Rosemount 7003D O2 Monitor-Rev J Manuals & Guides

Rosemount Analytical

ODEL

M

XYGEN MONITOR

O

NSTRUCTION MANUAL

I

7003D

N

OTICE

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

Ryton® is a registered trademark of Phillips Petroleum Co.
Teflon® is a registered trademark of E.I. duPont de Nemours and Co., Inc.

Manual Part Number 748054-J
July 1997
Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue
Anaheim, California 92807-1802

C

ONTENTS

PREFACE

Safety Summary...................................................................................................P-1

Specifications - Performance................................................................................P-3

Customer Service, Technical Assistance, and Field Service................................P-5

Returning Parts to the Factory..............................................................................P-5

Training.................................................................................................................P-5

Documentation......................................................................................................P-5

Compliances.........................................................................................................P-6

SECTION 1. INTRODUCTION

1.1 Oxygen Monitor............................................................................................1-1

1.2 Sensors........................................................................................................1-2

SECTION 2. INSTALLATION

2.1 Unpacking and Facility Preparation.............................................................2-1

2.2 Location and Mounting ................................................................................2-1

2.3 Electrical Connections.................................................................................2-1

2.3.1 Line Power Connection..................................................................2-2

2.3.2 System Grounding Connection......................................................2-2

2.3.3 Sensor Cable Connection.............................................................. 2-3

2.3.4 Output Cable Connection...............................................................2-3

2.3.5 Output Connections for Alarms......................................................2-5

2.4 Sensors - Rechargeable..............................................................................2-6

2.4.1 Installation of Sensor and Fast Response Flow Kit........................2-6

2.4.2 Installation of Sensor and In-Line Flow Kit.....................................2-8

2.4.3 Installation of Sensor and Submersion Kit.....................................2-10

2.5 Sensors - Non-Rechargeable.....................................................................2-13

2.5.1 Conversion of Oxygen Monitor from Use with Rechargeable

Sensor to Use with Non-Rechargeable Sensor.................2-13

2.5.2 Installation of Sensor and In-Line Flow Assembly..........................2-13

2.5.3 Installation of Sensor with Submersion Assembly..........................2-14

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SECTION 3. STARTUP AND CALIBRATION

3.1 System Startup............................................................................................ 3-1

3.2 Calibration................................................................................................... 3-1

3.2.1 Calibration with Air......................................................................... 3-2

3.2.2 Calibration with Span Gas............................................................. 3-2

3.3 Selection of Alarm Range, Setpoint and Deadbands................................. 3-2

3.4 Current Output Range................................................................................ 3-4

SECTION 4. OPERATION

4.1 Routine Operation....................................................................................... 4-1

4.2 Recommended Calibration Frequency........................................................ 4-1

4.3 Frequency of Sensor Recharging................................................................4-1

SECTION 5. THEORY

5.1 Electrochemical Theory............................................................................... 5-1

5.2 Variables Influencing Oxygen Measurement............................................... 5-2

SECTION 6. ROUTINE SERVICE AND TROUBLESHOOTING

6.1 Rechargeable Sensors................................................................................ 6-1

6.1.1 Recharging Sensor........................................................................ 6-1

6.1.2 Rejuvenating Cathode................................................................... 6-4

6.1.3 Cell Separator Kit .......................................................................... 6-4

6.2 Non-Rechargeable Sensors....................................................................... 6-5

6.3 Troubleshooting ......................................................................................... 6-5

6.3.1 Checking Rechargeable Sensor and Cable................................... 6-5

6.3.2 Checking Non-Rechargeable Sensor and Cable........................... 6-7

SECTION 7. REPLACEMENT PARTS

7.1 Circuit Board Replacement Policy............................................................... 7-1

7.2 Replacement Parts...................................................................................... 7-1

7.3 Replacement Parts - Sensors.................................................................... 7-2

7.3.1 Rechargeable Sensors.................................................................. 7-2

7.3.2 Non-Rechargeable Sensors.......................................................... 7-3

ATERIAL SAFETY DATA SHEET (ELECTROLYTE

M

ENERAL PRECAUTIONS FOR HANDLING

G

ARRANTY

W

IELD SERVICE AND REPAIR FACILITIES

F

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TORING HIGH PRESSURE CYLINDERS

748054-J

F

IGURES

1-1 Model 7003D Oxygen Monitor....................................................................1-1

1-2 Rechargeable Sensor.................................................................................1-3

1-3 Non-Rechargeable Sensor.........................................................................1-3

2-1 Power Supply Board...................................................................................2-2

2-2 Connections for Potentiometric Recorder with Non-Standard Span ............2-4

2-3 Typical Example of Oxygen Monitor Connected in Series with Several

Current Actuated Devices...........................................................2-4

2-4 Rechargeable Sensor with Fast Response Flow Assembly .......................2-7

2-5 Mounting Rechargeable Sensor in Fast Response Assembly....................2-7

2-6 Typical Installation Orientation of Rechargeable Sensor and Fast

Response Flow Assembly...........................................................2-8

2-7 Rechargeable Sensor with Gland and In-Line Flow Assembly...................2-9

2-8 Preferred Installation Orientation of Rechargeable Sensor and In-Line

Flow Assembly............................................................................2-10

2-9 Rechargeable Sensor with Submersion Assembly.....................................2-11

2-10 Typical Installation of Rechargeable Sensor and Submersion Assembly ...2-12
2-11 Typical Permanent Installation of Rechargeable Sensor/Submersion

Assembly During Plant Construction...........................................2-12

2-12 Typical Installation of Rechargeable Sensor/Submersion Assembly in

an Existing Plant .........................................................................2-13

2-13 Dimensions and Components of Non-Rechargeable Sensor In-Line

Flow Kit .......................................................................................2-16

2-14 Typical Installation of Non-Rechargeable Sensor with In-Line Flow Kit......2-17

2-15 Dimension and Components of Non-Rechargeable Sensor Submersion

Kit................................................................................................2-17

2-16 Typical Installation of Non-Rechargeable Sensor with Submersion Kit......2-18

3-1 Display Board.............................................................................................3-3

3-2 Isolated Current Output Board....................................................................3-5

5-1 Rechargeable Oxygen Sensor - Sectional View.........................................5-1

6-1 Rechargeable Sensor - Exploded View......................................................6-2

C

ONTENTS

T

ABLES

748054-J

6-1 Rechargeable Sensor Troubleshooting Guide ............................................6-6

6-2 Non-Rechargeable Sensor Troubleshooting Guide....................................6-7

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ONTENTS

D

RAWINGS (LOCATED IN REAR OF MANUAL

)

620434 Schematic Diagram, Isolated V/I Board
622228 Interconnect Diagram, Model 7003D Oxygen Monitor
622530 Schematic Diagram, Display Board
622538 Schematic Diagram, Power Supply Board
622617 Outline and Mounting Drawing, Model 7003D Oxygen Monitor

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AFETY SUMMARY

To avoid explosi on, l oss of l i fe, per sonal i nj ury and damage to this equipment and on-site
property, all personnel authorized to install, operate and service the Model 7003D
Oxygen Monitor should be thoroughly familiar with and strictly follow the instructions in
this manual.

If this equipment is used in a manner not specified in these instructions, protective
systems may be impaired.

Save these instructions.

DANGER

personal injury, death, or substantial property damage if the warning is ignored.

WARNING

personal injury, death, or substantial property damage if the warning is ignored.

CAUTION
minor

NOTE

important but not hazard-related.

is used to indicate the presence of a hazard which

is used to indicate the presence of a hazard which

is used to indicate the presence of a hazard which

personal injury or property damage if the warning is ignored.

is used to indicate installation, operation or maintenance information which is

will

cause

can

cause

will or can

severe

severe

cause

WARNING: ELECTRICAL SHOCK HAZARD

Do not operate without doors and internal circuit panel secure. Servicing
requires access to live parts which can cause death or serious injury.
Refer servicing to qualified personnel.

For safety and proper performance this instrument must be connected to
a properly grounded three-wire source of power. Electrical installation
must be made in accordance with any applicable national or local codes.

Alarm switching relay contacts wired to separate power source must be
disconnected before servicing.

WARNING: PARTS INTEGRITY

Tampering or unauthorized substitution of components may adversely
affect safety of this product. Use only factory documented components
for repair.

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7003D O

ODEL

This analyzer requires periodic calibration with known zero and standard
gases. Refer to General Precautions for Handling and Storing High
Pressure Cylinders, at the rear of this manual.

Unused cable conduit entries must be securely sealed by flameproof
closures to provide enclosure integrity in compliance with personnel
safety and environmental protection requirements. The plastic closures
provided are for shipping protection only. When installing instrument,
observe all notes on drawing 622617 (in rear of this manual).

XYGEN MONITOR

WARNING: HIGH PRESSURE GAS CYLINDERS

WARNING: HIGH PRESSURE GAS CYLINDERS

WARNING: ENCLOSURE INTEGRITY

WARNING: ELECTRICAL SHOCK HAZARD

To avoid shock hazard and AC pickup, do not route potentiometric output
or current output cables through the same conduit as power cable or
alarm output cable.

WARNING: CORROSIVE MATERIAL

Concentrated nitric acid is used in rejuvenating the sensor cathode
(Section 6.1.2). This material is highly corrosive.

CAUTION: CONDUIT GROUNDING

The non-metallic enclosure does not provide grounding between conduit
connections. Use grounding-type bushings and jumper wires.

