interfacing without exposing the
electronics.

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8.

An operator can operate and diagnostically troubleshoot the Two-Wire
In-Situ Oxygen Analyzer in one of two ways:

a.

Infrared Remote Control. The IRC allows access to faul t indication
menus on the Rosemount 5081 transmitter LCD display. Calibration
can be performed from the IRC keypad.

b.

Optional HART Interface (Figure 1-2). The Two-Wire In-Situ Oxygen
Analyzer's 4-20 mA output line transmits an analog signal
proportional to the oxygen level. The HART output is superimposed
on the 4-20 mA output line. This information can be accessed
through the following:

•

Field Communicator - The field communicator requires Device
Description (DD) software specific to the Two-Wire In-Situ
Oxygen Analyzer. The DD software will be supplied with many
field communicators but can also be programmed int o existing
units at most Fisher-Rosemount service offices. See Section 4:
HART/AMS, for additional HART information.

•

Personal Computer (PC) - The use of a personal computer
requires AMS software available from Fisher-Rosemount.

9.

Selected Distributed Control Systems - The use of distributed co nt rol
systems requires input/output (I/O) hardwar e and A MS Security codes
are provided to (by infrared remote control) 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 m easuring the net
oxygen concentration in the industrial process.

Figure 1-2. Two-Wire In-Situ Oxygen Analyzer HART Connections and AMS Application

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Handling the Analyzer The probe was specially packaged to prevent breakag e due to handling. Do

not remove the padding material from the probe unt il i m m ediately 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 each component of the
system with care to avoid physical damage. Some probe components are made from
ceramics, which are susceptible to shock when mishandled.

System Considerations Prior to installing your Rosemount Two-Wire In-Situ Oxygen Analyzer, make

sure you have all the components necessary to make the system installation.
Ensure all the components are properly integrated to m ake t he system
functional.

Figure 1-3. Typical System
Installation

After verifying that you have all the components, select mounting locations
and determine how each component will be placed in terms of available line
voltage, ambient temperatures, environment al considerations, convenience,
and serviceability. Figure 1-1 shows a typical sy st em package. A typical
system installation is shown in Figure 1-3.

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SPECIFICATIONS

A source of instrument air is optional at the oxygen probe for reference air
use. Since the unit is equipped with an in place calibration feature, provisions
can be made to permanently connect calibration gas b ottles to the oxygen
probe.

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

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

NOTE:

The electronics is rated Type 4X (IP65) and is capable of operat ion at
temperatures up to 65°C (149°F).

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

Transmitter

Net O2 Range 0 to 25% O
System Accuracy ±1.5% of reading or 0.05% O2, whichever is greater
System Response in Flue Gas Initial – less than 3 seconds,

Probe Lengths 20 in. (508 mm)

Process Temperature Limits: 550° to 1400°C (1022° to 2552°F)

Ambient Temperature Limits: -40° to 149°C (-40° to 300°F)
Mounting and Mounting Position Vertical or horizontal
Materials of Construction
(Process Wetted Parts):

Inner Probe
Outer Protection Tube

Probe Junction Box

T90 – less than 8 seconds

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

Operation to 1600°C (2912°F) with reduced cell life

Zirconia
Alumina [1600°C (2912°F) limit]
Inconel 600 [1000°C (1832°F) limit]
Cast aluminum

2

Speed of Installation/Withdrawal 1 in. (25,4 mm) per minute
Hazardous Area Certification See Section 8.
Reference Air Requirement 100 m per minute (2,119 scfh) of clean, dry

Calibration Check Gas Fittings 1/4 in. tube fittings
Cabling Two twisted pairs, shielded

Continued on Next Page

instrument air; 1/4 in. tube fittings

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Shipping Weight

10 lbs (4,5 kg)

Infrared Remote Control

Power Requirements

Three AAA atteries

Figure 1-4. Power Supply and
Load Requirements

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Electronics

Electronics Enclosure TYPE 4X (IP65), 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
Power Supply and Load Requirements See Figure 1-4
Inputs (from O

Output One 4-20 mA signal with superimposed digital HART

Hazardous Area Certification See Section 8.
Power Transient Protection IEC 801-4

Hazardous Area Certification ATEX EEx ia IIC Class 1, Div 1, Group A, B, C, D

Probe) Two wires - O2 signal

2

Two wires - type B thermocouple

signal

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Table 1-1. Product Matrix

5081FG High Temperature Oxygen Flue Gas Analyzer

Code Sensing Probe Type

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 Material - Maximum Operating Temperature

1

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

2

Inconel Alloy - 1832°F (1000°C) maximum - 1.25 NPT mounting

Code Mounting Adapter- Stack Side

0

No adapter plate required uses 1.25 NPT
("0" must also be chosen under "Mounting 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 Adapter - Probe Side

0

No adapter plate

1

ANSI 2 in. 150 lb flange to 1.25 NPT adapter
(6 in. dia. flange, 4.75 in. BC with 4 x 0.75 in. dia. holes)

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 BC with 4 x 13 mm dia. holes)

4

Model 450 to 1.25 NPT adapter

5

Competitor's mounting flange

Code Electronics & Housing TYPE 4X, IP65

H1 5081-G HART Electronics – ATEX/IECEx
H2 5081-G HART Electronics - CSA
H3 5081-G HART Electronics - FM

Code Housing Mounting

1

Surface or wall mounting

2

1/2 to 2 in. pipe mounting

Code Communications

1

No remote control

2

Infrared Remote Control (IRC)
(LCD display through cover window

Code Calibration Accessories

1

No hardware

2

Calibration and reference air flowmeters and
reference air pressure regulator

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)

5081FG 2 1 0 0 1 1 1 2 11 Example

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Section 2 Installation

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2

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

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-11

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-14

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

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PRE-INSTALLATION
Inspect Carefully inspect the shipping container for any evi dence of damage. If the

container is damaged, notify the carrier immediately.

Packing List Confirm that all items shown on the packing list are present. Notify

Rosemount immediately if items are missing.

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

MECHANICAL INSTALLATION

Avoid installation locations near steam soot blowers.

Locating Oxygen Probe 1. The location of the oxygen probe in the stack or flue i s im portant for

maximum accuracy in the oxygen analyzing process. The pro be must
be positioned so the gas it measures is representative of the process.
Longer ducts may require several analyzers since the O
to stratification. A point too near the wall of the duct, or the in-side radius

of a bend, may not provide a representative sample because of the very
low flow conditions. The sensing point should be selected so the
process gas temperature falls within a range of 55 0° to 1400°C (1022°
to 2552°F). Figure 2-1 provides mechanical installation references.

2.

Check the flue or stack for holes and air leakage. The presence of this
condition will substantially affect the accuracy of the oxygen reading.
Therefore, either make the necessary repairs or install the probe
upstream of any leakage.

3.

Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance access to the probe. Allow
adequate clearance for probe removal (Figure 2-1).

can vary due

2

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Figure 2-1. Probe Installation Details

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Installing Oxygen Probe

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

1.

Ensure all components are available to install the probe.

NOTE

Leave the probe inner protective cover in place until i nstal l ation. This is
required to protect the ceramic cell during mov em ent.

2.

If using an optional adapter plate (Figure 2-2) or an optional mounting
flange (Figure 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.

3.

If the optional adapter plates are not used, a 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 f or the probe's
process fitting.

4.

Where high particulate or slag is in the flue 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 depth.

5.

Use high temperature material (alumina wool) to seal around the probe
during insertion. This prevents hot gases from escaping or cold air from
entering the stack or duct.

6.

Initially insert the probe to a depth of 3 in. (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.

7.

After initial insertion, insert the probe at a rate of 1 i n. (25,4 mm) per
minute until the probe is fully inserted.

8.

Install anti-seize compound on the pipe threads and scre w t he probe
into the process flange or adapter.

9.

If insulation was removed to access the duct work for probe mounting,
make sure the insulation is replaced. See Figure 2-4.

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

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Figure 2-2. Optional Adapter Plate

Figure 2-3. Optional Probe Mounting Flange

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Figure 2-4. Horizontal Probe Installation

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Figure 2-5. Adjusting Probe Insertion Depth

Locating Rosemount 5081 Transmitter

1.

Ensure the Rosemount 5081 transmitter is easily acc essible for
maintenance and service and for using the infrared remote control (if
applicable).

Do not allow the temperature of the Rosemount 5081 transmitter exceed 65°C (149°F) or
damage to the unit may result.

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2.

Installing Rosemount 5081 Transmitter

3.

1.

2.

Figure 2-6. Flat Surface Mounting Dimensions

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

Locate the Rosemount 5081 transmitter within 150 ft (45, 7 m) of the
oxygen probe due to wiring and signal considerations.

