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Instruction Manual

748054-L May 2003

Model 7003D

Oxygen Monitor

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ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated techni cal products, you

MUST properly install, use, and maintain them

normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

to ensure they continue to operate within their

• Read all instructions

prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical 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 Instruc- tion Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel

to install, operate, update, program,

and maintain the product.

• When replacement parts are required, ensure that qualified people use replace ment parts specified by Rosemount. Unauthorized parts and procedures can affect the product’ s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY

Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

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

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

Emerson Process Management Rosemount Analytical Inc.

Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com

http://www.processanalytic.com

Model 7003D

PREFACE...........................................................................................................................................P-1

Definitions...........................................................................................................................................P-1

Safety Summary.................................................................................................................................P-2

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

Compliances.......................................................................................................................................P-5

1-0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1

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

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

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

a. Performance....................................................................................................................1-3

b. Electrical..........................................................................................................................1-3

c. Alarm...............................................................................................................................1-3

d. Physical...........................................................................................................................1-3

e. Sensor.............................................................................................................................1-4

Instruction Manual

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2-0 INSTALLATION ....................................................................................................................2-1

2-1 Unpacking And Facility Preparation......................................................................................2-1

2-2 Location And Mounting..........................................................................................................2-1

2-3 Electrical Connections...........................................................................................................2-1

a. Line Power Connection...................................................................................................2-1

b. System Grounding Connection.......................................................................................2-1

c. Sensor Cable Connection...............................................................................................2-2

d. Output Cable Connection................................................................................................2-2

e. Output Connections for Alarms.......................................................................................2-4

2-4 Sensors – Rechargeable.......................................................................................................2-5

a. Installation of Sensor and Fast-Response Flow Kit........................................................2-5

b. Installation of Sensor and In-Line Flow Kit .....................................................................2-7

c. Installation of Sensor and Submersion Kit......................................................................2-9

2-5 Sensors - Non-Rechargeable................................................................................................2-12

a. Conversion Of Oxygen Monitor From Use With Rechargeable Sensor To Use With

Non-Rechargeable Sensor .............................................................................................2-12

b. Installation of Sensor and In-Line Flow Assembly..........................................................2-12

c. Installation of Sensor with Submersion Assembly..........................................................2-12

3-0 STARTUP AND CALIBRATION...........................................................................................3-1

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

3-2 Calibration..............................................................................................................................3-1

a. Calibration with Air..........................................................................................................3-1

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

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

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

4-0 OPERATION .........................................................................................................................4-1

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

4-2 recommended Calibration Frequency...................................................................................4-1

4-3 Frequency of Sensor Recharging..........................................................................................4-1

Rosemount Analytical Inc. A Division of Emerson Process Management Contents i

Instruction Manual

748054-L May 2003

5-0 THEORY................................................................................................................................5-1

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

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

6-0 ROUTINE SERVICE AND TROUBLESHOOTING...............................................................6-1

6-1 Rechargeable sensors...........................................................................................................6-1

a. Recharging Sensor.........................................................................................................6-1

b. Rejuvenating Cathode ....................................................................................................6-3

c. Cell Separator Kit............................................................................................................6-4

6-2 Non-Rechargeable Sensors..................................................................................................6-4

6-3 Troubleshooting.....................................................................................................................6-4

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

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

7-0 REPLACEMENT PARTS......................................................................................................7-1

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

7-2 Replacement Parts................................................................................................................7-1

7-3 Replacement Parts - Sensors................................................................................................7-2

a. Rechargeable Sensors ...................................................................................................7-2

b. Non-Rechargeable Sensors............................................................................................7-3

Model 7003D

8-0 RETURN OF MATERIAL......................................................................................................8-1

8-1 Return Of Material.................................................................................................................8-1

8-2 Customer Service..................................................................................................................8-1

8-3 Training..................................................................................................................................8-1

ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

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

Figure 1-2. Rechargeable Sensor............................................................................................ 1-2

Figure 1-3. Non-Rechargeable Sensor.................................................................................... 1-2

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

Figure 2-2. Connections for Potentiometric Recorder with Non-Standard Span..................... 2-3

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

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

Figure 2-4. Rechargeable Sensor with Fast Response Flow Assembly.................................. 2-6