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S

PECIFICATIONS

Operating Range
Sample Temperature
Ambient Temperature
Ambient Humidity
System Linearity

S

PECIFICATIONS

Power Requirements

Potentiometric Output

Voltage Output
Current Output
(Option)

S

PECIFICATIONS

Range
Contacts
Contact Rating

- P

ERFORMANCE

0 - 19.99% to 0 to 25% oxygen by volume
32°F to 110°F (0°C to 44°C)

-20°F to 122°F (-29°C to 50°C) for instrument
Up to 95% relative humidity, non-condensing
For constant sample temperature after correction for sensor

zero offset: ±1% of fullscale

- E

LECTRICAL

107 to 127 VAC, 50/60 Hz, 0.2 A or 214 to 254 VAC, 50/60
Hz, 0.1

Selectable: 0-25%, 0-10%, 0-5% or 0-1% oxygen fullscale
Minimum load: 2K ohms
Selectable: 0-10V, 0-5V, or 0-1V fullscale
Isolated 0-20mA or 4-20mA over same range as

potentiometric output. Minimum load: 600 ohms.

- A

LARM

Selectable: 0-25%, 0-10%, 0-5%, or 0-1% oxygen fullscale
Two independently adjustable SPDT relay contact actuations
Maximum switching voltage: 250 VAC, 30 VDC

(resistive load)
Deadband

Repeatability

S

PECIFICATIONS

Mounting

Dimensions
Weight
Enclosure

Sensor Cable

1

The optional air purge, when installed along with user supplied components, is designed to equip the
instrument enclosure with T ype Z purge protection per Standard ANSI/NFPA 496-1986. This reduces the
classification within the enclosure from Class I, Division 2 (norm ally non-hazardous) to non-hazardous, thus
permitting installation in a location classified Class I, Groups A, B, C, D, Division 2. T his method of protection
is recognized in Article 500-1 of the National Electrical Code (NEC)< ANSI/NFPA 70.

Maximum switching current: 3A
Adjustable from less than 2% to 20% of range at any

setpoint

0.1% of range

±

- P

HYSICAL

Standard: Panel mount
Optional: Surface mount, pipe mount

10.4 x 8.9 x 8.3 inches (265 x 225 x 210 mm) HxWxD

4.2 lbs (1.9 kg)
NEMA-4X general purpose.
Optional air purge designed to NFPA-496 Type Z.
1000 ft (305 m) Maximum length between instrument and

sensor.

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PECIFICATIONS

Type
Stability

Temperature
Compensations

Response Time

Sample Pressure

- S

ENSOR

Rechargeable, non-rechargeable (disposable)

1% of fullscale at any given temperature per 24 hours, for

±

an equilibrated senso r
32°F to 110°F (0°C to 44°C) ±6% of reading
60°F to 90°F (15°C to 32°C) ±3% of reading
For any other 30°F (16°C) ±4% of reading
90% in 20 seconds for a step change, using an equilibrated

sensor at 25°C
0 to 50 psig (0 to 345 kPa)

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USTOMER SERVICE

For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:

R

ETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call:

Order Number.

Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic,
corrosive or other hazardous material or used in such a hazardous environment, the
user must attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written
certification that the material has been decontaminated, disinfected and/or detoxified.

Model Number, Serial Number, and Purchase Order Number or Sales

, T

ECHNICAL ASSIST ANCE AND FIELD SERVICE

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

T

RAINING

A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the
the Technical Services Department at:

D

OCUMENTATION

The following Model 7003D Oxygen Monitor instruction materials are available.
Contact Customer Service or the local representative to order.

748054 Instruction Manual (this document)

Current Operator and Service Training Schedule

Rosemount Analytical Inc.

Phone: [phone]

FAX: [phone]

contact

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7003D O

ODEL

XYGEN MONITOR

OMPLIANCES

The Model 7003D Oxygen Monitor is designed to comply with applicable American
standards for protection against electrical shock, mechanical and fire hazards in non­hazardous (ordinary) locations. The instrument must be installed in accordance with
the provisions of the National Electrical Code (NEC), ANSI/NFPA 70, and/or any
applicable national or local code(s), and operated and maintained in the
recommended manner.

The oxygen sensors and interconnecting cable used with the Model 7003D Oxygen
Monitor are non-incendive in normal operation and comply with the requirements of
Articles 501-3 (b)(1) c and 501-4 (b), Exception, of the National Electrical Code,
ANSI/NFPA 70-1987, for installations in Class I, Groups A, B, C, D Division 2
classified locations.

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NTRODUCTION

1

The Model 7003D Oxygen Monitor (Figure 1-1) automatically and continuously
measures the oxygen concentration in gaseous samples. The determination is
based on measurement of the electrical current developed by an amperometric
sensor in contact with the sample.

The monitor provides direct readout of concentration in % by volume. Alarms and a
potentiometric output are provided as standard. The fullscale range of the alarms
and the potentiometric output are each independently selectable. Thus, the range of
the potentiometric output may be changed without the need to readjust alarm
setpoints.

The Model 7003D is used with a sensor which is housed in a submersion assembly
or flow assembly and is connected to the monitor by a multi-conductor shielded
cable.

1.1 OXYGEN MONITOR

The oxygen monitor conditions the sensor output signal to provide direct readout of
oxygen in % by volume. It also contains current-measuring circuitry, operating
controls, digital display, alarms, and signal outputs provisions.

LOW

SET PT

Model 7003D Oxygen Monitor

Figure 1-1. Model 7003D Oxygen Monitor

%

LOW

SET PT

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XYGEN MONITOR

The monitor is designed for panel mounting. Accessory Pipe Mounting Kit permits
the oxygen monitor to be mounted on a vertical or horizontal pipe. Accessory Wall
Mounting Kit permits wall (surface) mounting. An optional air purge kit is designed to
meet requirements for NFPA-496 Type Z air purge (see specifications) .

An accessory Isolated Current Output Board provides a field-selectable 0 to 20 mA,
or 4 to 20 mA isolated current output.

1.2 SENSORS

Rosemount Analytical offers rechargeable and disposable oxygen sensors which can
be used with the Model 7003D. See Figures 1-2 and 1-3. These sensors are
supplied alone or in kits: Submersion, in-line flow, and fast response.. Sensors are
available constructed of polypropylene or Ryton. See Sections 2.4 - Sensors,
Rechargeable, 2.5 - Sensors - Non-Rechargeable and 7.3 - Sensors, Replacement
Parts for additional information.

ECHARGEABLE

R

AST-RESPONSE FLOW

- F

The fast-response flow assembly allows minimum volume gas flow that permits
mounting the sensor in a flowing gas stream. Sample is supplied at slightly above
atmospheric pressure, flows through the assembly and discharges to atmospheric
pressure. Internal volume of the assembly is low to minimize system response time.

ECHARGEABLE

R

- IN-L

INE FLOW

The in-line pressure compensated flow assembly permits mounting the sensor in a
variable pressure gas stream at pressures up to 50 psig (345 kPa). The typical
application is in-line monitoring with the flow assembly connected directly into the
process stream pipeline. An alternative application involves discharge to
atmospheric pressure where discharge rates are high.

ECHARGEABLE

R

UBMERSION ASSEMBLY

- S

The submersion assembly permits placing the sensor at depth, in an open or closed
vessel, at a maximum pressure of 50 psig (345 kPa). The submersion assembly
provides a convenient means of mounting the sensor, and also affords protection for
the sensor cable connection a feature particularly desirable in high humidity
environments.

NON-R

ECHARGEABLE

- IN-L

INE FLOW

The in-line flow assembly permits mounting the sensor in a flowing gas stream. Also
included is a universal mounting bracket and a cable assembly for connecting the
disposable oxygen sensor to the monitor.

NON-R

ECHARGEABLE

UBMERSION

- S

The submersion assembly adapts the oxygen sensor so that it may be inserted
through the wall of a vessel or pipe to monitor the oxygen concentration existing in
the vessel or pipe.

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NTRODUCTION

Figure 1-2. Rechargeable Sensor

Figure 1-3. Non-Rechargeable Sensor

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NSTALLATION

2

2.1 UNPACKING AND FACILITY PREPARATION

Carefully examine the shipping carton and contents for signs of damage.
Immediately notify the shipping carrier if the carton or contents is damaged. Retain
the carton and packing material until all components associated with the Model
7003D Oxygen Monitor are operational.

Outline and mounting dimensions for the oxygen monitor are given in the outline and
mounting drawing 622617.

2.2 LOCATION AND MOUNTING

Mount the sensor in an environment within the permissible range of 32°F to 110°F
(0°C to 44°C) The sensor is supplied, as ordered, in a kit that includes a submersion
assembly or flow chamber.

Sensor and amplifier are interconnected by a multi-conductor shielded cable. It is
supplied in the standard 10 foot length, or in any length specified by customer, up to
1000 feet (305 m). See Section 7.

The oxygen monitor is designed to meet NEMA-4X requirements, and may be
mounted outdoors Permissible ambient temperature range is -20°F to +122°F (-29°C
to +50°C).

Panel mount the amplifier, or use the accessory wall mount kit or accessory pipe
mount kit as desired.

2.3 ELECTRICAL CONNECTIONS

WARNING: ELECTRICAL SHOCK HAZARD

Do not operate without doors and internal circuit panel secure. Servicing
requires access to live parts which can cause death or serious injury.
Refer servicing to qualified personnel.

For safety and proper performance this instrument must be connected to
a properly grounded three-wire source of power. Electrical installation
must be made in accordance with any applicable national or local codes.

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XYGEN MONITOR

2.3.1 L

INE POWER CONNECTION

The Model 7003D provides switch-selectable operation on either 107 VAC to 127
VAC or 214 VAC to 254 VAC, 50/60 Hz.

Electrical power is supplied to the monitor via a customer-supplied three-conductor
cable, type SJT. minimum wire size 18 AWG. Route power cable through conduit
and into appropriate opening in monitor enclosure. Connect power cable leads to
terminal strip TB5 on the power supply board, as shown in Figure 2-1 and drawing

622228.

OLTAGE SELECT

V

1. Open the monitor door.

2. Loosen the retainer screw which holds the display board and pivot the display
board to access the power supply board.

3. Verify that the line voltage selector switch S1 is set to indicate the nominal line
voltage: either 115 or 230 (Figure 2-1).