Ensure all components are available to install the Rosemount 5081
transmitter.

Choose a method or location to mount the transmitter.
a.

Flat Surface Mounting. The transmitter 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 inst al lation
references.

b.

Pipe Mounting. An optional pipe mounting bracket i s available for
this type of installation. Refer to Figure 2-7 for installation references.

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Figure 2-7. Pipe Mounting Dimensions

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Figure 2-8. Display Positioning
Assembly

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3.

For correct viewing orientation, the display may be changed 90 degrees,
using the following procedure:

a.

Refer to Figure 2-8. Loosen the cover lock screw until the cover lock
is disengaged from the knurled surface on the thread ed circuit end
cap.

b.

Remove the circuit end cap.

c.

Remove the three screws retaining the display bo ard in place.

d.

Lift and rotate the display board 90 degrees either way.

e.

Reposition the display board on the standoffs. I nst al l and tighten all
three screws.

f.

Install the circuit end cap and tighten the cover lo ck screw to secure
the cover lock in place.

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ELECTRICAL INSTALLATION

All wiring must conform to local and national codes.

For intrinsically safe applications, refer to the installation drawings on Emerson.com for the
model 5081FG.

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

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

To meet the Safety Requirements of IEC 61010 (EC requirement), and ensure safe
operation of this equipment, connection to the main electrical power supply must be made
through a circuit breaker (min 10 A) which will disconnect all current-carrying conductors
during a fault situation. This circuit breaker should also include a mechanically operated
isolating switch. If not, then another external means of disconnecting the supply from the
equipment should be located close by. Circuit breakers or switches must comply with a
recognized standard such as IEC 947.

General The power supply and signal wiring should be shielded. Also, make sure the

signal wiring is grounded at the Rosemount 5081 transmitter end only. Do not
ground the signal loop at more than one point. Twisted pai rs are
recommended. Ground the transmitter housing to an earth ground to prevent
unwanted electromagnetic interference ( EMI) or radio frequency interference
(RFI).

NOTE

For optimum EMI/RFI immunity, shield the 4-20 mA current loop cable and
enclose in an earth grounded metal conduit.

NOTE

Never run signal or sensor wiring in the same conduit, or open tray, with
power cables. Keep signal or sensor wiring at least 12 i n. (0,3 m) away from
other electrical equipment and 6.5 ft (2 m) from heavy elect rical equipment.

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Oxygen Probe Signal Connections

Figure 2-9. Oxygen Probe
Terminal Block

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

It is necessary to prevent moisture from entering the Rosemount 5081
transmitter housing. The use of weather-tight cabl e 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.

1.

Two signals represent the O2 value and the cell temperature. The probe
provides these values to the Rosemount 5081 transmitter for processing

and signal conditioning.

2.

Wiring connections for the probe are shown in Figure 2-9.

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Rosemount 5081 Transmitter 4-20 mA and Signal Connections

Figure 2-10. Transmitter
Terminal Block

1.

A 4-20 mA signal represents the O2 value. Superimposed on the
4-20 mA signal is HART information that is accessible through a

HART field communicator or AMS software.

2.

Two signals representing the O2 value and the cell temperature are
supplied to the Rosemount 5081 transmitter from the oxygen probe.

3.

Wiring connections for the Rosemount 5081 tran smi t ter are shown in
Figure 2-10.

NOTE

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

4.

Connect wire shields to terminal 1. Connect earth ground as shown.

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PNEUMATIC INSTALLATION

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General Reference air is required for O

required during a calibration check. Refer to Figure 2-11 for the gas
connections on the oxygen probe.

calculation, and calibration check gas is

2

Reference Air Package After the oxygen probe is installed, connect the reference air set. Install the

reference air set according to Figure 2-11.

Instrument Air (Reference Air)

Figure 2-11. Air Set, Plant Air Connections

Instrument air is required for reference. Refer to the reference air schematic,
Figure 2-12. Use 10 psig (68,95 kPa gage) minimum, 225 psig (1551,38 kPa
gage) at 0.2 scfh (100 m /min.); less than 40 parts-per-million total
hydrocarbons. Regulator outlet pressure shoul d be set at 5 psi (35 kPa).

Figure 2-12. Reference Air Schematic

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Calibration Gas Two calibration check gas concentrations are used with the Two-Wire In-Situ

Oxygen Analyzer: Low Gas - 0.4% O
balance in nitrogen.

and High Gas - 8% O2, each with the

2

Do not use 100% nitrogen as a low gas (zero gas). It is suggested that gas for the low (zero)

Figure 2-13. Gas Connections at
Oxygen Probe

be between 0.4% and 2.0% O
than 40 parts per million. Failure to use proper gases will result in erroneous readings.

Do not use 100% nitrogen for the low (0%) check gas. See Figure 2-13 for the
probe connections. Set both calibration check gases at the same flow rate: 5
scfh (2,5 /min).

. Do not use gases with hydrocarbon concentrations of more

2

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Section 3 Startup and Operation

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

Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1

Establishing Proper Calibration Gas Flow Rate . . . . . . . page 3-3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-4

Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-7

Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-16

Cal Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-21

GENERAL

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.

Verify Mechanical Installation

Ensure the Two-Wire In-Situ Oxygen Analy zer is installed correctly. See
Mechanical Installation in Section 2: Installation for mechanical installation
information.

Verify Terminal Block Wiring

Ensure the wiring of both the oxygen probe terminal block and Rosemount
5081 transmitter terminal block is correct. Refer to Electrical Installation in
Section 2: Installation for electrical installation and wiring information.

POWER UP General

The Two-Wire In-Situ Oxygen Analyzer displays the current oxygen reading
on the LCD face of the Rosemount 5081 transmitter. The O

cell temperature, and 4-20 mA output current are displayed as shown in
Figure 3-1. This and other information may also be accessed using
HART/AMS.

Startup Display

When the probe is first inserted into the stack, some time is required until the
minimum operating temperature [550°C (1022°F)] is 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 temperature is
reached and the electronics are working properly (approximately 5 minutes).

concentration,

2

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Figure 3-1. Normal Operation
Display

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Operating Display

After the probe has reached operating temperature s, the Rosemount 5081
transmitter display should look similar to Figure 3-1. The display will now track
the O

concentration, cell temperature, and 4-20 mA output current.

2

Figure 3-2. Faulted Operation
Display

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ESTABLISHING
PROPER CALIBRATION
GAS FLOW RATE

The calibration gas flow must be enough to ensure that no combustion flue
gases mix with the calibration check gases and only clean, good calibration
check gas surrounds the cell without expending excess gas (Figure 3-3).
Monitor the O
calibration 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.

1.

Adjust the calibration check gas flow to 5 scfh (2,5 /min. ) t o ensure the
cell is surrounded by calibration check gas. Due t o the cooling effect of
the gas, the cell temperature will decrease slightly, causing the O

concentration to drop. Once the electronics compensates for this effect,
the O

2

2.

Next, slowly reduce the calibration check gas fl ow until the O
concentration changes, which indicates that the cali bration check and
flue gases are mixing. Increase the flow rate until t hi s effect is
eliminated.

Figure 3-3. Proper Calibration Check Gas Flow Rate

concentration using an IRC or a field communicator. Set the

2

concentration will stabilize.

2

2

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OPERATION
Overview This section explains the operator controls and displays of the Two-Wire

In-Situ Oxygen Analyzer. The use of the Infrared Remote Control (IRC) and
the Rosemount 5081 transmitter Liquid Crystal Display (LCD) are described
in detail.

HART/AMS operation is not covered here. Refer to Section 4: HART/AMS.

Display The LCD on the circuit end of the Rosemount 5081 transmitter displays O

concentration, cell temperature, and 4-20 mA output current during normal
operation (Figure 3-4). The LCD will also display fault conditions when they
occur. To interact with the transmitter, use the IRC and navigate through a
series of menus displayed on the LCD.

Menu Tree The screens that can be displayed are shown in the menu tree of Figure 3-5.

These screens are displayed on the LCD and are acce ss ed using the IRC
keypad.

2

Figure 3-4. Normal Operation Display

\

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Figure 3-5. Transmitter Menu Tree

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Navigation The IRC in Figure 3-6 is used to interact with the Rosemount 5081 transmitter

and navigate through the screens on the LCD.

1.

Hold the IRC within 6 ft (1,8 m) of the Rosemount 5081 transmitter and
within 15 degrees from the centerline of the transmit t er LCD. The
amount of ambient light may also affect IRC performance:

NOTE

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

2.

Use the keys on the IRC to navigate through the menu screens. Refer to
Figure 3-6. General usage is as follows:

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 decreases the value of the cu rr ently
selected digit on the display.

e.