Figure 2-5. Mounting Rechargeable Sensor in Fast Response Flow Assembly...................... 2-6

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

Flow Assembly.......................................................................................................2-7

Figure 2-7. Rechargeable Sensor with Gland and In-Line Flow Assembly ............................. 2-8

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

Assembly ............................................................................................................... 2-9

Figure 2-9. Rechargeable Sensor with Submersion Assembly.............................................. 2-10

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

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

Assembly During Plant Construction................................................................... 2-11

Figure 2-12. Typical Installation of Sensor/Submersion Assembly in an Existing Plant.......... 2-11

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

Flow Kit................................................................................................................ 2-14

Figure 2-14. Typical Installation of Non-Rechargeable Sensor with In-Line Flow Kit.............. 2-15

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

Submersion Kit..................................................................................................... 2-15

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

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

Figure 3-2. Isolated Current Output Board...............................................................................3-4

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

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

Instruction Manual

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May 2003

LIST OF ILLUSTRATIONS

LIST OF TABLES

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

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

LIST OF DRAWINGS

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

Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii

Instruction Manual

748054-L May 2003

Model 7003D

iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

Model 7003D

PREFACE

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Model 7003D Oxygen Monitor.

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

DEFINITIONS

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

DANGER .

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May 2003

Highlights the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

WARNING .

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.

CAUTION.

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

NOTE

Highlights an essential operating procedure, condition or statement.

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1

Instruction Manual

748054-L May 2003

Model 7003D

SAFETY SUMMARY

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

AUTHORIZED PERSONNEL

To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property, all personnel authorized to install, operate and service the this equipment should be thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS.

DANGER.

ELECTRICAL SHOCK HAZARD

Do not operate without doors and covers 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 produc t. Use only factory documented components for repair.

CAUTION .

HIGH PRESSURE GAS CYLINDERS

This module requires periodic use of pressurized gas. See General Precautions for Handling and Storing High Pressure Gas Cylinders, page P-4.

P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

Model 7003D

WARNING.

ENCLOSURE INTEGRITY

Unused cable conduit entries must be securely sealed by flameproof closures to prov ide 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).

WARNING

ELECTRICAL SHOCK HAZARD

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

WARNING

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CORROSIVE MATERIAL

Concentrated nitric acid is used in rejuvenating the sensor cathode (Section 6-1b on page 6-3). 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.

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3

Instruction Manual

748054-L May 2003

Model 7003D

GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH

PRESSURE GAS CYLINDERS

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 extreme s 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 whe n an empty cylinder is attached to a pressurized system.

7. No part of cylinder should be subjected to a temperature higher than 125 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 wel ding, precautions must be taken to prevent striking an arc against the cylinder.

F (52°C). A flame should

P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

Model 7003D

DOCUMENTATION

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

748054 Operator Manual (this document)

COMPLIANCES

The Model 7003D Oxygen Monitor is designed to comply with applicable American standard s for protectio n against electrical shock, mechanical and fire hazards in non-hazardous (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.

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The oxygen sensors and interconnecting cable used with the Model 7003D Oxygen Monitor are nonincendive 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.

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5

Instruction Manual

748054-L May 2003

Model 7003D

P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

The Model 7003D Oxygen Monitor (Figure 1-1 below) 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.

Instruction Manual

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SECTION 1

DESCRIPTION AND SPECIFICATIONS

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.

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.

LOW

SET PT

Model 7003D Oxygen Monitor

Figure 1-1. Model 7003D Oxygen Monitor

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

Instruction Manual

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1-2 SENSORS

Rosemount Analytical offers rechargeable and disposable oxygen sensors which can be used with the Model 7003D. See Figure 1-2 below and Figure 1-3 below. These sensors are supplied alone or in kits: Submersion, inline flow, and fast response.. Sensors are available constructed of polypropylene or Ryton. See Section 2-4 on page 2-5 - Sensors, Rechargeable, Section 2-5 on page 2-12 Sensors - Non-Rechargeable and Section 7-3 on page 7-2 - Sensors, Replacement Parts for additional information.

Rechargeable - Fast-Response Flow

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.

Rechargeable - In-Line 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.