2.3.2 S

YSTEM GROUNDING CONNECTION

A ground terminal (TB5-GND) is provided on the power supply board. Refer to
Figure 2-1. This terminal must be connected, via the ground lead of the
three-conductor power cable to a good earth ground.

R

Isolated V/I Board
(Option)
(see Figure 3-2)

Recorder
TB3

1

R4

R5 R6

U6

R3

R8

CR2

R9

POWER SUPPLY BOARD 622537

J1

Sensor
TB2

Figure 2-1. Power Supply Board

U1 J1

U2

C2

U3

U4

C4

O
G

I

C5

1 2 3 4

I G O

TB1

30K
THERM

TB2

Current Output
TB3

C1

CR

U5

3K/10K
THERM

SHLD

CATH

AM

C3

G
O

I

TB3

CR2

U5

O
G

I

U1

U3

O
G

I

O

O

G

I

I

G

U2 U4

SHIELD

+VOLTAGE OUT

-VOLTAGE OUT

+CURRENT OUT

-CURRENT OUT

CR3

CR4

O
G

CR1

I

K2

K1

TB4

C2 C1

NO

COM

ALARM

NC

NO

COM

ALARM

NC

C3

T1

Voltage Select Switch

F1

TB5

GND

NEUTRAL/L2

HOT/L1

S1

S1

AC Power
TB5

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NSTALLATION

2.3.3 S

ENSOR CABLE CONNECTION

If a long cable is used, it should be routed to the amplifier through appropriate
conduit. Connect the amplifier end of the cable to terminal strip TB2 on the power
supply board, as shown in Figure 2-1 and drawing 622228.

Connect the cable to the sensor when installation of the sensor is complete.

2.3.4 O

UTPUT CABLE CONNECTION

WARNING: ELECTRICAL SHOCK HAZARD

To avoid shock hazard and AC pickup, do not route potentiometric output
or current output cables through the same conduit as power cable or
alarm output cable.

If a recorder, controller, or other output device is used, connect it via number 22 or
number 24 AWG two-conductor shielded cable. Route the output cable through
conduit to the oxygen monitor, and into the case through the appropriate opening
shown in drawing 622617.

OTENTIOMETRIC OUTPUT

P

1. Connect leads of shielded recorder cable to VOLTOUT + and VOLTOUT ­terminals of TB3 on power supply board (Figure 2-1). Connect shield to SHD
terminal.

2. Connect other end of output cable to appropriate terminals of recorder or other
potentiometric device.

a. For devices with spans of 0 to 1.0 to 5, or 0 to 10 volts connect cable directly

to input terminals of the device, making sure polarity is correct.

b. For devices with intermediate spans. i.e., between the specified values,

connect cable to device via a suitable external voltage divider. as shown in
Figure 2-2.

SOLATED CURRENT OUTPUT ACCESSORY

I

1. Verify that the current output board (Isolated V/I Board) is properly mounted on
the power supply board in connector J2. See Figure 2-1. If originally ordered
with the oxygen monitor, the board is factory installed.

2. Connect leads of shielded cable to CURRENT OUT + and CURRENT OUT ­terminals of TB3 on power supply board. Connect shield to SHD terminal.

3. Connect other end of output cable to input terminals of recorder or other
current-actuated device, making sure polarity is correct. If two or more
current-actuated devices are used, they must be connected in series. Refer to
Figure 2-2.

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XYGEN MONITOR

Note
Total resistance of all output devices and associated interconnection

cable must not exceed 600 ohms.

Since neither the CUROUT + nor CUROUT - output terminal is grounded, the current

loop should be grounded at some point within the circuit. The ground point
should be chosen to minimize noise or other undesirable interactions.

7003D

Monitor

Position of Recorder Output

Selector Plug

10 mV 1K Ohm
100 mV 10K Ohm
1 V 100K Ohm
5 V 2K Ohm

Voltage Divider
(Customer Supplied)

Minimum Permissible Resistance for

R1 + R2

Potentiometric

Recorder

Input
Terminals

(Verify polarity
is correct)

Figure 2-2. Connections for Potentiometric Recorder with Non-Standard Span

7003D

Monitor

mA

+

-

+

-

+

-

+

-

Recorder

Controller

Remote

Indicator

Figure 2-3. Typical Example of Oxygen Monitor Connected in Series with Several

Current Actuated Devices

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NSTALLATION

2.3.5 O

UTPUT CONNECTIONS FOR ALARMS

LARM OUTPUT CONNECTIONS

A

The alarm output provides two sets of relay contacts for actuation of alarm and/or
process-control functions. Leads from the customer-supplied external alarm system
connect to terminal block TB4 on the power supply board. See Figure 2-1 and
drawing 622228.

If the alarm contacts are connected to any device that produces radio frequency
interference (RFI), it should be arc-suppressed. Accessory Arc Suppressor is
recommended. When possible, the oxygen monitor should operate on a different AC
power source, to minimize RFI.

LARM RELAY CHARACTERISTICS

A

The HI ALARM and LO ALARM outputs are provided by two identical single-pole
double-throw relays. Relay contacts are rated at (resistive load):

3 A, 250 VAC
3 A, 30 VDC

Removal of AC power from the analyzer, as in a power failure, de-energizes both
relays.

HI ALARM R

ELAY

The HI ALARM relay coil is energized when the display moves upscale through the
value that corresponds to the setpoint plus deadband. This relay coil is de-energized
when display moves downscale through the value that corresponds to setpoint minus
deadband.

LO ALARM R

ELAY

The LO ALARM relay coil is energized when the display moves downscale through
the value that corresponds to setpoint minus deadband. This relay coil is
de-energized when the display moves upscale through the value that corresponds to
setpoint plus deadband.

LARM RESET

A

The HI ALARM and LO ALARM functions both incorporate automatic reset. When
the meter reading goes beyond the pre-selected limits, the corresponding relay is
energized; when the meter reading returns within the acceptable range, the relay is
automatically de-energized.

AIL SAFE APPLICATIONS

F

By appropriate connection to the double-throw relay contacts, it is possible to obtain
either a contact closure or a contact opening for an energized relay. The
de-energized relay then provides a contact opening or contact closure, respectively.
It is important for failsafe applications that the user understand what circuit

748054-J

July 1997

Rosemount Analytical

2-5

M

ODEL

7003D O

XYGEN MONITOR

conditions are desired in event of power failure and the resultant relay
de-energization. Relay contacts should then be connected accordingly.

2.4 SENSORS - RECHARGEABLE

This section provides instructions on installation and gas connections of the sensors
in the three available mounting configurations. Refer to Section 2.6 for electrical
connections to sensor. Refer to Section 7 for part numbers of sensors, sensor kits,
and accessories. The sensor is shipped assembled, charged, and ready for use.

2.4.1 I

NSTALLATION OF SENSOR AND FAST-RESPONSE FLOW KIT

The Fast-Response Flow Assembly is used to mount the sensor in a gaseous
sample flow stream. It is used when the sample is supplied at slightly above
atmospheric pressure. Internal volume is low to minimize system response time.

OUNTING FLOW CHAMBER

M

The flow chamber has two .2 diameter clearance holes for mounting screws (screws
supplied by user). See Figure 2-4.

Mount the flow chamber as shown in Figure 2-6. Preferably, mount the flow
chamber so that the sensor is vertical as shown in Figure 2-6A. Horizontal mounting,
Figure 2-6B, is acceptable provided the sample enters the lower port of the chamber
and discharges from the upper port.

NSTALLING SENSOR

I

1. Refer to Figure 2-5. Remove the sensor cap from the sensor. Slide the stainless
steel ring clamp onto the threads for the sensor cap until stops against sensor
body. Replace the sensor cap. The ring clamp is held between the cap and body
of the sensor.

2. Insert the o-ring and cap end of the sensor into the flow chamber.

3. Slide the flow chamber nut down the body of the sensor and tighten onto flow
chamber.

The o-ring between the bottom of the chamber and the sensor cap now effects a
seal.

AS CONNECTIONS

G

Sample inlet and outlet connections are 1/8 inch NPT (Figure 2-4). Normally, sample
is supplied to the flow chamber via a customer supplied needle valve which provides
flow adjustment.

RESSURE AND FLOW

P

The flow chamber is designed for discharge at atmospheric pressure. Maximum
recommended flow is 2 liters per minute. Minimum acceptable flow rate depends on
required rate of system response, which is dependent on length of the sample line,
and in some cases, the volume of gas sample that can be wasted.

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July 1997

748054-J

Sensor

p

p

Ring Clamp

Cable to Oxygen Analyzer

3.6

[9.1]

I

NSTALLATION

Nut

Sample Inlet/Outlet
1/8 NPT

O-Ring

Flow
Chamber

.4

[9]

1.5
[37]

Mounting Holes (2)
!.2 THRU
C'BORE ! .38 x .25 DP

DIMENSIONS

Inch

[mm]

! 3.0

[76]

1.5

[38]

Figure 2-4. Rechargeable Sensor with Fast Response Flow Assembly

Ring
Clam

Sensor Ca

Flow Chamber

Nut

Sensor Body

O-Ring

Figure 2-5. Mounting Rechargeable Sensor in Fast Response Flow Assembly

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7003D O

ODEL

XYGEN MONITOR

A. Vertical Installation (Preferred)

Vent to
Atmosphere

B. Horizontal Installation

Vent to

Atmosphere

Sample In

Sample In

Figure 2-6. Typical Installation Orientation of Rechargeable Sensor and Fast

Response Flow Assembly

2.4.2 I

NSTALLATION OF SENSOR AND IN-LINE FLOW KIT

The In-Line Flow Assembly is used to mount the sensor in a variable-pressure
gaseous or liquid sample stream, at pressures up to 50 psig (345 kPa).

The typical application is in-line monitoring, with the flow assembly connected directly
into the process-stream pipeline. An alternative application involves discharge to
atmospheric pressure where hig h di schar g e rates ar e desi red.