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

Figure 3-6. Infrared Remote
Control (IRC)

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CODE

Use to enter the access code for this analyzer; select 555

000 - 999 (excluding 000 and 555)

000 (no code)

to display designated analyzer code

FAULT VAL

Use to designate a 4-20mA value that when displayed

3.8mA - 24mA

3.6mA

will indicate an analyzer-faulted condition

UPPER RANGE VAL

Use to set upper O2% limit equivalent to 20mA output

2.0% - 25.0%

25%
CELL T HI

Use to set upper cell temperature for no-fault condition

650°C - 1600°C

1600°C

SET O2 FILTER TIME

Use to adjust analyzer response time to changing O2%

0 - 300 seconds

0 seconds

SET HI BOTTLE O2

Use to define actual O2% of high calibration check gas

8%

SET LO BOTTLE O2

Use to define actual O2% of low calibration check gas

2%

SET CODE

Use to set security code for this analyzer

000 - 999 (excluding 000 and 555)

000 (no code)

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f.

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

g.

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

h.

ENTER. Initiates the editing process and causes t he most
significant digit of the edited item to start flashing. Also processes the
entry so the previous value updates to the new value ent ered using
the arrow keys. Failure to press ENTER before exiti ng a screen will
cancel the input value and revert to the previous value.

i.

NEXT. Accesses the next user screen a s shown in the menu tree.
Any non-entered number in the exited state will be i gnored, 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 non-entered num ber in the
exited state will be ignored, and the previous data will be used.

PROGRAM MENU The PROGRAM MENU branch of the menu tree allows you to program and

edit some process parameters, faults, out put s, 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). If secu rity is enabled, you
must enter the analyzer code to gain further acces s t o the screens in this
branch. Each screen in this branch is accessed sequentially using the NEXT

Operator Adjustable Parameters

Table 3-1. Adjusatble
Parameters

Parameter Function Range Factory Default

key. Refer to Figure 3-5 during the following menu and screen descriptions.

NOTE

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. Not e 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 val ue. When finished
editing, press ENTER to accept the value. To go to the next screen in the
menu, press NEXT.

Figure 3-1 lists the range and default value of operat or-adjustable variables
used by the Rosemount 5081 transmitter. Each of these variables may be
adjusted using the PROGRAM MENU screens.

(adjust the slope of the analyzer)

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Code Refer to Figure 3-7. After pressing the PROG key, this screen will display if

security is enabled (see Set Code). Use this screen to identify a specif ic
analyzer in a process to prevent accessing an adjacent analyzer when using
the IRC.

Press ENTER to begin editing. At this point, you can either specify the
analyzer by its access code or view its code if it i s unk nown.

1.

To gain f urt her access to the screens in the PROGRAM M ENU 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.

2.

If the analyzer access code is un-known, enter 555 and press ENTER to
access the DISPLAY CODE screen. In t hat screen you will be able to
view the analyzer access code.

Figure 3-7. Code

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Display Code Refer to Figure 3-8. 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 Code. To return to the CODE screen, press NEXT.

Fault Val Refer to Figure 3-9. Use this screen to set the value t hat the 4-20 mA output

will drive to and display during a fault condition. Press ENTER t o begin
editing. Use the arrow keys to enter a fault value. The f aul t value can be
between 3.8 and 24 mA. Then, press ENTER to accept the value. Pressing
NEXT displays the UPPER RANGE VAL screen. Refer to Section 5:
Troubleshooting, for the actual fault conditions.

Figure 3-8. Display Code

Figure 3-9. Fault Val

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Upper Range Val Refer to Figure 3-10. Use this screen to set the value of the upper range limit.

This value is the maximum limit of the O
used to scale the 4-20 mA output. Press ENTER to begin editing. Use the

arrow keys to select and change the value. The upper range value can be
between 0 and 25%. Then, press ENTER to accept the value. Pressing NEXT
displays the CELL T HI screen.

concentration measurement and is

2

Cell T Hi Refer to Figure 3-11. Use this screen to set the value of the upper cell

temperature fault condition. This value is the m aximum allowed cell
temperature before a fault condition is indicated. P ress ENTER to begin
editing. Use the arrow keys to select and change the value. The value must
be between 550°C and 1600°C. Press ENTER to accept the value. Pressing
NEXT displays the RESET MAX CELL T screen.

Figure 3-10. Upper Range Val

Figure 3-11. Cell T Hi

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Reset Max Cell T Refer to Figure 3-12. 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 O

FILTER TIME screen.

2

Set O2 Filter Time Refer to Figure 3-13. In some applications it is beneficial to dampen the raw

signal coming from the cell. Use this screen to enter the am ount of time it

O

2

will take the O
editing. Use the arrow keys to select and change the sc reen value to the O
filter value (in seconds). Enter a value between 0 and 300 seconds and press
ENTER to accept the value. Press NEXT to access the TRIM 4 mA? screen.

Figure 3-12. Reset Max Cell T

to reach 90% of the new reading. Press ENTER to begin

2

2

Figure 3-13. Set O2 Filter Time

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Trim 4mA Refer to Figure 3-14. Use this screen to trim the 4 mA value of the 4-20 mA

output.

NOTE

Before trimming the 4 mA value you must break the l oop to add the ammeter.
Power down the unit, connect the ammeter in serie s wit h Rosemount 5081
transmitter terminals 15(-) and 16(+), power up t he unit, and return to the
TRIM 4 mA screen.

Press ENTER to begin editing. Use the arrow keys to select and change the
screen value to the value displayed on the installed ammeter. Press ENTER
to accept the value. After the value is entered, the unit cali brates itself to
ensure it outputs 4 mA. Both the display and the amm eter will display 4 mA.
Pressing EXIT returns to the initial TRIM 4 mA screen, and pressing NEXT
displays the TRIM 20 mA? screen.

Figure 3-14. Trim 4mA

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Trim 20mA Refer to Figure 3-15. Use this screen to trim the 20 mA value of the 4-20 mA

output.

NOTE

Before trimming the 20 mA value you must break the l oop to add the
ammeter. Power down the unit, connect the amm eter in series with
Rosemount 5081 transmitter terminals 15(-) and 16(+), power up the unit, and
return to the TRIM 20 mA screen.

Figure 3-15. Trim 20mA

Press ENTER to begin editing. Use the arrow keys to select and change the
screen value to the value displayed on the installed a m m eter. Press ENTER
to accept the value. After the value is entered, the unit cali brates itself to
ensure it outputs 20 mA. Both the display and the ammeter will display 20 mA.
Pressing EXIT returns to the initial TRIM 20 mA sc reen, and pressing NEXT
displays the SET HI BOTTLE O

screen.

2

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Set Hi Bottle O

Set Lo Bottle O

2

2

Figure 3-16. Set Hi Bottle O

Refer to Figure 3-16. Use this screen to identify, wit hi n the electronics, the
percentage of O
begin editing. Use the arrow keys to select and change the screen value to

the O
the value.

Refer to Figure 3-17. Use this screen to identify, wit hi n the electronics, the
percentage of O
begin editing. Use the arrow keys to select and change the screen value to

the O
the value. Press NEXT to display the SET O

2

percentage of the high calibration check gas. Pres s E NTER to accept

2

percentage of the low calibration check gas. Press E NTER to accept

2

used as the high calibration check gas. Press E NTER to

2

used as the low calibration check gas. Press ENTER to

2

TRACKING screen.

2

Figure 3-17. Set Lo Bottle O

2

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Set O2 Tracking Refer to Figure 3-18. Use this screen to permit the 4-20 mA line to track the

value during a calibration check. Press ENTER to begin editing. Use the

O

2

arrow keys to select Y or N. Entering Y (yes) will allow the 4-20 mA line to
track the O

value steady during the calibration check. Press ENTER to accept the

O

2

value. Press NEXT to display the SET CODE screen.

value during the calibration check. Entering N (n o) will hold the

2

Set Code Refer to Figure 3-19. Use this screen to set the security code for the

Rosemount 5081 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 c ode is set. Code 555
accesses the DISPLAY CODE screen. Press ENTER to accept the value.
Pressing NEXT returns to the FAULT VAL screen at the beginning of the

Figure 3-18. Set O2 Tracking

PROGRAM MENU.

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Figure 3-19. Set Code

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DIAGNOSTICS MENU The DIAGNOSTICS MENU branch of the menu tree allows you to examine

outputs, current faults, and unit information. None of the items in the
DIAGNOSTICS MENU are editable. This branch of the menu tree may be
accessed by pressing DIAG on the IRC when in the PRO CE SS DISPLAY
screen (Normal or Faulted). Each screen in thi s branch is accessed
sequentially by pressing NEXT. Refer to the menu in F i gure 3-5 when
reviewing the following menu and screens.