Rechargeable - Submersion Assembly

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-Rechargeable - In-Line Flow

The in-line flow assembly permits mounting the sensor in a flowing gas stream. Also included is a universal mounting bracket and a

Model 7003D

cable assembly for connecting the disposable oxygen sensor to the monitor.

Non-Rechargeable - Submersion

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.

Figure 1-2. Rechargeable Sensor

Figure 1-3. Non-Rechargeable Sensor

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

1-3 SPECIFICATIONS

a. Performance

Operating Range........................... 0 - 19.99% to 0 to 25% oxygen by volume

Sample Temperature..................... 32°F to 110°F (0°C to 44°C)

Ambient Temperature.................... -20°F to 122°F (-29°C to 50°C) for instrument

Ambient Humidity .......................... Up to 95% relative humidity, non-condensing

System Linearity............................ For constant sample temperature after correction for sensor zero

b. Electrical

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

Potentiometric Output.................... Selectable: 0-25%, 0-10%, 0-5% or 0-1% oxygen fullscale

Voltage Output............................... Selectable: 0-10V, 0-5V, or 0-1V fullscale

Current Output (Option)................. Isolated 0-20mA or 4-20mA over same range as potentiometric

Instruction Manual

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offset: ±1% of fullscale

Minimum load: 2K ohms

output. Minimum load: 600 ohms.

c. Alarm

Range............................................ Selectable: 0-25%, 0-10%, 0-5%, or 0-1% oxygen fullscale

Contacts ........................................ Two independently adjustable SPDT relay contact actuations

Contact Rating (resistive load)...... Maximum switching voltage: 250 VAC, 30 VDC

Maximum switching current : 3A

Deadband...................................... Adjustable from less than 2% to 20% of range at any setpoint

Repeatability.................................. ±0.1% of range

d. Physical

Mounting........................................Standard: Panel mount

Optional: Surface mount, pipe mount

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

Weight ........................................... 4.2 lbs (1.9 kg)

Enclosure....................................... NEMA-4X general purpose.

Optional air purge designed to NFPA-496 Type Z.

Sensor Cable................................. 1000 ft (305 m) Maximum length between instrument and sensor.

The optional air purge, when installed alon g with user supplied components, is designed to equip the instrument enclosure

with Type Z purge protection per Standard ANSI/NFPA 496-19 86. This reduces the classification within the enclosure from Class I, Division 2 (normally non-hazardous ) to non-hazardous, thus permitting installation in a location classifie d Class I, Groups A, B, C, D, Division 2. This method of protection is recognized in Article 500-1 of the National Electrical Code (NEC)< ANSI/NFPA 70.

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

Instruction Manual

748054-L May 2003

e. Sensor

Type............................................... Rechargeable, non-rechargeable (disposable)

Stability.......................................... ±1% of fullscale at any given temperature per 24 hours, for an

Temperature Compensations........ 32°F to 110°F (0°C to 44°C) ±6% of reading

Response Time............................. 90% in 20 seconds for a step change, using an equilibrated sensor

Sample Pressure........................... 0 to 50 psig (0 to 345 kPa)

Model 7003D

equilibrated sensor

60°F to 90°F (15°C to 32°C) ±3% of reading

For any other 30°F (16°C) ±4% of reading

at 25°C

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

Instruction Manual

748054-L

May 2003

SECTION 2

INSTALLATION

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.

a. Line 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 on page 22 and drawing 622228.

Voltage Select

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.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

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

b. System Grounding Connection

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

Instruction Manual

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Isolated V/I Board (Option) (see

Figure 3-2 on page 3-3)

Recorder TB3

Sensor TB2

R 1

POWER SUPPLY BOARD 622537

R5 R6

O G I

CR2

1 2 3 4

I G O

TB1

30K THERM

TB2

Current Output TB3

U1 J1

I G O

3K/10K THERM

SHLD

CATH

TB3

CR2

O G

U2 U4

SHIELD

+VOLTAGE OUT

-VOLTAGE OUT

+CURRENT OUT

-CURRENT OUT

CR3

CR4

O G

CR1

Model 7003D

C2 C1

TB4

COM

LARM

COM

LARM

TB5

GND

NEUTRAL/L2

HOT/L1

Voltage Select Switch S1

AC Power TB5

c. Sensor 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 above and drawing 622228.