Note that the sensor responds to partial pressure of oxygen in the sample. If total
pressure changes, the oxygen r esponds accor ding l y .

For liquid sample streams, it is recommended that the assembly be mounted so the
sensor is in the vertical position, as shown in Figure 2-8. In this orientation the
sample enters the lower port of the assembly and discharges to the upper port. The
horizontal arrangeme nt ensures that during se tup there will be immed iate discharge
of any gas in the flow chamber or any entrained gases in the sample stream.

For gaseous sample streams, the assembly may be mounted with the sensor
horizontal, if desired.

OUNTING FLOW CHAMBER

M

Outline and mounting dimensions are given in Figure 2-7. The flow chamber has two
.22 diameter clearance holes for mounting screws (screws supplied by user). The
sample inlet and sample outlet are 1/2 FPT. Mount the flow chamber as shown in
Figure 2-8.

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July 1997

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NSTALLING SENSOR

I

1. Remove the clamp and adapter ring from the flow chamber.

2. Insert the sensor (with gland) into the flow chamber.

3. Replace the adapter ring and clamp.

AS CONNECTIONS

G

Sample inlet and sample outlet connections are 1/2 FPT.

RESSURE AND FLOW

P

GAS STREAM LIQUID STREAM

I

NSTALLATION

MAXIMUM
PRESSURE

MAXIMUM FLOW
MINIMUM FLOW

Adapter Ring

Clamp

Flow Chamber

Sample Inlet/Outlet
1/2 NPT Female

Gland

50 psig (345 kPa) 50 psig (345 kPa)

2 cfm (60 L/min) 5 gal/min (6 L/min)
dependent on desired response

1.5 gal/min (6 L/min)

time

.75

[19]

4.5

[127]

Mounting Holes
.219 [6] DIA

DIMENSIONS

Inch

[mm]

4.0

[102]

Figure 2-7 Rechargeable Sensor with Gland and In-Line Flow Assembly

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ODEL

7003D O

XYGEN MONITOR

Sample In To drain or process

stream

Figure 2-8. Preferred Installation Orientation of Rechargeable Sensor and In-Line

Flow Assembly

2.4.3 I

NSTALLATION OF SENSOR AND SUBMERSION KIT

The Submersion Assembly permits placing the sensor at depth in an open or closed
vessel. The Submersion Assembly provides a convenient means of mounting the
sensor, and also affords protection for the sensor cable connection, a feature
particularly desirable in high-humidity environments.

For liquid sample stream, it is recommended that the submersion assembly be
mounted in horizontal position, as shown in Figure 2-10. This arrangement prevents
entrapment on the membrane of gas bubbles which could cause erroneous oxygen
readings.

For installation made during plant construction, a swing-arm piping arrangement
installed in the side of the tank has proved most satisfactory. The sensor cable is led
from the sensor through the supporting pipe. A junction box located in a manhole on
the deck beside the aeration vessel may be included optionally to facilitate pulling of
the cable. Permanently installed conduit carries the sensor cable to the amplifier,
which may be located in any convenient building or protective enclosure. Figures 2­11 and 2-12 illustrate typical installations.

OUNTING IN GASEOUS SAMPLE STREAM

M

For gaseous samples, the submersion assembly may be oriented horizontally or
vertically.

PERATING PRESSURE

O

Maximum permissible operating pressure is 50 psig (345 kPa), equivalent to a water
depth of approximately 100 feet (approximately 30 m).

IQUID SAMPLE FLOW

L

For liquid sample streams, velocity of the liquid past the sensor tip must be at least

1.5 feet per second (45 cm/sec) for flow-independent oxygen readout.

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July 1997

748054-J

I

Adap

g

A

y

NSTALLATION

OUNTING CHAMBER

M

The chamber is mounted to 3/4 inch pipe (customer supplied), which the sensor
cable is fed through. See Figures 2-9 and 2-10.

NSTALLING SENSOR

I

1. Remove the clamp and adapter ring from the flow chamber.

2. Insert the sensor (with gland) into the flow chamber.

3. Replace the adapter ring and clamp.

ENSOR CABLE

S

In a permanent installation, the sensor cable is normally routed through a customer­supplied conduit, which screws into the 3/4 inch NPT connection on the submersion
assembly.

In applications where the sensor cable is not housed in conduit, the cable connector
accessory (PN 856832) may be used. This separately ordered item provides
watertight sealing to prevent leakage around the cable. The connector is
constructed of aluminum and includes a inner sealing grommet and compression
nut.

2.0

[51]

Chamber
Ring Clamp

ter Rin

1.9

[48]

Aluminum Cable Connector
(Accessory)

7.4

[187]

Submersion

ssembl

3.4

[86]

Figure 2-9. Rechargeable Sensor with Submersion Assembly

2.9

[73]

3/4 - 14 NPT

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July 1997

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ODEL

7003D O

Customer supplied 3/4 inch pipe

XYGEN MONITOR

Sensor Cable to Oxygen Monitor

Submersion Assembly horizontal

1. Preferred orientation in liquid sample stream.

2. Orientation in gaseous sample may be either horizontal or vertical.

Internal Sensor membrane

vertical

Figure 2-10. Typical Installation of Rechargeable Sensor and Submersion Assembly

Manhole

Cable to Oxygen Monitor

Submersion Assembly

Diffuser

Pipe and fittings to s ui t installation

Chain to Deck
Level

Figure 2-11. Typical Permanent Installation of Rechargeable Sensor with

Submersion Assembly During Plant Construction

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Rosemount Analytical

July 1997

748054-J

I

NSTALLATION

Handrail

Cable to Oxygen Monitor

Pipe and fittings to s ui t installation

Diffuser

Capped pipe clamped to handrail

Union (loose to act as swivel)

Submersion Assembly

Chain to
Handrail

Figure 2-12. Typical Installation of Sensor/Submersion Assembly in an Existing

Plant

2.5 SENSORS - NON-RECHARGEABLE

2.5.1 C

ONVERSION OF OXYGEN MONITOR FROM USE WITH RECHARGEABLE

ENSOR TO USE WITH NON-RECHARGEABLE SENSOR

S

The 7003D monitor is shipped from the factory configured for use with a
rechargeable sensor. To convert the instrument for use with a non-rechargeable
sensor, a Non-Rechargeable Sensor Conversion Kit must be installed. The
Conversion Kit changes the gain of the monitor to match the output current available
from the non-rechargeable sensor. Follow the instructions supplied in the kit.

2.5.2 I

NSTALLATION OF SENSOR AND IN-LINE FLOW ASSEMBLY

This kit consists of a non-rechargeable oxygen sensor designed for analysis of
gaseous oxygen samples, a flow chamber and associated nut, a universal mounting
bracket, a connecting cable to connect the monitor to the sensor, and appropriate
loose hardware (see Figure 2-13). The PVC flow chamber is designed for use with a
non-rechargeable oxygen sensor when a flowing gas stream with discharge of the
effluent from the flow chamber at atmospheric pressure is being measured. This
requirement means that upstream sample pressure reduction must be performed on
the process sample from a pressurized source before it is presented to the flow
chamber for analysis by the sensor. Sample input flow rate should be selected in the
range of 50 to 100 cc/min and care must be taken with downstream pressure drops
to prevent back pressurization of the sensor.

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ODEL

7003D O

OUNTING THE FLOW CHAMBER

M

XYGEN MONITOR

Refer to Figure 2-15. The preferred mounting configuration of the sensor is with the
electrical connector at the top of the flow chamber/sensor assembly. Operation in
the horizontal plane is also possible. To facilitate mounting the flow chamber to a
bench surface, wall or pipe, employ the universal mounting bracket included as part
of the kit. The flow chamber has one port which should be capped off with the fitting
cap supplied in the kit. The port to be capped is determined by the user, depending
on the particular application.

NSTALLING THE SENSOR

I

The sensor is inserted into the flow chamber to form a face seal on the front of the
sensor with the O-ring present in the bottom of the flow chamber. The nut is then
placed over the connector end of the sensor and tightened hand tight to form a seal
on the face of the sensor.

AS CONNECTIONS

G

Sample inlet and outlet connections are 1/8-inch NPT. Normally, sample is supplied
at slightly above ambient pressure by use of a customer supplied needle valve which
provides the necessary pressure and flow adjustment to the desired 50 to 100 cc/min
flow rate level.

2.5.3 I

NSTALLATION OF SENSOR WITH SUBMERSION ASSEMBLY

This kit consists of a non-rechargeable oxygen sensor for gas phase oxygen
measurements, a head space submersion assembly, and assorted required loose
hardware (see Figure 2-15). It is intended for use when the gas phase sensor is to
be inserted through a vessel wall as in the monitoring of a process vessel head
space or when a large diameter process is being monitored directly by insertion of
the sensor through the pipe.

OUNTING THE SUBMERSION ASSEMBLY

M

Refer to Figure 2-15. The sensor installs in the submersion assembly by placing the
doughnut shaped thin rubber gasket on the connector side of flange of the oxygen
sensor by gently slipping it over the sensor body and then connecting the cable to
the cable sensor using the mating connectors. The end of the cable emerging from
the threaded portion of the submersion assembly should then be gently pulled to
seat the sensor within the receiving cavity of the submersion assembly. At this point,
the cap should be placed over the front end of the submersion assembly and then
screwed down snugly. At this point the blue silicone rubber plug has moved with the
cable and is now no longer seated in the threaded portion of the submersion
assembly. Hold the cable securely and move the plug back into the submersion
assembly until it is firmly seated.

The submersion assembly is now ready to be connected to the 3/4-inch pipe in a
manner dictated by the local installation requirements. See Figure 2-16.

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July 1997

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I

NSTALLATION

ENSOR CABLE

S

In permanent installations the sensor cable is normally routed through a customer
supplied conduit, which screws into the 3/4-inch NPT connection at the end of the
submersion assembly.