Show Fault Refer to Figure 3-20. After pressing DIAG, this screen displays. Pressing

ENTER accesses a screen displaying the current faul t (if any). If more than
one fault exists, and you are in the FAULT screen, press NEXT to go to the
next fault. Information on the fault screens can be fou nd i n Section 5:
Troubleshooting. Press EXIT to return from this fault sub-menu and press
NEXT to access the T/C mV screen.

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Figure 3-20. Show Fault

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T/C mV Refer to Figure 3-21. Use this screen to examine t he cell thermocouple mV

output. Three decimal places are displayed. Pressing NEXT accesses the O
CELL mV screen.

O2 CELL mV Refer to Figure 3-22. Use this screen to examine the O

Pressing NEXT accesses the CELL IMPEDANCE screen.

CELL mV output.

2

Figure 3-21. T/C mV

Figure 3-22. O

CELL mV

2

2

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Cell Impedance Refer to Figure 3-23. Use this screen to examine the O

status. GOOD indicates the cell is operating normally. WARN indicates the
cell has degraded but is still operational. HI indi cates that the cell has
degraded but is still operational; however, fail ure will occur soon. Pressing
NEXT accesses the CURRENT SLOPE screen.

NOTE

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

cell impedance

2

Current Slope Refer to Figure 3-24. 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

over the life of the probe. Tracking the slope will indic ate if the probe is
degrading. Press NEXT to access the CURRENT CO NS TANT screen.

Figure 3-23. Cell Impedance

value. For each calibration check, record the slope

2

Figure 3-24. Current Slope

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Current Constant Refer to Figure 3-25. Use this screen to examine the cell zero constant

calculated from the most recent calibration check. T he constant represents
the voltage generated by the cell when no difference exists between the
amount of O
access the PREVIOUS SLOPE screen.

on the reference and process sides of the cell. Press NEXT to

2

Previous Slope Refer to Figure 3-26. Use this screen to examine the slope value stored from

the second to last calibration check. The slope is the amount of cell voltage
generated for a given O

over the life of the probe. Tracking the slope will indicate if the probe is
degrading. Press NEXT to access the PREVIOUS CO NST ANT screen.

Figure 3-25. Current Constant

value. For each calibration check, record the slope

2

Figure 3-26. Previous Slope

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Previous Constant Refer to Figure 3-27. Use this screen to examine the cell zero constant stored

from the second to last calibration check. The constant represents the voltage
generated by the cell when no difference exists between the amount of O

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

Max Cell T Refer to Figure 3-28. Use this screen to examine the maximum temperature

attained by the O2 cell. This value can be reset under the PROGRAM MENU.
Pressing NEXT accesses the SW VER screen.

Figure 3-27. Previous Constant

Figure 3-28. Max Cell T

on

2

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SW Ver (SOFt) Use this screen to see the software version number f or the Rosemount 5081

transmitter. Pressing NEXT accesses the U NI T SER # screen.

Unit Ser # (SEr) Use this screen to see the unit serial number for the Rosemo unt 5081

transmitter. Pressing NEXT accesses the SW BUILD NUMBER screen.

SW Build Number (bLdn) Use this screen to see the software build number for the Rosemount 5081

transmitter. Pressing NEXT accesses the SW BUILD DATE screen.

SW Build Date (bd) Use this screen to see the software build date for the Rosemount 5081

transmitter. Pressing NEXT returns to the beginni ng of the DIAGNOSTICS
MENU branch (the SHOW FAULT screen).

CAL CHECK MENU The CALCHECK MENU branch of the menu tree (Figure 3-5) allows you to

perform a calibration check of the analyzer. Bef ore performing a calibration
check, ensure the high calibration check gas and low calibration check gas O

percentages are entered into the electronics via the PROGRAM MENU. To
set these values, refer to Set Hi Bottle O2 and Set Lo Bottle O2.

Once these values are set, access the CAL-CHECK MENU branch by
pressing CAL on the IRC when in the PROCESS DISPLAY screen (Normal or
Faulted). Each screen in this branch identifies a pro cess step in the
calibration check procedure. The first screen in t he sequence is the IN
MANUAL? screen.

2

In Manual?

Figure 3-29. In Manual?

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

Refer to Figure 3-29. If the O
control loops the loop must be placed in manual to begin 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); press ENTER to start
a calibration check and to display the ACCEPT HIGH O

output value is used in any automatic process

2

screen.

2

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Accept High O

Accept Low O

2

2

Figure 3-30. Accept High O

Refer to Figure 3-30. After pressing ENTER to begin the calibration check, the
high calibration check gas starts to flow. Aft er waiting approximately three
minutes for the displayed O

value to settle, press NEXT to accept the high

2

calibration check gas reading and apply the low calibration check gas. The
next screen to display is the ACCEPT LOW O

screen.

2

Refer to Figure 3-31. Once the low calibration check gas is applied, wait
approximately three minutes for the displayed O

value to settle. Once the

2

value settles, press NEXT to accept the reading and to display the SLOPE
screen.

2

Figure 3-31. Accept Low O

2

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Slope Refer to Figure 3-32. 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
life of the probe. Tracking the slope will indicate if t he probe is degrading.
Press NEXT to access the CONSTANT screen.

Constant Refer to Figure 3-33. Use this screen to examine the cell zero constant

calculated from the current calibration check. The constant represents the
voltage generated by the cell when no difference ex i sts between the amount

on the reference and process sides of the cell. Note this value for

of O

2

comparison against future calibration checks. P ress RESET or EXIT to return
to the PROCESS DISPLAY screen.

Figure 3-32. Slope

value. After each calibration check, record the slope over the

2

Figure 3-33. Constant

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Section 4 HART/AMS

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

Field Communicator Signal Line Connections . . . . . . . . page 4-2

Field Communicator PC Connections . . . . . . . . . . . . . . . page 4-4

Off-Line and On-Line Operations . . . . . . . . . . . . . . . . . . . page 4-4

HART/AMS Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-4

Field Communicator Start Cal Check Method . . . . . . . . . page 4-8

OVERVIEW The HART field communicator is a hand-held communications interface

device. It provides a common communications link to all microproces­sor-based instruments that are HART compatible. The field communicator has
a liquid crystal display (LCD) and keypad. A pocket-sized manual, included
with the field communicator, details the specific functions of the keypad keys.

To interface with the Rosemount 5081FG Analyzer, the field communicator
requires a termination point along the 4-20 mA current loop and a minimum
load resistance of 250 ohms between the field com m uni cator and the power
supply.

The field communicator accomplishes its task using a frequency shift keying
(FSK) technique. With the use of FSK, high-frequency digital communication
signals are superimposed on the analyzer's 4-20 mA curre nt loop. The field
communicator does not disturb the 4-20 mA signal, since no net energy is
added to the loop.

The field communicator may be interfaced with a personal computer (PC),
providing that special software has been installed. To connect the field com­municator to a PC, an interface adapter is required. Refer to the proper field
communicator documentation regarding the P C interface option.

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FIELD COMMUNICATOR SIGNAL LINE CONNECTIONS

The field communicator can connect to the analy zer 's analog output signal
line at any wiring termination in the 4-20 mA current loop. There are two meth­ods of connecting the field communicator to the signal line. For applications in
which the signal line has a load resistance of 250 ohms or more, refer to
method 1. For applications in which the signal line load resistance is less than
250 ohms, refer to method 2.

Method 1, For Load Resistance 250 Ohms

Refer to Figure 4-1 and the following steps to connect the field communicator
to a signal line < 250 ohms or more of load resistance.

Explosions can result in death or serious injury. Do not make connections to the field
communicator's serial port, 4-20 mV signal line, or NiCad recharger jack in an explosive
atmosphere.

Using the supplied lead set, connect the field comm unicator in parallel with to
the Rosemount 5081FG Analyzer. Use any wiring termination points in the
analog output 4-20 mA signal line.

Figure 4-1. Signal Line Connections, 250 Ohms Load Resistance

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Method 2, For Load Resistance < 250 ohms

Refer to Figure 4-2 and the following steps to connect the field communicator
to a signal line with < 250 ohms load resistance.

Explosions can result in death or serious injury. Do not make connections to the field
communicator's serial port, 4-20 mA signal line, or NiCad recharger jack in an explosive
atmosphere.

1.

At a convenient point break the analog output 4-20 mA signal line and
install the optional 250 ohm load resistor.

2.

Plug the load resistor into the rear panel of the field communicator.

Figure 4-2. Signal Line Connections, < 250 Ohms Load Resistance

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FIELD COMMUNICATOR PC CONNECTIONS

OFF-LINE AND ON-LINE OPERATIONS

There is an option to interface the field communicato r with a personal com­puter. Refer to the applicable field communicator documentation regarding the
PC interface option.