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

d. Output Cable Connection

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

Figure 2-1. Power Supply Board

through conduit to the oxygen monitor, and into the case through the appropriate opening shown in drawing 622617.

Potentiometric Output

1. Connect leads of shielded recorder cable to VOLTOUT + and VOLTOUT

- terminals of TB3 on power supply board (Figure 2-1 above). Connect shield to SHD terminal.

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

WARNING

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 on page 2-3.

2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

Instruction Manual

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Isolated Current Output Accessory

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 on page 2-2. If originally ordered with the oxygen monitor, the board is fac-

must be connected in series. Refer to Figure 2-2 below.

NOTE

Total resistance of all output devices and associated interconnection cable must not exceed 600 ohms.

tory installed.

4. Since neither the CUROUT + nor

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

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.

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

7003D

Monitor

Potentiometric

Recorder

Voltage Divide (Customer Supplied)

Input Terminals

(Verify pol arity is correct )

Position of Recorder Outpu t

Selector Plu g

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

Min i mum Per missible Re si stance for

R1 + R2

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

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3

Instruction Manual

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Model 7003D

7003D

Monitor

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

Recorder

Controller

Remote

Indicator

Devices

e. Output Connections for Alarms

Alarm Output Connections

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 on page 2-2 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.

Alarm Relay Characteristics

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 Relay

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 Relay

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.

Alarm Reset

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

2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

Instruction Manual

748054-L

May 2003

Fail Safe Applications

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 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 2-3c on page 2-2 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.

2-6B on page 2-7, is acceptable provided the sample enters the lower port of the chamber and discharges from the upper port.

Installing Sensor

1. Refer to Figure 2-5 on page 2-6. 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.

a. Installation 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.

Mounting Flow Chamber

The flow chamber has two .2 diameter clearance holes for mounting screws (screws supplied by user). See Figure 2-4 on page 2-6.

Mount the flow chamber as shown in Figure 2-6 on page 2-7. Preferably, mount the flow chamber so that the sensor is vertical as shown in Figure 2-6A on page 2-7. Horizontal mounting, Figure

Gas Connections

Sample inlet and outlet connections are 1/8 inch NPT (Figure 2-4 on page 2-6). Normally, sample is supplied to the flow chamber via a customer supplied needle valve which provides flow adjustment.

Pressure and Flow

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.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5

Instruction Manual

∅

748054-L May 2003

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

Ring Clamp

Sample Inlet/Outlet 1/8 NPT

DIMENSIONS

Inch

[mm]

Flow Chamber

Sensor

Nut

O-Ring

Sensor Ca

Flow Chamber

Ring Clam

O-Ring

Cable to Oxygen Analyzer

[9]

Nut

Sensor Body

1.5

[37]

3.0

[76]

Model 7003D

3.6

[9.1]

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

1.5

[38]

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

2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

Instruction Manual

748054-L

May 2003

A. Vertical Installation (Preferred)

Vent to Atmosphere

Sample In

B. Horizontal Installation

Vent to

Atmosphere

Sample In

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

Assembly

shown in Figure 2-8 on page 2-9. In this

b. Installation 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).

orientation the sample enters the lower port of the assembly and discharges to the upper port. The horizontal arrangement ensures that during setup there will be immediate discharge of any gas in the flow chamber or any entrained gases in the sample stream.

The typical application is in-line monitoring, with the flow assembly connected directly into the process-stream pipeline. An alternative application involves discharge to

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

atmospheric pressure where high discharge rates are desired.

Note that the sensor responds to partial pressure of oxygen in the sample. If total pressure changes, the oxygen responds accordingly.

For liquid sample streams, it is recommended that the assembly be mounted so the sensor is in the vertical position, as

Mounting Flow Chamber

Outline and mounting dimensions are given in Figure 2-7 on page 2-8. 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 on page 2-9.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7

Instruction Manual

748054-L May 2003

Installing Sensor

Model 7003D

3. Replace the adapter ring and clamp.

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

Gas Connections

Sample inlet and sample outlet connec-

2. Insert the sensor (with gland) into the

tions are 1/2 FPT.

flow chamber.