PERATING PRESSURE

O

Maximum operating pressure is 50 psig (345 kPa).

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July 1997

Rosemount Analytical

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ODEL

7003D O

XYGEN MONITOR

Cable

Nut

Fitting, Plug

1/8MPT SS

Flow Chamber

2.1

[54]

10-32 x 1/2" DP
2 Places

2.5

[64]

Fitting (2 ea.)
Male Connector
1/8T - 1/8MPT SS

O-Ring

Bracket Mounting
Hardware (2 ea.):
Screw 10-32 x 5/8
Lock Washer No. 10
Flat Washer No. 10

4.8

[122]

2.6

[67]

3.8

[97]

5.2

[133]

.5

[13]

.2 [5] DIA

.7

[18]

.5

[12]

.2

[5]

2 Holes

.1

[2]

1.1

[28]

.3

[8]

.7

[17]

Figure 2-13. Dimensions and Components of Non-Rechargeable Sensor with In-Line

Flow Kit

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July 1997

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p

LIQUID GAS

I

NSTALLATION

To

Drain

or

Process

Preferred orientation
of In-Line Flow
Assembly

Sample

In

To

Drain

or

Process

Preferred orientation
of In-Line Flow
Assembly

Sample

In

Figure 2-14. Typical Installation of Non-Rechargeable Sensor with In-Line Flow Kit

2.0
[51]

Grommet/Plug

1-11 1/2NPT

ter

Ada

Cable

5.7

[146]

Nut

Gasket

1.0

[25] 2.3

[57]

Figure 2-15. Dimensions and Components of Non-Rechargeable Sensor with

Submersion Kit

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ODEL

7003D O

XYGEN MONITOR

A. INSTALLATION DURING PLANT CONSTRUCTION

Manhole

Cable to Oxygen Monitor

Pipe and fittings to suit
installation.

B. INSTALLATION IN EXISTING PLANT

Handrail

Cable to Oxygen Monitor

Diffuser

Diffuser

Chain to
Deck Level

Sensor/Submersion Assembly

Capped Pipe Clamped

Union (loose to act as

Chain to
Deck Level

Pipe and fittings to suit
installation.

Sensor/Submersion Assembly

Figure 2-16. Typical Installation of Non-Rechargeable Sensor with Submersion Kit

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S

TARTUP AND CALIBRATION

3

Prior to startup and calibration, familiarization with Figure 3-1 is recommended. This
figure gives locations and brief descriptions of operating controls and adjustments on
the display board.

3.1 SYSTEM STARTUP

After completing the installation per Section 2, proceed as follows:

1. On the Display Board (refer to diagram inside door and Figure 3-1):
a. Select potentiometric output fullscale range by placing output/alarm switch S3

in ON position. Choices are 0 to 25%, 0 to 10%, 0 to 5%, and 0 to 1%
oxygen.

b. Select potentiometric output fullscale voltage by placing output volts switch S2

in ON position. Choices are 0 to 1, 0 to 5, and 0 to 10 volts, fullscale.

c. Set alarm switches S4 and S5 to OFF position, to avoid activating either alarm

before setpoints and deadbands have been adjusted (Section 3.3).

2. Turn on line power.

3. Wait for a suitably stable reading on the digital display. The time required by the
user for stabilization of the sensor to levels of perf ormance where the stability of
the sensor meets the requirement of a particular user is defined as the
equilibration time, that is, the time when the sensor is said to be equilibrated.
Normal operation of the analyzer involves adjustments of only the front-panel
controls: ZERO and SPAN, and RANGE Switch, if provided. See Figure 1-1.

3.2 CALIBRATION

ENSOR

S

Each sensor has an individual residual current that must be zeroed out by
adjustment of R52 on the Display Board. The sensor is purged with nitrogen gas
until a stable reading is obtained. Adjust R52 for a zero reading. This adjustment is
required each time a new or recharged sensor is installed.

After the sensor has stabilized, the instrument is ready for calibration. Perform the
procedure in Section 3.2.1 or 3.2.2, as appropriate.

ESIDUAL CURRENT ZEROING

- R

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7003D O

XYGEN MONITOR

3.2.1 C

ALIBRATION WITH AIR

Calibration with dry air is the preferred method, applicable in all situations. The most
convenient source of dry air, when available, is a cylinder of compressed air. It is
important, however, to know the actual oxygen content of the cylinder. Cylinder
compressed air is frequently a prepared blend of O2 and N2, and is not necessarily
labeled as such. U.S. Government standards require only that cylinders labeled
"air" contain between 19% and 23% oxygen.

To determine oxygen content, request an analysis when purchasing the cylinder air.
Another way to determine oxygen content is to pass ambient outdoor air through an
efficient drier on the way to the analyzer, preferably using a diaphragm-type pump.
The concentration of oxygen will then be very close to 21%.

1. On the Display Board, set RANGE switch S7 at 25%, expose sensor to suitable
dry air at ambient atmospheric pressure.

2. Change RANGE switch to CAL position, wait for display reading to stabilize.
Then adjust CAL control (disregard decimal point) to bring display reading to:

760 X % O2 in sample

20.95

In most situations. ambient air may be used in place of the recommended dry air.
Only in instances where temperature and relative humidity are high will significant
errors be introduced through the use of ambient air. At a near-sea-level barometric
pressure, errors are less than 2% for relative humidity under 40% and temperatures
below 95°F (35°C). At 60% relative humidity, ambient air temperatures as high as
82°F (27.8°C) produce a maximum error of 2%. As a rule-of-thumb. dry air should
be used for calibration where ambient temperature exceeds 80°F (26.7°C) and/or
relative humidity exceeds 60%. For calibration with ambient air, the procedure is the
same, except that the sensor is exposed to ambient air instead of dry air.

3.2.2 C

ALIBRATION WITH SPAN GAS

1. Set RANGE switch S7 to 25% or 19.99%, depending upon concentration of span
gas, and expose sensor to span gas, exhausting to ambient pressure.

2. W ait for reading to stabilize, then adjust CAL control to bring display reading to
known concentration of span gas.

3.3 SELECTION OF ALARM RANGE, SETPOINT, AND
DEADBANDS

1. Select alarm fullscale range by placing one slide of output/alarm switch S3 in ON

position. Choices are 0 to 25%. 0 to 10%, 0 to 5% and 0 to 1% oxygen. Refer to
diagram on inside of door.

2. The HI ALARM and LO ALARM setpoint potentiometers are adjustable from 0%

to 100% of the fullscale span. The potentiometers are graduated from 0 to 100.
Required potentiometer setting for either setpoint adjustment is determined from
the equation:

required potentiometer setting = desired alarm reading x 100 fullscale span

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Rosemount Analytical

July 1997

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19.99 25 CAL

A

S

TARTUP AND CALIBRATION

LOW ALARM
INDICATOR LED
CR1

LOW ALARM
SETPOINT ADJUST
R43

LOW ALARM
DEADBAND ADJUST
R44

SENSOR CONVERSION
HEADER
J5

RANGE SWI T CH S7

CAL CONTROL R14

AMPLIFIER ZERO R46

DISPLAY SPAN R24

RESIDUAL ZERO CONTROL R52

HIGH ALARM
INDICATOR LED
CR2

HIGH ALARM
SETPOINT ADJUST
R40

HIGH ALARM
DEADBAND ADJUST
R41

AUTO OFF ON

OUTPUT VOLTAGE

LOW ALARM SWITCH

SWITCH S2

S4

OUTPUT/ALARM
SWITCH S3

Figure 3-1. Display Board

S2

OFF ON

S3

OFF ON

E OUT

LARM

AUTO OFF ON

HIGH ALARM
SWITCH S5

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July 1997

Rosemount Analytical

3-3

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ODEL

7003D O

EXAMPLE:

XYGEN MONITOR

Alarm range, 0 to 25%; desired Hi Alarm setpoint, 20%; desired Lo Alarm
setpoint, 15%

required Hi ALARM setting = x 100 = 80
required LO ALARM setting = x 100 = 60

20
25

15
25

1. Select the desired deadband. The HI ALARM and LO ALARM deadband

potentiometers are adjustable from 1% of fullscale (counterclockwise limit) to
20% of fullscale (clockwise limit). Deadband is essentially symmetrical with
respect to the setpoint.

2. When setpoints and deadbands have been selected, set alarm switches S4 and

SS to the AUTO position, to activate the alarms.

3. T o test external alarm devices, temporarily set alarm switch S4 or S5 in the ON

position. The associated alarm is then unconditionally on.

3.4 CURRENT OUTPUT RANGE

Select 0 to 20 or 4 to 20 milliamperes to be minimum current for isolated current
output (if present).

1. On the Display Board (Figure 3-1), set RANGE switch S7 to CAL position.

2. With power OFF, disconnect anode and cathode leads from terminal strip TB2 on

the Power Supply Board (Figure 2-1). Secure the leads so that they will not
contact any board or component.

3. Turn power ON. On the Display Board (Figure 3-1), adjust residual ZERO control

R52 until potentiometric output device indicates 0 volt.

4. On the Isolated Current Output Board, adjust ZERO control R1 (Figure 3-2) so

that current output device indicates the low range-limit desired for the output
range: 0 milliamperes or 4 milliamperes.

5. Turn power OFF. If sensor is rechargeable, connect a 10K ohm resistor between

the anode and the cathode terminals on the Power Supply Board terminal strip
TB2 (Figure 2-1). If sensor is non-rechargeable, connect a 320K ohm resistor
across TB2. This resistor permits the polarizing voltage supply to provide a small
current that simulates the sensor output signal.

6. Turn power ON. On front panel controls, adjust CAL clockwise to produce a

fullscale reading on the potentiometric output device.

7. On the Isolated Current Output Board (Figure 3-2), adjust SPAN control R2 for

reading of 20 milliamps on current output device.