The field communicator can be operated both of f-line and on-line.
Off-line operations are those in which the communicator is not connected to

the Rosemount 5081FG Analyzer. Off-line operat ions can include interfacing
the field communicator with a PC (refer to applicable HA RT docum ent ation
regarding HART/PC applications.

In the on-line mode, the communicator is connected to the 4-20 mA analog
output signal line. The communicator is conne ct ed i n parallel to the
Rosemount 5081FG Analyzer or in parallel to the 250 ohm load resistor.

NOTE

If the field communicator is turned on while connected to the 4-20 mA analog
output signal line, an undefined status indicatio n appears while the
communicator warms up. Wait until the warm-up pe riod ends to continue.

The opening menu displayed on the LCD is different for on-line and off-line
operations. When powering up a disconnected (off -line) communicator, the
LCD will display the Main Menu. When powering up a connected (on-line)
communicator, the LCD will display the On-lin e Menu. Refer to the field com­municator manual for detailed menu information.

HART/AMS MENU TREE This section consists of a menu tree for the field communicator. This menu is

specific to Two-Wire In -S i t u Oxygen Analyzer applications.

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Figure 4-3. HART/AMS Menu Tree (Sheet 1 of 3)

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Figure 4-3. HART/AMS Menu Tree (Sheet 2 of 3)

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Figure 4-3. HART/AMS Menu Tree (Sheet 3 of 3)

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FIELD COMMUNICATOR START CAL CHECK METHOD

To perform a calibration check on the Two-Wire In-Situ Oxygen Analyzer with
the field communicator, use the following proced ure. If necessary, use the
menu tree in Figure 4-3 (sheet 1 of 3) for reference.

NOTE

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

NOTE

Pressing ABORT at any time during this process will purge the calibration
check gases and end the calibration check procedure.

1.

From the DEVICE SETUP SCREEN, select DIAG/SERVICE.

2.

From the DIAG/SERVICE screen, select O2 CALCHECK.

3.

Before starting the calibration check procedure, first set up the high
calibration check gas, low calibration check gas, and tracking using
HART/AMS.

4.

From the O2 CALCHECK screen, select menu item 1, START
CALCHECK, to access the calibration check procedure.

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

5.

In the first screen, a “Loop should be removed from automatic control"
warning appears. Remove the analyzer from any automatic control
loops to avoid undesirable equipment performance a nd press OK.

6.

The next screen prompts you to apply the high calibration check gas.
This message will only display for approximately t hree seconds. Press
OK.

7.

At this point, calibration check gas will flow for approximately three min­utes until the gas reading is taken. Once the gas is measured, the mes­sage, "Hi gas reading taken," displays for three seconds.

8.

Next, the screen prompts you to apply the low calibration check gas.
Press OK.

9.

The low calibration check gas will flow for approximat el y three minutes
until the reading is taken. Once the gas is measured, the message,
"Low gas reading taken,” displays for three seconds.

10.

Next, the screen prompts you to disconnect the calibration check gases.
Press OK. Once the gases are disconnected the system will purge the
gases for approximately three minutes.

11.

When the “Loop may be returned to automatic control” note appears,
return the analyzer to the automatic control loops previously removed
and press OK.

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Section 5 Troubleshooting

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

Probe Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-1

Fault Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-3

Identifying And Correcting Fault Indications . . . . . . . . . . page 5-4

Calibration Passes, But Still Reads Incorrectly . . . . . . . . page 5-8

GENERAL This troubleshooting section describes how to i dentify and isolate faults that

may develop in the Two-Wire In-Situ Oxygen Analyzer.

PROBE LIFE The zirconium oxide technology for measuring oxygen is very stable and

should provide accurate service for several year s.
Life of the probe is negatively impacted by:

•

Continued operation at elevated temperatures abov e 1300°C (2372°F).

•

Operation in processes that contain high level s of sulfur, SO2, or other
acidic compounds.

Operating conditions with simultaneously high levels of SO

are particularly damaging.

O

2

and low levels of

2

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 output from a
cell for a given O

value (represented as slope) will remain very stable to the

2

point where cell impedance increases to approximately 100 ohms.
Frequently conduct calibration checks to look for t he following conditions:

•

Continued degradation of cell slope.

•

Sluggish response. (Note how long it takes the cell to res pond to the
application of calibration check gases.) See Figure 5-2.

The slope will be valid only for the process temperatur e 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)].

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Figure 5-1. Slope vs. Impedance

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Figure 5-2. Speed of Response

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FAULT INDICATIONS The fault conditions for the Two-Wire In-Situ Oxygen Analyzer will be indi-

cated by the faulted operation display as shown in Figure 5-3. This screen
displays when a fault that invalidates the O

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

Figure 5-3. Faulted Operation
Display

reading is present. When the

2

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IDENTIFYING AND CORRECTING FAULT INDICATIONS

Figure 5-4. Transmitter Terminal
Block

A fault in the operation of the Two-Wire In-Situ Oxy gen 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 3: Startup and Operatio n.

The following paragraphs describe the faults, possi ble causes, and corrective
actions. Refer to Figure 5-4 as needed for test points and wiring information.

NOTE

Allow adequate time for the oxygen probe to reach its operating temperature
[approximately 500°C (932°F)] before invest igating a fault. 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.

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Figure 5-5. Fault 1, Open Thermocouple

Fault 1, Open Thermocouple

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

1.

Refer to Figure 5-4 and check the
thermocouple wiring connections at
terminals 8 and 10. Ensure the wires are
properly connected.

2.

Remove power. Disconnect the
thermocouple 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.

3.

If the thermocouple is open, replace the
oxygen probe per Oxygen Probe
Replacement in Section 6: Maintenance
and Service.

Figure 5-6. Fault 2, Reversed Thermocouple

Fault 2, Reversed Thermocouple Active

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

1.

Allow adequate time for the oxygen probe
to reach operating temperatures. Probe
temperatures below approximately 500°C
(932°F) may result in this fault.

2.

Refer to Figure 5-4. Check the gray (to
terminal 10) and red (to terminal 8) wires
for the proper placement.

3.

Using a multimeter, measure between
terminals 8(-) and 10(+). If the reading is
negative, the thermocouple wiring is
reversed. Rewire as necessary.

4.

If the wiring is correct and the probe is at
operating temperature, then the transmitter
electronics are bad. Replace the faulty
analog or CPU board per Electronics
Replacement in Section 6: Maintenance
and Service.

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Figure 5-7. Fault 3, Shorted Thermocouple

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Fault 3, Shorted Thermocouple

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

1.

Allow adequate time for the oxygen probe
to reach operating temperatures. Probe
temperatures below approximately 500°C
(932°F) may result in this fault.

2.

Refer to Figure 5-4. Using a multimeter,
measure between terminals 8(-) and 10(+).

3.

If the multimeter reading, in voltage mode,
is between -0.5 and +0.5 mV, the
thermocouple is shorted.

4.

If the thermocouple is shorted, replace the
oxygen probe per Oxygen Probe
Replacement in Section 6: Maintenance
and Service.

5.

If the thermocouple is not shorted, then
replace the faulty analog or CPU board per
Electronics Replacement in Section 6:
Maintenance and Service.

Figure 5-8. Fault 4, High Probe Temperature

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.

1.

If the probe temperature exceeds the
maximum cell temperature setpoint, the
4-20 mA signal output will become invalid
and go to the default value.

2.

Verify that the upper cell temperature
setpoint is configured as desired under the
PROGRAM MENU in Section 3: Startup
and Operation.

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Figure 5-9. Fault 5, O2 Cell Open

Fault 5, O2 Cell Open

The O
displays as shown in Figure 5-9.

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

cell connection is open. The fault

2

1.

Allow adequate time for the oxygen probe
to reach operating temperatures. Probe
temperatures below approximately 500°C
(932°F) may result in this fault.

2.

Refer to Figure 5-4 and check the O2 cell
wiring connections at terminals 7 and 8.
Ensure the wires are properly connected.

NOTE

3.

Apply low calibration check gas (0.4% O2).
Measure the cell output from the O
wires at the probe terminal block. The cell
output should be 100 ±20 mV. If no voltage
can be measured the cell is open.

4.

If the O2 cell is open, replace the oxygen
probe per Oxygen Probe Replacement in
Section 6: Maintenance and Service.

2

cell

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

Fault 6, Cell Impedance Too High

The O
The fault displays as shown in Figure 5-10.

cell impedance has exceeded 100 ohms.

2

1.

This fault is usually indicated in conjunction
with Fault 5, Cell Open. Correcting Fault 5
should correct Fault 6.

2.

Fault 6 appears independently, the cell has
degraded beyond specification.

3.

If the O2 cell has become too old, replace
the oxygen probe per Oxygen Probe

Replacement in Section 6: Maintenance
and Service.