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Rosemount Analytical

July 1997

748054-J

ZERO
R1

SPAN
R2

S

TARTUP AND CALIBRATION

R
1

C1

U1 J1
R
2

CR

R3

R8

R4

R5 R6

R9

U6

CR2

U2

U3

O
G

I

1 2 3 4

Figure 3-2. Isolated Current Output Board

C4

C5

C2

U4

I G O

C3

I
G
O

U5

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Rosemount Analytical

3-5

M

ODEL

N

OTES

7003D O

XYGEN MONITOR

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July 1997

748054-J

O

PERATION

4

4.1 ROUTINE OPERATION

After startup and calibration (Section 3) the monitor will automatically and
continuously indicate the oxygen concentration of the sample.

If potentiometric output or alarms are used on the 0% to 1% oxygen range after
calibration at 20.95% oxygen, an appropriate interval is needed to permit the sensor
to equilibrate to a low concentration of oxygen. The time required for equilibration
depends upon how long the sensor was operated at the higher oxygen level. Thus, a
sensor which has been in operation on air for 24 hours prior to calibration will
typically show a reading of 0.05% oxygen, or less within one hour after exposure to
pure nitrogen. This reading will decrease to 0.01% or so within the next few hours.

Inability to obtain a low-level oxygen reading in a gas of known low-level oxygen
content usually indicates a leak in the sample system. To check this possibility,
increase sample flow rate, block off the flow of gas into and out of the flow chamber,
and note the response of the oxygen monitor. An increase in reading, with time,
indicates a leak in the system. If the re is no leak in th e system, anoth er possibility is
that a rechargeable sensor should be rejuvenated or that a disposable sensor should
be replaced. The procedure for sensor rejuvenation, which is outlined in Section Six,
must be followed carefully if satisfactory results are to be achieved.

4.2 RECOMMENDED CALIBRATION FREQUENCY

For the first few days of operation the instrument should be calibrated daily to
compensate for initial stabilization of the membrane in the sensor.

After the sensor has stabilized, an instrument in continuous operation should be
calibrated at least once a week until the appropriate calibration interval is
determined. A log of periodic calibrations helps establish desired calibration intervals
for given applications.

4.3 FREQUENCY OF SENSOR RECHARGING

Nominal useful life of a sensor charge is approximately three to six months; after this
time, the sensor should be removed from the installation and recharged. Refer to
Section 6.1.1. Physical damage to the membrane is the most frequent cause of
failure for service periods less than three months. Proper handling and installation of
the sensor into the sample system are essential.

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ODEL

7003D O

XYGEN MONITOR

The service life of a disposable 0xygen sensor is application-dependent and no
rejuvenation or recharging is possible. It is difficult to determine the prospective shelf
life of the disposable oxygen sensor, since no time related failure mechanisms are
apparent at this time.

4-2

Rosemount Analytical

July 1997

748054-J

T

HEORY

5

The Model 7003D Oxygen Monitor system consists of an amperometric oxygen
sensor and an amplifier unit interconnected by a multi-conductor shielded cable. The
sensor responds to the partial pressure of oxygen. The amplifier conditions the
sensor signal, providing a readout of oxygen in percent by volume.

The following Sections detail the major principles of operation. Section 5.2 describes
variables that influence the oxygen measurement.

5.1 ELECTROCHEMICAL THEORY

With the sensor placed in the process stream, a voltage is applied across the
cathode and anode (see Figure 5-1). Oxygen in the process stream diffuses through
the membrane and is reduced at the cathode. The reduction of oxygen results in a
current flow proportional to the partial pressure of oxygen in the sample.

When oxygen is not present, no electrical current flows in the sensor. When oxygen
is present, electrical current flows in the sensor according to the characteristic curve
for the particular potential applied to the electrodes. The magnitude of the current
depends upon the partial pressure of the dissolved oxygen in the sample.

CABLE
CONNECTOR

THERMISTOR

BODY

ELECTROLYTE

CAP

O-RINGS

MEMBRANE

Figure 5-1. Rechargeable Oxygen Sensor - Sectional View

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ANODE

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5.2 VARIABLES INFLUENCING OXYGEN MEASUREMENT

Since the amperometric oxygen sensor responds to the partial pressure of oxygen,
any variable that affects that partial pressure should be taken into account to ensure
accurate measurement in the desired units. The two basic variables involved are
barometric pressure and relative humidity.

Since dry air contains 20.95% oxygen by volume, regardless of barometric pressure,
the partial pressure of oxygen is directly proportional to the total barometric pressure,
according to Dalton's law of partial pressures. Thus for dry air, if the total barometric
pressure is known, the partial pressure of oxygen can be computed. However, the
procedure is valid only for dry air. Humid air has the effect of reducing the partial
pressure of oxygen and the other gases in the air without affecting the total
barometric pressure. Another way of expressing this relationship is by the following
equation:

P (atm) = P (gas)+ P (oxygen) + P (water)

where:

P (atm) = total barometric pressure
P (gas) = partial pressure of all gases other than oxygen and water vapor
P (oxygen) = partial pressure of oxygen
P (water) = partial pressure of water vapor

Thus, for constant barometric pressure, if the humidity in the air is not zero, the
partial pressure of oxygen is less than the value for dry air. For most measurements
taken below 80°F (26.7°C) and below 60% RH, the effect of water vapor may be
ignored.

At a barometric pressure of 760 mm Hg (101 kPa), the partial pressure of oxygen in
dry air is approximately 160 mm Hg (21.1 kPa).

To determine the partial pressure of oxygen in air at various levels of humidity and
barometric pressure. the partial pressure of water is subtracted from the total
barometric pressure: this difference is then multiplied by 20.95%.

EXAMPLE

barometric pressure = 740 mm Hg (98.5 kPa)

5-2

partial pressure H20 = 20 mm Hg ( 2.7 kPa)
partial pressure O

Rosemount Analytical

= (740-20) x 0.2095 mm Hg = 151 mm Hg (20.1 kPa)

2

July 1997

748054-J

R

OUTINE SERVICE AND TROUBLESHOOTING

6

Most service and maintenance problems involve the sensor. Failures within the
amplifier unit are less frequent. In system checkout, the recommended procedure is
first to isolate the amplifier from the sensor, then perform a few simple tests to
determine if the amplifier is performing satisfactorily. The sensor can be checked and
then recharged, rejuvenated, or replaced, as necessary.

6.1 RECHARGEABLE SENSORS

Most routine maintenance involves the sensor. Sensor maintenance consists of
periodic recharging and cleaning, or rejuvenating the sensor cathode. The usual
indication that the sensor requires rejuvenation and recharging is that, during
calibration. the correct upscale reading is unobtainable by adjustment of the CAL
control. Normally, the inability to calibrate is preceded by a gradual, day-to-day
reduction in sensor output, with a resultant lower instrument indication. The rate
of reduction increases with the increase in internal resistance of the sensor.
Other indicators of need for rejuvenation may be sluggish response or the
presence of an appreciable residual signal when the sensor is exposed to a zero
reference sample.

Note
If sensor is disassembled for inspection, it must be recharged utilizing

a new membrane.

Normally, the sensor should be recharged with fresh electrolyte at three-month
intervals. However, the interval may be extended, depending upon the application
in which the sensor is used. In general, correcting a low output can be
accomplished by recharging with fresh electrolyte, as described in Section 6.1.1.
If output still remains low, or the other symptoms exist, the gold cathode should
be rejuvenated as described in Section 6.1.2.

In event of "spiking," i.e., non-oxygen-related transient response, the accessory
Cell Separator Kit is recommended. Refer to Section 6.1.3.

6.1.1 R

ECHARGING SENSOR

The sensor must be removed from the process installation and disconnected
from the sensor cable for recharging.

The recharging kit consist of electrolyte, membranes, pressure-compensating
rubber diaphragms, O-rings for the membrane retainer, O-rings for the sensor
body, and washers for the diaphragms.

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7003D O

CAP

XYGEN MONITOR

MEMBRANE

RETAINER

CELL SEPARATOR
(Accessory)

HOLDER

O-RING

BREATHER
HOLE

CATHODE

O-RING

DIAPHRAGM

WASHER

DIAPHRAGM
SCREW

Figure 6-1. Rechargeable Sensor - Exploded View

ECHARGEING PROCEDURE

R

For this procedure refer to Figure 6-1.

1. Unscrew knurled cap from end of sensor body. Remove membrane assembly,
consisting of membrane fixed between holder and retainer. Empty all
electrolyte from sensor. Flush sensor with distilled or deionized water to
remove all particulate matter.

2. Place a piece of adhesive tape over the breather hole in the pressure
compensation diaphragm port (not the slotted fill plug).

3. Examine cathode for:
a. Staining or uneven coloration. which indicates that the cathode should be

rejuvenated as described in Section 6.1.2.

b. Any deposited material, typically white to gray. present in or around the

grooves in the plastic surrounding the cathode. This must be removed to
ensure best operation. Most of these deposits are water-soluble and may
be removed by a water jet from a squeeze bottle. Any insoluble deposits in
the annular and channel grooves may be removed with a toothpick;
however, care must be used to avoid deforming the grooves.

4. Disassemble the membrane assembly. This consists of a plastic membrane, a
holder, a retainer, and an O-ring. Remove retainer from holder by placing
finger into center hole of holder and pressing fingernail against inner edge of
retainer. Remove and discard the old membrane.

5. Verify that O-ring is properly positioned in associated groove in holder.

6-2

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July 1997

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!

OUTINE SERVICE AND TROUBLESHOOTING

6. Holding a single membrane by the edges only, place it across membrane
holder and snap retainer in place. Membrane is now fixed in proper position,
between holder and retainer.

CAUTION: CONTAMINATION

Never touch center area of membrane with fingers. Membranes are
easily contaminated with foreign substances. Contaminated
membranes cause drifting or erratic readings.

7. Using a sharp razor blade, carefully trim away excess membrane around edge
of membrane assembly. Take care that razor blade does not cut into edges of
membrane assembly.

8. Set sensor body on a flat surface, with cathode facing upward. Verify that
O-ring in groove at end of sensor body is properly positioned around cathode.
Pour the electrolyte over the cathode/central post assembly so that it runs
down into the sensor electrolyte well. Fill the well to a le vel flush with the top
of the sidewall.

Put the membrane assembly directly onto the cathode so that the face of the
holder (i.e., the part with the larger-diameter central hole) fits against the
O-ring in the end of the sensor body.

The membrane is now in place. It will spread any electrolyte remaining on the
cathode into a thin film that wets the entire surface. The membrane assembly
should now be centered over the cathode.

9. Taking care not to disturb the central orientation of the membrane assembly,
carefully place the cap on the sensor body. Screw the cap on, fingertight only.
Then lay the sensor on its side, with the side port up. Remove side port
screw, rubber pressure-compensating diaphragm, and washer. Add
electrolyte, if necessary, to bring the level into the side port and then rock the
sensor from end to end to remove any air pockets. Add electrolyte, if
necessary, to bring the level even with the shoulder. With the side port still
facing up, tighten the cap further until it is snug, and the membrane is
stretched taut across the cathode. Any excess electrolyte displaced from the
electrolyte well into the side port may now be removed by blotting with a
tissue.

10. Insert new rubber diaphragm into side port, place new washer over
diaphragm, and secure with side port screw. Do not overtighten screw.

11. Inspect sensor for possible leaks or damage to membrane.

12. Remove the adhesive tape installed in Step 2 from the pressure
compensation port.

748054-J

Sensor is ready for operation. Connect cable. If sensor does not operate properly
refer to Section 6.3.

If normal operation is not obtained with the specified recharging procedure,
perform rejuvenation, as detailed in Section 6.1.2.

July 1997

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6.1.2 R

EJUVENATING CATHODE

If simple recharging does not correct symptoms of low output, clean and/or
rejuvenate the cathode as follows:

WARNING: CORROSIVE MATERIAL

Concentrated nitric acid is used in the following procedure. This
material is highly corrosive. Avoid contact with skin, eyes, clothing,
and precision instrument parts. Use rubber gloves and eye protection.
If body contact occurs, flush copiously with water and seek medical
attention.

1. Disassemble sensor. Remove cap and membrane assembly. Discard the used
electrolyte. Flush the sensor with distilled or deionized water to remove all particulate
material.

2. Over a sink, use a cotton swab to treat the cathode with concentrated reagent grade
nitric acid, obtainable from a laboratory supply house. Submerge the tip of the swab
in the nitric acid. Press the swab against the side of the nitric acid container to
remove excess acid. Swab the cathode ar ea lig htly for five minutes.

3. Take care to confine the nitric acid to the button area. Only a thin film of nitric acid
should be present on the surface of the cathode during the cleaning operation.
Excessive application may result in the destruction of the epoxy annulus surrounding
the button, with resultant sensor failure.

4. Rinse the button and sensor cavity thoroughly with distilled or deionized water. Then
rinse the sensor with electrolyte by pouring it over the cathode into the sensor cavity
until it is filled. Discard this electrolyte.

5. Recharge the sensor in the normal fashion.

If normal operation is not obtained with the specified rejuvenation procedure, the sensor
is depleted and must be replaced.

6.1.3 C

The cell separator is used to eliminate "spiking," i.e., non-oxygen-related transient
response on the analyzer output.

This condition is usually caused by r eaction pr oducts w hic h slough off the anode and are
transported to the cathode surface, where they are reduced. During reduction, the anode
accepts electrons, resulting in the undesired transi ent response.

The condition may be corrected by installing a separator disk which mechanically
separates the cathode and anode (see Figure 6-1). The kit contains ten disks.

To install the separator in an oxygen sensor, remove the cap and membrane holder.
pour out the electrolyte, and position the hole in the separator over the cathode post.
Then gently push the separator down into the sensor body until it rests on top of the
anode. Fill the sensor with fresh electrolyte and reassemble in the conventional manner.

ELL SEPARATOR KIT

6-4

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July 1997

748054-J

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OUTINE SERVICE AND TROUBLESHOOTING

6.2 NON-RECHARGEABLE SENSORS

The non-rechargeable sensor has no user accessible internal parts. No sensor
maintenance is possible other than gentle brushing to remove deposits on the
face of the sensor to restore its sensitivity and response time.

If the performance of the sensor has degraded beyond acceptable limits, it must
be replaced.

6.3 TROUBLESHOOTING

The most frequent fault is a progressive development of insensitivity of the
sensor. During calibration, the CAL control must be turned farther and farther
clockwise to set the meter to the desired calibration value. Finally, after several
months of operation, rotating the CAL control to its clockwise limit fails to bring
the meter to the desired calibration setting.

The cause of this characteristic change is the gradual exhaustion or occlusion of
the sensor. Accordingly, the sensor must be maintained as described in Section

6.
System problems can be isolated to the sensor or the amplifier by the following

procedure:

1. Disconnect AC power from the instrument.

2. Set alarm switches S4 and S5 (Figure 3-1) to OFF position.

3. On TB2 (Figure 2-1) make following connections:
a. Disconnect all leads of sensor cable.
b. Connect a 10K ohm resistor across the three l0K THMS terminals. This

resistor simulates the resistance of the thermistor at 25°C.

c. If the sensor is rechargeable, connect a 10 K ohm resistor across

terminals marked AN (for anode) and CATH (for cathode). If the sensor is
non-rechargeable, connect a 320 K ohm resistor across the terminals. This
resistor permits the polarizing voltage supply to provide a small current
that simulates the sensor output signal.

4. Set RANGE switch to CAL (Figure 3-1).

5. Rotate CAL control throughout its range to verify that the outputs of the
instrument respond from near zero to above fullscale.

If test yields correct results, amplifier is operational. The fault is in sensor or
cable. Remove 10 K ohm resistors from TB2 and proceed to tests given in
Section 6.3.1 or 6.3.2.

If these tests do not yield correct results, contact a factory authorized service
representative.

6.3.1 C

For convenience, the sensor cable may be regarded as part of the sensor.
Accordingly, electrical checks are made at the terminal ends of the cable,

748054-J

HECKING RECHARGEABLE SENSOR AND CABLE

July 1997

Rosemount Analytical

6-5

M

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7003D O

XYGEN MONITOR

disconnected from the amplifier at TB2. Verification of electrical integrity of the
sensor is determined by making the following checks with an ohmmeter:

1. Resistance between white and green leads should be 10 ohms +1% at 25°C
(approximately 30 ohms at 0°C, and 4 ohms at 50°C). Readings from white or
green lead to any other lead of the sensor cable should indicate open circuit,
or at least 100M ohms. Readings less than this indicate a shunt resistance
path which produces an error in the measurement.

2. The black and white lead is connected to the grounding shield. Readings from
this lead to any other lead of the sensor cable should be at least 100M ohms.

3. If checks in Steps I or 2 indicate trouble, or if other symptoms indicate the
sensor to be faulty, determine the probable cause by reference to the
appropriate symptom(s) in Table 6-1. This table is a compilation of the most
common sensor problems.

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Abnormally high oxygen readings

Hole in sensor membrane Replace membrane

(unable to calibrate)

Gold cathode loose Replace sensor
Open thermistor Replace sensor

Abnormally low oxygen readings
(unable to calibrate)

High internal cell
resistance

Rejuvenate/recharge
sensor

Membrane too loose Tighten cap or replace

membrane
Contaminated electrolyte1Clean/recharge sensor
Thermistor shorted Replace sensor

Sensor noisy (motion sensitive) Membrane loose Replace membrane

Low electrolyte level Fill properly
Cathode contaminated

1

Rejuvenate/recharge

sensor

Upscale reading with known

Gold cathode loose Replace sensor

oxygen-free sample
Slow response (sluggish) Contaminated electrolyte1Rejuvenate/recharge

sensor

Table 6-1. Rechargeable Sensor Troubleshooting Guide

1

"Contamination" may be the normal accumulation resulting from long-term operation, indicative that the

standard cell-rejuvenation procedure is required.

6-6

Rosemount Analytical

July 1997

748054-J

R

OUTINE SERVICE AND TROUBLESHOOTING

6.3.2 C

HECKING NON-RECHARGEABLE SENSOR AND CABLE

To check the cable disconnect it from the monitor and the sensor. The resistance
between any two leads should be at least 100 M ohms. A continuity check on any
lead should produce a reading of less than 15 ohms per thousand feet.

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Abnormally high oxygen readings Hole in sensor membrane Replace sensor
(unable to calibrate) Open thermistor Replace sensor

Cell contaminated Replace sensor
Abnormally low oxygen readings Thermistor shorted Replace sensor
(unable to calibrate) Membrane surface dirty Clean front surface
Upscale reading with known

oxygen-free sample (greater than

0.1% O2 or equivalent)

Sensor contaminated Adjust sensor zero

control
Check linearity with

standards

Slow response (sluggish) Contaminated electrolyte1Replace sensor

Table 6-2. Non-Rechargeable Sensor Troubleshooting Guide

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July 1997

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!

EPLACEMENT PARTS

7

WARNING: PARTS INTEGRITY

Tampering or unauthorized substitution of components may adversely
affect safety of this product. Use only factory documented components
for repair.

7.1 CIRCUIT BOARD REPLACEMENT POLICY

In most situations involving a malfunction of a circuit board, it is more practical to
replace the board than to attempt isolation and replacement of the individual
component, as the cost of test and replacement will exceed the cost of a rebuilt
assembly. As standard policy, rebuilt boards are available on an exchange basis.