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Figure 5-11. Fault 7, Reversed O2 Cell

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Fault 7, Reversed O

The O
displays as shown in Figure 5-11.

cell connections are reversed. The fault

2

1.

Refer to Figure 5-4. Check the black (to
terminal 7) and white (to terminal 8) wires
for the proper placement. Rewire if
necessary.

2.

Apply the low calibration check gas
(0.4% O

3.

Using a multimeter measure between
terminals 7(+) and 8(-). If the cell output
reading is negative, the O
reversed.

4.

If the wiring is correct, check if the
multimeter reading is the same as the
reading shown on the O
diagnostics screen (Section 3: Startup and

Operation).

5.

If the reading is different the transmitter
electronics are faulty. Replace the faulty
analog or CPU board per Electronics
Replacement in Section 6: Maintenance
and Service.

).

2

Cell

2

cell wiring is

2

CELL mV

2

CALIBRATION PASSES, BUT STILL READS INCORRECTLY

Probe Passes
Calibration, O2 Still
Reads High

There are fault conditions where no alarm indicatio n i s pre sent and the probe
passes calibration, but the O

reading may still be incorrect:

2

External Reference Air Leak - There may be a leak t hat is permitting
ambient air to mix with the process gases. Since many combustion processes
are slightly negative in pressure, ambient air can be dra wn into the cell area,
biasing the O

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

Bad Reference Side Cell Electrode - A bad reference side cell electrode can
cause an elevated O

“Calibration Recommended” alarm and increasing cell impedance readings. A
high cell impedance can be calibrated out, but if the i m pedance continues to
increase rapidly, the sensing cell must be replaced.

reading upward.

2

reading. This fault is usually indicated by a frequent

2

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Section 6 Maintenance and Service

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

Electronics Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-1

Oxygen Probe Replacement . . . . . . . . . . . . . . . . . . . . . . . page 6-3

OVERVIEW This section provides the procedures to maintain and service the Rosemount

5081FG Two-Wire In-Situ Oxygen Analyzer.

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.

ELECTRONICS
REPLACEMENT

Display Board
Replacement

Before replacing any electronic components v erify that the power to the
Rosemount 5081 transmitter is removed. Refer t o Section 7: Replacement
Parts for replacement part numbers.

Use the following procedure to replace the displ ay board (12, Figure 6-1).

1.

Loosen screw (15) until cover lock (16) disengages f rom the knurled
surface of circuit end cap (14). Remove circuit end cap.

2.

Remove three screws (13) retaining the electroni cs in place.

3.

Lift display board (12) to disconnect from CPU board (11). The display
board is plugged into the CPU board; use care when removing the
display board.

4.

Align and plug the replacement display board (12) in t he desired
orientation. Carefully plug the display board into the mating connector
on CPU board (11). Ensure the display board is full y seated.

5.

Install and tighten all three screws (13).

6.

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

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

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Spare Board Stack Replacement

The spare board stack is composed of the analog board (10, Figure 6-1) and
the CPU board (11). Use the following procedure to re place either of these
boards.

1.

Loosen cover lock screw (15) until cover lock (16) di sengages from the
knurled surface of circuit end cap (14). Remove cir cuit end cap.

2.

Remove three screws (13).

3.

Lift display board (12) to disconnect from CPU board (11). The display
board is plugged into the CPU board; use care when removing the
display board.

4.

Remove terminal end cap (5).

5.

Remove two screws (4) and lockwashers (3). Lift terminal block (6) until
the analog board (10) is unplugged from the terminal board.

6.

Lift failed board stack from housing (1) by the standoffs. Reinstall
terminal block (6), lockwashers (3), and screws (4).

NOTE

Rosemount 5081 analyzers shipped after August 2008 incorporate a new
display board. If display board replacement is nee ded for an earlier analyzer
unit, both the display and spare board stack must be replaced as matching
parts. The earlier model analyzer uses a ribbon cable to connect the display
board (12) to the CPU board (10).

7.

Install new spare board stack into housing (1). Carefully seat the analog
board onto housing pins. Press firmly on the CPU board standoffs to
ensure good contact.

8.

Align and plug the replacement display board (12) int o the mating
connector on the CPU board (11). Ensure the displ ay board is fully
seated.

9.

Install and tighten all three screws.

10.

Install terminal end cap (5) and circuit end cap (14). Tighten cover lock
screw (15) until cover lock (16) engages knurled surface of circuit end
cap (14).

OXYGEN PROBE REPLACEMENT

The oxygen probe is designed with ceramic materials 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. When the im pedance
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 pr ovided by the
electronics through the process of flowing t wo calibration check gases
of known values. Record the generated slope an d constant values.

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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.

Do not install or remove probes from a process where pressures are more than a few
inches of H
personal injury.

O positive pressure. Hot gases may escape from the stack and cause severe

2

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 causing 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.

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 5: Troubleshooting for more information.

Refer to Table 7-1 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.

1.

Remove the end cap of the probe to expose the terminal block.

2.

Refer to Figure 6-2. Disconnect the four wires (two oxygen signal wires
and two thermocouple wires) from the terminal block.

3.

Disconnect the reference air and the calibration check gas lines.

4.

Unscrew the probe from the stack and remove.

5.

Using a replacement probe, refer to Mechanical Installation in Section 2:
Installation for mechanical installation instructions.

6.

Refer to Electrical Installation in Section 2: Installation for electrical
installation instructions.

7.

Refer to Pneumatic Installation in Section 2: Installation for reference air
and calibration check gas installation instructions.

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Figure 6-2. Oxygen Probe
Terminal Block

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Figure and

1-1, 2

6A00093G01

Rosemount 5081 Transmitter ATEX

1-1, 2

6A00093G02

Rosemount 5081 Transmitter CSA

1-1, 2

6A00093G03

Rosemount 5081 Transmitter FM

1-1, 3

5R10092G01

20" Replacement Oxygen Probe, with Alumina Outer

1-1, 3

5R10092G02

26" Replacement Oxygen Probe, with Alumina Outer

1-1, 3

5R10092G03

38" Replacement Oxygen Probe, with Alumina Outer

1-1, 3

5R10092G09

20" Replacement Oxygen Probe, with Inconel 600 Outer

1-1, 3

5R10092G10

26" Replacement Oxygen Probe, with Inconel 600 Outer

1-1, 3

5R10092G11

38" Replacement Oxygen Probe, with Inconel 600 Outer

6-1, 6

1A99777H04

Terminal Block

6-1, 10, 11,

1A99777H06

Spare Board Stack, HART Compatible, with Display

6-1, 12

1A99777H05

Display Board Assembly

6-1, 14

23593-01

Circuit End Cap (with Glass)

6-1, 5

1A99777H01

Terminal End Cap (witout Glass)

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Section 7 Replacement Parts

Table 7-1. Replacement Parts
List

Index Number Part Number Description

Protection Tube

Protection Tube

Protection Tube

Protection Tube

Protection Tube

Protection Tube

12 and 13

Board Assembly

NOTE

Rosemount 5081 analyzers shipped after Augu st 2008 incorporate a new
display board. If display board replacement is nee ded for an earlier analyzer
unit, both the display and spare board stack must be r epla ced. The earlie r
model analyzer uses a ribbon cable to connect the di splay board (12) to the
CPU board (11).

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Section 8 Rosemount 5081-G Product

Certifications

European Directive information

A copy of the EC Declaration of Conformity can be f ound at t he end of the Quick Start Guide. The most recent
revision of the EC Declaration of Conformity can be found at Emerson.com/Rosemount

Ordinary location certification

As standard, the transmitter has been examined and t est ed to determine that the design meets the basic electrical,
mechanical, and fire protection requirements by a nationally recognized test laboratory (NRTL) as accredited by the
Federal Occupational Safety and Health Admi ni st ration (OSHA).

.

Installing equipment in North America

The US National Electrical Code (NEC) and the Canadian Electrical Code (CEC) permit the use of Division marked
equipment in Zones and Zone marked equipment in Divi sions. The markings must be suitable for the area
classification, gas, and temperature class. T hi s information is clearly defined in the respective codes.

USA

FM

Certificate: FM17US0021X
Standards: FM Class 3600:2011, FM Class 3610:2015, FM Class 3611:2016

Markings:

FM Class 3615:2006, FM Class 3810:2005, ANSI/TYPE 250:1991

Intrinsically Safe for use in Class I, II and III, Division 1, Groups A, B, C, D, E, F, and G; T4 Ta = -20 °C to 70 °C; Per Control
Drawing Numbers 1400227; 1400228
Nonincendive for Class I, Division 2, Groups A, B, C, D; T4 Ta = -20 °C to 70 °C; Per Control Drawing Numbers 1400227;
1400228
Dust-Ignitionproof for use in Class II and Class III, Division 1, Groups E, F, G; T6 Ta = -20 °C to 70 °C; Per Control Drawing
Number 1400678
Explosionproof for use in Class I, Div 1, Groups B, C, and D; T6 Ta = -20 °C to 70 °C; Per Control Drawing Number 1400678
Type 4X

Canada

CSA

Certificate: 1132747
Standards: C22.2 No. 0-M1987, C22.2 No. 25-1966, C22.2 No. 30-M1986

Markings:

C22.2 No. 94-M91, C22.2 No 142-M1987, C22.2 No. 157-92,
C22.2 No. 213-M1987

Intrinsically Safe for Class I Groups A, B, C, D; Class II Groups E, F, G; Class III; T4 Tamb = 70 °C, per Installation Drawing
1400229, 1400230
Non-Incendive for Class I, Div. 2 for Groups A, B, C, D; Class II, Div. 2, Groups F and G; Class III; T4 Tamb = 70 °C, per
Installation Drawing 1400229, 1400230

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Explosion-proof for Class I, Groups B, C, D; Class II, Groups E, F, G, Class III, T6 Tamb = 70 °C
Type 4X

Europe

ATEX

Certificate: Baseefa04ATEX0052X
Standards: EN 60079-0:2012+A11:2013

Markings: II 1 G

Special Conditions for Safe Use (X):

1. The equipment enclosure may contain light metals. The equipment must be installed in such a manner as to minimize the risk of impact or friction with other metal surfaces

EN 60079-11:2012

Ex ia IIC T4 Ga
(-20°≤ Ta ≤ +65°C)

International

IECEx

Certificate: IECEx BAS 09.0159X
Standards: IEC 60079-0:2011

Markings: Ex ia IIC T4 Ga

IEC 60079-11:2011
(-20°≤ Ta ≤ +65°C)

Special Conditions for Safe Use (X):

1. The Model 5081 enclosure may be made of aluminum alloy and given a protective polyurethane paint finish; however, care should be
taken to protect it from impact or abrasion if located in a zone 0 environment.

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Appendix A Safety Data

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page A-1

Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . page A-2

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SAFETY INSTRUCTIONS IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING

AND INSTALLATION OF THIS APPARATUS

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

1.

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

2.

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

3.

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

4.

All wiring shall be suitable for use in an ambient tempe rat ure of greater
than 75°C.

5.

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

6.

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

7.

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

8.

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

9.

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

10.

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

11.

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

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SAFETY DATA SHEET
FOR CERAMIC FIBER
PRODUCTS

JULY 1, 1996
SECTION I. IDENTIFICATION

PRODUCT NAME

Ceramic Fiber Heaters, Molded Insulation Modul es and Ceramic Fiber
Radiant Heater Panels.

CHEMICAL FAMILY

Vitreous Aluminosilicate Fibers with Silicon Diox i de.

CHEMICAL NAME

N.A.

CHEMICAL FORMULA

N.A.

MANUFACTURER'S NAME AND ADDRESS

Watlow Columbia
2101 Pennsylvania Drive
Columbia, MO 65202
573-814-1300, ext. 5170
573-474-9402

HEALTH HAZARD SUMMARY WARNING

•

Possible cancer hazard based on tests with laboratory animals.

•

May be irritating to skin, eyes and respiratory tract.

•

May be harmful if inhaled.

•

Cristobalite (crystalline silica) formed at high temperatures (above
1800ºF) can cause severe respiratory disease.

SECTION II. PHYSICAL DATA

APPEARANCE AND ODOR

Cream to white colored fiber shapes. With or without opt ional whit e to
gray granular surface coating and/or optional black surface coating.

SPECIFIC WEIGHT: 12-25 LB./CUBIC FOOT
BOILING POINT: N.A.
VOLATILES (% BY WT.): N.A.
WATER SOLUBILITY: N.A.

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SECTION III. HAZARDOUS INGREDIENTS
MATERIAL, QUANTITY, AND THRESHOLD/EXPOSURE LIMIT VALUES

Aluminosilicate (vitreous) 99+ % 1 fiber/cc TWA
CAS. No. 142844-00-0610 fibers/cc CL
Zirconium Silicate0-10% 5 mg/cubic meter (TLV)
Black Surface Coating**0 - 1% 5 mg/cubic meter (TLV)
Armorphous Silica/Silicon Dioxide0-10% 20 mppcf (6 mg/cubic meter)
PEL (OSHA 1978) 3 gm cubic meter
(Respirable dust): 10 mg/cubic meter,
Intended TLV (ACGIH 1984-85)
**Composition is a trade secret.

SECTION IV. FIRE AND EXPLOSION DATA

FLASH POINT: None
FLAMMABILITY LIMITS: N.A.
EXTINGUISHING MEDIA

Use extinguishing agent suitable for type of surrounding fire.

UNUSUAL FIRE AND EXPLOSION HAZARDS / SPECIAL FIRE FIGHTING PROCEDURES

N.A.

SECTION V. HEALTH HAZARD DATA

THRESHOLD LIMIT VALUE

(See Section III)

EFFECTS OF OVER EXPOSURE

•

EYE - Avoid contact with eyes. Slightly to moderately irritating.
Abrasive action may cause damage to outer surface of eye.

•

INHALATION - May cause respiratory tract irritation. Repeated or
prolonged breathing of particles of respirable size m ay cause
inflammation of the lung leading to chest pain, difficult breathing,
coughing and possible fibrotic change in the lung (Pneumoconiosis).
Pre-existing medical conditions may be aggravated b y exposure:
specifically, bronchial hyper-reactivity and chronic bronchial or lung
disease.

•

INGESTION - May cause gastrointestinal disturbances. Symptoms
may include irritation and nausea, vomiting and diarrhea.

•

SKIN - Slightly to moderate irritating. May cause irritation and
inflammation due to mechanical reaction to sharp, broken ends of
fibers.

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EXPOSURE TO USED CERAMIC F IBER PRODUCT

Product which has been in service at elevated temperat ures (greater
than 1800ºF/982ºC) may undergo partial conversion to cristobalite, a
form of crystalline silica which can cause severe respiratory disease
(Pneumoconiosis). The amount of cristobalite present will depend on
the temperature and length of time in service. (See Secti on IX for
permissible exposure levels).

SPECIAL TOXIC EFFECTS

The existing toxicology and epidemiology data bases for RCF's are still
preliminary. Information will be updated as studies are completed and
reviewed. The following is a review of the results t o date:

EPIDEMIOLOGY

At this time there are no known published reports demonstrating
negative health outcomes of workers exposed t o ref ractory ceramic
fiber (RCF). Epidemiologic investigations of RCF production workers
are ongoing.

1.

There is no evidence of any fibrotic lung disease (interstitial fibrosis)
whatsoever on x-ray.

2.

There is no evidence of any lung disease among those employees
exposed to RCF that had never smoked.

3.

A statistical "trend" was observed in the exposed population between
the duration of exposure to RCF and a decrease in some measures
of pulmonary function. These observations are clinically insignificant.
In other words, if these observations were made on a n i ndi vidual
employee, the results would be interpreted as being within the
normal range.

4.

Pleural plaques (thickening along the chest wall) have been
observed in a small number of employees who had a long duration of
employment. There are several occupational and non-occupational
causes for pleural plaque. It should be noted that plaques are not
"pre-cancer" nor are they associated with any measurable effect on
lung function.

TOXICOLOGY

A number of studies on the health effects of inhalation exposure of rats
and hamsters are available. Rats were exposed to RCF in a series of
life-time nose-only inhalation studies. The animals were exposed to 30,
16, 9, and 3 mg/m3, which corresponds with approxi m at el y 200, 150,
75, and 25 fibers/cc.

Animals exposed to 30 and 16 mg/m3 were observed to have
developed a pleural and parenchymal fibroses; ani mals exposed to 9
mg/m3 had developed a mild parenchymal fibrosis; ani m als exposed to
the lowest dose were found to have the response typically observed any
time a material is inhaled into the deep lung. While a stat ist i cally
significant increase in lung tumors was observ ed following exposure to
the highest dose, there was no excess lung cancers at the other doses.
Two rats exposed to 30 mg/m3 and one rat exposed t o 9 m g/m3
developed masotheliomas.

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The International Agency for Research on Cancer (IARC) reviewed the
carcinogenicity data on man-made vitreous fibers (including ceramic
fiber, glasswool, rockwool, and slagwool) in 1987. IA RC classified
ceramic fiber, fibrous glasswool and mineral wool (rockwool and
slagwool) as possible human carcinogens (Group 2B).