Because of the exchange policy covering circuit boards, the following list does not
include individual electronic components. If circumstances necessitate replacement
of an individual component, which can be identified by inspection or from the
schematic diagrams, obtain the replacement component from a local source of
supply.

7.2 REPLACEMENT PARTS

858728 Arc Suppressor
637358 Cell Separator Kit (10 separator disks)
622529 Display Board
777156 Fuse, 1/4 A - 120 VAC (Package of 5)
777360 Fuse, 1/8 A - 240 VAC (Package of 5)
620433 Isolated Current Output Board (Option)
622621 Pipe Mounting Kit
622537 Power Supply Board
193265 Sensor Cable
191748 Sensor Cable 10'
856831 Sensor Cable Connector Accessory
191755 Sensor Recharge Kit (10 recharges)
652117 Wall Mounting Kit

1

Length specified by customer, any length up to 1000'.

748054-J

1

July 1997

Rosemount Analytical

7-1

M

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7003D O

XYGEN MONITOR

7.3 REPLACEMENT PARTS - SENSORS

7.3.1 R

ENSOR

S

ENSOR KITS (SENSOR

S

ECHARGEABLE SENSORS

:

MATERIAL PART NUMBER

Polypropylene 623371
Polypropylene 623370 (use with Fast Response Kit)
Ryton 190408
Ryton 190409 (use with Fast Response Kit)

INCLUDED

NOT

DESCRIPTION PART NUMBER USE WITH SENSOR

Submersion, Polypropylene 639904 623371
In-Line Flow, Polypropylene 639905 623371
Fast Response, Polypropylene 639906 623370
Submersion, Ryton 646628 190408
In-Line Flow, Ryton 646629 190408
Fast Response, Ryton 646630 190409

):

ENSOR KITS (SENSOR INCLUDED

S

):

DESCRIPTION PART NUMBER

Submersion, Polypropylene 400011
In-Line Flow, Polypropylene 400012
Fast Response, Polypropylene 400013
Submersion, Ryton 400021
In-Line Flow, Ryton 400022
Fast Response, Ryton 400023

7-2

Rosemount Analytical

July 1997

748054-J

R

EPLACEMENT PARTS

7.3.2 NON-R

ENSOR

S

Polypropylene 623742

ENSOR KITS (SENSOR

S

Submersion, Polypropylene 623716 623742
In-Line Flow, Polypropylene 623715 623742

ENSOR KITS (SENSOR INCLUDED

S

Submersion, Polypropylene 500011
In-Line Flow, Polypropylene 500012

ECHARGEABLE SENSORS

:

MATERIAL PART NUMBER

INCLUDED

NOT

):

DESCRIPTION PART NUMBER USE WITH SENSOR

):

DESCRIPTION PART NUMBER

748054-J

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Rosemount Analytical

7-3

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Rosemount Analytical

July 1997

748054-J

ENERAL PRECAUTIONS FOR HANDLING AND

G

TORING HIGH PRESSURE GAS CYLINDERS

S

Edited from selected paragraphs of the Compressed
Gas Association's "Handbook of Compressed Gases"
published in 1981
Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202
Used by Permission

1. Never drop cylinders or permit them to strike each other violently.

2. Cylinders may be stored in the open, but in such cases, should be protected against
extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders
should be stored in the shade when located in areas where extreme temperatures are
prevalent.

3. The valve protection cap should be left on each cylinder until it has been secured
against a wall or bench, or placed in a cylinder stand, and is ready to be used.

4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be
moved by using a suitable hand-truck.

5. Never tamper with safety devices in valves or cylinders.

6. Do not store full and empty cylinders together. Serious suckback can occur when an
empty cylinder is attached to a pressurized system.

7. No part of cylinder should be subjected to a temperature higher than 125°F (52°C). A
flame should never be permitted to come in contact with any part of a compressed gas
cylinder.

8. Do not place cylinders where they may become part of an electric circuit. When electric
arc welding, precautions must be taken to prevent striking an arc against the cylinder.

4125 E

AST LA PALMA AVENUE

Rosemount Analytical Inc.

• A
J

ULY

, C

NAHEIM

ALIFORNIA

1997 • 748525-C • P

92807-1802 • 714-986-7600 • FAX [phone]

RINTED IN

USA

(blank)

ARRANTY

W

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from
defects in workmanship and material under normal use and service for a period of twelve (12)
months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid
junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and
material under normal use and service for a period of ninety (90) days from date of shipment by
Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or
material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods,
part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid,
within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of
consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for
replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in
the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall
not operate to condemn such commercial unit when such goods, part(s) and consumables are
capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or
indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any
other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER
GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER W ARRANTIES ARE
GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN
PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL
BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD W ARRANTY CLAUSE. IN
NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S
LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY
SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT
SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL
DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS
OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND
DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE
OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR
PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE
AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH
SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.

Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond
Seller's direct control.

Rosemount Analytical

4125 E

AST LA PALMA AVENUE

Rosemount Analytical Inc.

• A

F

EBRUARY 1997 • 7485189-C • PRINTED IN USA

NAHEIM

, C

ALIFORNIA

92807-1802 • 714-986-7600 • FAX [phone]

(blank)

IELD SERVICE AND REPAIR FACILITIES

F

Field service and repair facilities are located worldwide.

U.S.A.

To obtain field service on-site or assistance with a service problem, contact (24 hours, 7
days a week):

National Response Center

1-800-654-7768

INTERNATIONAL

Contact your local Rosemount Sales and Service office for service support.

FACTORY

For order administration, replacement Parts, application assistance, on-site or factory repair,
service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

RETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when you call:

Model Number, Serial Number, and Purchase Order Number or Sales Order Number.

Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sende r, f re ight collect.

When return ing any product or compon ent that has been expo sed to a toxic, co rrosive or
other hazardous material or used in such a hazardous environment, the user must attach an
appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification that the material
has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

4125 E

AST LA PALMA AVENUE

Rosemount Analytical Inc.

• A

ULY 1997 • 748190-G • PRINTED IN USA

J

NAHEIM

, C

ALIFORNIA

92807-1802 • 714-986-7600 • FAX [phone]

(blank)

Rosemount Analytical

ATERIAL SAFETY DATA SHEET

M

748595-J

Product : O
Part No.:

XYGEN SENSOR ELECTROLYTE

192580 (1

PINT

, 474 ML)

Distributor : Rosemount Analytical Inc.
Address: 4125 East La Palma Ave., Anaheim, CA 92807-1802
Telephone: [phone]

24 HOUR EMERGENCY TELEPHONE NO.: CHEMTREC [phone]

SECTION I - GENERAL

Chemical name and synonyms :

potassium chloride/water solution

Trade name and synonyms :
Chemical family :
Formula:
CAS Number:

SECTION II - HAZARDOUS INGREDIENTS COMPOSITION

Hazardous mixtures of other liquids,
solids or gases:

SECTION III - PHYSICAL DATA

Boiling point:
Melting point:
Vapor pressure :
Vapor density (air=1) :
Specific gravity (H2O=1) :
% Volatile by volume :
Evaporation rate (H2O=1) :
Solubility in water :
Appearance and odor :

SECTION IV - FIRE AND EXPLOSION HAZARD DATA

Flash point :
Extingu is hin g me dia :
Special fi re fi g htin g pr oce dur es :
Unusual f ire and e xpl os ion haza rds :

electrolyte
metal halide salt solution
KCl + H2O (5% KCl, 95% H2O)
potassium chloride: 7447-40-7 water: 7732-18-5

none

100°C
NA
24 mm Hg

0.5
1
90+
1
water soluble
clear, odorless
solution

1

NA
NA
NA

NA

SECTION V - REACTIVITY DATA

Stability :
Conditions to avoid :
Incompatibility (materials to avoid) :
Hazardous decomposition or
byproducts :
Hazardous polymerization :

1

Is contained in the f ollowing sensors : 190404, 190408, 1 90409, 623246, 6 23370, 623371, 62 3372, 623373,

623374, 623375, 623740, 623741, 62374 2

AST LA PALMA AVENUE

4125 E

• A

stable
none
none

none

none

Rosemount Analytical Inc.

NAHEIM

ULY

J

, C

1997

ALIFORNIA

• 748595-J

92807-1802 • [phone] • FAX: [phone]

RINTED IN

• P

USA

M

ATERIAL SAFETY DATA SHEET

SECTION VI - HEALTH HAZARD DATA

Threshold limit value:
Routes of Entry:
Effects of overexposure :
Emergency & First Aid

Procedures:

NA
NA
NA
NA

SECTION VII - SPILL OR LEAK PROCEDURE

Steps to be take n in ca se material
is released or spilled :

Waste disposal method :

NA

no special requirement

SECTION VIII - SPECIAL PROTECTION INFORMATION

Respiratory protection :
Ventilation :
Protective gloves :
Eye protection :
Other protective equipment :

none
mechanical (general)
NA
safety glasses suggested
none

SECTION IX - SPECIAL PRECAUTIONS

Precautions to be taken in
handling and storing :
Other precautions:

none
none

748595-J

SECTION X. TRANSPORTATION DATA

Must be in compliance with Federal, State and Local regulations

NOTICE: WHILE ROSEMOUNT ANALYTICAL BELIEVES THE INFORMATION CONTAINED HEREIN IS VALID AND
ACCURATE, ROSEMOUNT ANALYTICAL MAKES NO WARRANTY OR REPRESENTATION AS TO ITS VALIDITY,
ACCURACY, OR CURRENCY. ROSEMOUNT ANALYTICAL SHALL NOT BE LIABLE OR OTH ERWISE RESPONSIBL E
IN ANY WAY FOR USE OF EITHER THIS INFORMATION OR THE MATERIAL TO WHICH IT APPLIES. DISPOSAL OF
HAZARDOUS MATERIAL MAY BE SUBJECT TO FEDERAL, STATE, OR LOCAL LAWS OR REGULATIONS.

Sheet 2 of 2 July 1997