EMERGENCY FIRST AID PROCEDURES

•

EYE CONTACT - Flush eyes immediately with large amounts of
water for approximately 15 minutes. Eye lids should be held away
from the eyeball to insure thorough rinsing. Do not rub ey es. Get
medical attention if irritation persists.

•

INHALATION - Remove person from source of exposure and move
to fresh air. Some people may be sensitive to fiber induced irritation
of the respiratory tract. If symptoms such as short ness of breath,
coughing, wheezing or chest pain develop, seek medical attention. If
person experiences continued breathing difficulties, administer
oxygen until medical assistance can be rendered.

•

INGESTION - Do not induce vomiting. Get medical attention if
irritation persists.

•

SKIN CONTACT - Do not rub or scratch exposed skin. Wash area of
contact thoroughly with soap and water. Using a skin cream or lotion
after washing may be helpful. Get medical attention if irritation
persists.

SECTION VI. REACTIVITY DATA

STABILITY/CONDITIONS TO AVOID

Stable under normal conditions of use.

HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID

N.A.

INCOMPATIBILITY/MATERIALS TO AVOID

Incompatible with hydrofluoric acid and concentrated alkali.

HAZARDOUS DECOMPOSITIO N PRODUCTS

N.A.

SECTION VII. SPILL OR LEAK PROCEDURES

STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED

Where possible, use vacuum suction with HEPA filters to clean up
spilled material. Use dust suppressant where sweeping if necessary.
Avoid clean up procedure which may result in water pollut ion. (Observe
Special Protection Information Section VII I.)

WASTE DISPOSAL METHODS

The transportation, treatment, and disposal of this waste material must
be conducted in compliance with all applicable Federal, State, and Local
regulations.

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SECTION VIII. SPECIAL PROTECTION INFORMATION

RESPIRATORY PROTECTION

Use NIOSH or MSHA approved equipment when ai rborne exposure
limits may be exceeded. NIOSH/MSHA approved breathing equipment
may be required for non-routine and emergency use. (S ee S ect i on IX
for suitable equipment).

Pending the results of long term health effects studies, engineering
control of airborne fibers to the lowest levels attainable is advised.

VENTILATION

Ventilation should be used whenever possible to control or reduce
airborne concentrations of fiber and dust. Carbon monoxide, carbon
dioxide, oxides of nitrogen, reactive hydrocarbons and a small amount
of formaldehyde may accompany binder burn off duri ng first heat. Use
adequate ventilation or other precautions to elim i nat e vapors resulting
from binder burn off. Exposure to burn off fumes ma y cause respiratory
tract irritation, bronchial hyper-reactivity and asthmatic response.

SKIN PROTECTION

Wear gloves, hats and full body clothing to prevent skin contact. Use
separate lockers for work clothes to prevent fiber t ransfer to street
clothes. Wash work clothes separately from othe r clothing and rinse
washing machine thoroughly after use.

EYE PROTECTION

Wear safety glasses or chemical worker's goggles to prevent eye
contact. Do not wear contact lenses when working with this substance.
Have eye baths readily available where eye contact can occur.

SECTION IX. SPECIAL PRECAUTIONS

PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING

General cleanliness should be followed.
The Toxicology data indicate that ceramic fiber should be handled with

caution. The handling practices described in this MSDS must be strictly
followed. In particular, when handling refractory ceramic fiber in any
application, special caution should be taken to avoi d unnecessary
cutting and tearing of the material to minimize gene rat ion of airborne
dust.

It is recommended that full body clothing be worn to reduce the potential
for skin irritation. Washable or disposable clothing may be used. Do not
take unwashed work clothing home. Work clothes sh oul d be washed
separately from other clothing. Rinse washing machine thoroughly after
use. If clothing is to be laundered by someone else, inform launderer of
proper procedure. Work clothes and street clothes s houl d be kept
separate to prevent contamination.

Product which has been in service at elevated temperat ures (greater
than 1800°F/982°C) may undergo partial conversion to cristobalite, a
form of crystalline silica. This reaction occurs at the furnace lining hot
face. As a consequence, this material becomes more friable; special
caution must be taken to minimize generation of ai r-borne dust. The
amount of cristobalite present will depend on t he temperature and
length in service.

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Concentration Personal Protective Equipment

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IARC has recently reviewed the animal, human, and o ther relevant
experimental data on silica in order to critically evaluate and classify the
cancer causing potential. Based on its review, IARC classified
crystalline silica as a group 2A carcinogen (probable human
carcinogen).

The OSHA permissible exposure limit (PEL for cristobalite is 0.05
mg/m3 (respirable dust). The ACGIH threshold l i m it value (TLV) for
cristobalite is 0.05 mg/m3 (respirable dust) (ACGIH 1 991-92). Use
NIOSH or MSHA approved equipment when airborne exposure limits
may be exceeded. The minimum respiratory protect ion recommended
for given airborne fiber or cristobalite concentrations are:

CONCENTRATION

3

0-1 fiber/cc or 0-0.05 mg/m
cristobalite (the OSHA PEL)

Up to 5 fibers/cc or up to 10 times
the OSHA PEL for cristobalite

Up to 25 fibers/cc or 50 times the
OSHA PEL for cristobalite (2.5

3

)

mg/m

Greater than 25 fibers/cc or 50
times the OSHA PEL for
cristobalite (2.5 mg/m

3

)

Optional disposable dust respirator (e.g. 3M
9970 or equivalent).

Half face, air purifying respirator equipped
with high efficiency particulate air (HEPA)
filter cartridges (e.g. 3M 6000 series with
2040 filter or equivalent).

Full face, air purifying respirator with high
efficiency particulate air (HEPA) filter
cartridges (e.g. 3M 7800S with 7255 filters
or equivalent) or powered air purifying
respirator (PARR) equipped with HEPA filter
cartridges (e.g. 3M W3265S with W3267
filters or equivalent).

Full face, positive pressure supplied air
respirator (e.g. 3M 7800S with W9435 hose
& W3196 low pressure regulator kit
connected to clean air supply or equivalent).

If airborne fiber or cristobalite concentrations are not known, as
minimum protection, use NIOSH/MSHA appr oved half face, air purifying
respirator with HEPA filter cartridges.

Insulation surface should be lightly sprayed with water before removal to
suppress airborne dust. As water evaporates during removal, additional
water should be sprayed on surfaces as needed. Only enough water
should be sprayed to suppress dust so that water does not run onto the
floor of the work area. To aid the wetting process, a surfactant can be
used.

After RCF removal is completed, dust suppres sing cleaning methods,
such as wet sweeping or vacuuming, should be used t o clean t he work
area. If dry vacuuming is used, the vacuum must be equipped with
HEPA filter. Air blowing or dry sweeping should not be used. Dust
suppressing components can be used to clean up light dust.

Product packaging may contain product residue. D o not reuse except to
reship or return Ceramic Fiber products to the fact ory .

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Appendix B Return of Material

RETURNING MATERIAL SERVICE SUPPORT - To expedite t he return process outside of the United

States, contact the nearest Emerson representat i ve. Within the United States,
call the Emerson Instrument and Valves Response Center using the
1-800-654-RSMT (7768) toll-free number. This center, available 24 hours a
day, will assist you with any needed information or materials. The center will
ask for product model and serial numbers, and will prov i de a Return Material
Authorization (RMA) number. The center will also as k for the process material
to which the product was last exposed. Emerson Instrument and Valves
Response Center representatives will explain the additional information and
procedures necessary to return goods exposed t o hazardous substances.

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EC Declaration of Conformity

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部件名称

有害物质 / Hazardous Substances

铅

汞

镉

六价铬

(Cr +6)

多溴联苯

(PBB)

多溴联苯醚

(PBDE)

Assembly

Assembly

-0100-4882, Rev AB

表格

Table 1: List of Model Parts with China RoHS Concentration above MCVs

1:

含有

China RoHS

管控物质超过最大浓度限值的部件型号列

Part Name

Lead
(Pb)

Mercury

(Hg)

Cadmium

(Cd)

Hexavalent

Chromium

Polybrominated

biphenyls

Polybrominated

diphenyl ethers

电子组件

Electronics

X O O O O O

壳体组件

Housing

本表格系依据

This table is proposed in accordance with the provision of SJ/T11364

意为该部件的所有均质材料中该有害物质的含量均低于

O:
O: Indicate that said hazardous subs tance in all of the homogeneous mat erials for this part is below the limit requirement of GB/T

26572.

: 意为在该部件所使用的所有均质材料里，至少有一类均质材料中该有害物质的含量高于

X
X: Indicate that said hazardous s ubstance contained in at least one of the homogeneous materials used for this part is above the
limit requirement of GB/T 26572.

SJ/T11364

X O O X O O

的规定而制作。

GB/T 26572

所规定的限量要求。

GB/T 26572

所规定的限量要求。