Pressure and Flow

GAS STREAM LIQUID STREAM

MAXIMUM PRESSURE 50 psig (345 kPa) 50 psig (345 kPa) MAXIMUM FLOW 2 cfm (60 L/min) 5 gal/min (6 L/min) MINIMUM FLOW dependent on desired response time 1.5 gal/min (6 L/min)

Gland

Adapter Ring

Flow Chamber

Clamp

4.5

[127]

Sample Inlet/Outlet 1/2 NPT Female

.75

[19]

Mounting Holes .219 [6] DIA

DIMENSIONS

Inch

[mm]

4.0

[102]

3.5

[89]

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

2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

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

c. Installation 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.

Sample In

Instruction Manual

748054-L

May 2003

To drain or process stream

Assembly

Mounting in Gaseous Sample Stream

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

Operating Pressure

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

For liquid sample stream, it is recommended that the submersion assembly be mounted in horizontal position, as shown in Figure 2-10 on page 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. Figure 2-11 on page 2-11 and Figure 2-12 on page 2-11 illustrate typical installations.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9

Liquid Sample Flow

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 flowindependent oxygen readout.

Mounting Chamber

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

Installing Sensor

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.

Instruction Manual

748054-L May 2003

Sensor Cable

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.

Submersion Assembl

3.4

[86]

Chamber Ring Clamp Adapter Ring

2.0

[51]

1.9

[48]

Model 7003D

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.

Aluminum Cable Connector (Accessory)

2.9

[73]

3/4 - 14 NPT

7.4

[187]

Figure 2-9. Rechargeable Sensor with Submersion Assembly

Sensor Cable to Oxygen Monitor

Customer supplied 3/4 inch pipe

1. Preferred orientation in liquid sample stream.

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

Submersion Assembly horizontal

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

Internal Sensor membrane vertical

2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

Instruction Manual

748054-L

May 2003

Cable to Oxygen Moni-

Pipe and fittings to suit installation

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

Pipe and fittings to suit installation

Manhole

Handrail

Diffuser

During Plant Construction

Cable to Oxygen Moni-

Chain to

Diffuser

Handrail

Submersion Assembly

Chain to Deck Level

Capped pipe clamped to handrail

Union (loose to act as swivel)

Submersion Assembly

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

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11

Instruction Manual

748054-L May 2003

2-5 SENSORS - NON-RECHARGEABLE

a. Conversion Of Oxygen Monitor From

Use With Rechargeable Sensor To Use With Non-Rechargeable Sensor

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 nonrechargeable sensor. Follow the instructions supplied in the kit.

b. Installation 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 on page 2-14). 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.

Mounting the Flow Chamber

Refer to Figure 2-15 on page 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

Model 7003D

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.

Installing the Sensor

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.

Gas Connections

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.

c. Installation 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 on page 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.

Mounting the Submersion Assembly

Refer to Figure 2-15 on page 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

2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

Instruction Manual

748054-L

May 2003

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 on page 2-16.

Sensor Cable

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.

Operating Pressure

Maximum operating pressure is 50 psig (345 kPa).

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-13

Instruction Manual

748054-L May 2003

Fitting, Plug

1/8MPT SS

Flow Chamber

2 Holes

Nut

2.1

[54]

[13]

1.1

[28]

[2]

[8]

10-32 x 1/2" DP 2 Places

2.5

[64]

[17]

Cable

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

O-Ring

.2 [5] DIA

[18]

[12]

[5]

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

Model 7003D

4.8

[122]

2.6

[67]

3.8

[97]

5.2

[133]

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

2-14 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

LIQUID GAS

Drain

Process

Stream

Preferred orientation of In-Line Flow Assembly

Drain

Process

Stream

Sample

Instruction Manual

748054-L

May 2003

Sample

Preferred orientation of In-Line Flow Assembly

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

Grommet/Plug

2.0 [51]

Adapter

1-11 1/2NPT

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

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-15

Instruction Manual

748054-L May 2003

A. INSTALLATION DURING PLANT CONSTRUCTION

Cable to Oxygen Monitor

Pipe and fittings to suit installation.

B. INSTALLATION IN EXISTING PLANT

Handrail

Pipe and fittings to suit installation.

Manhole

Cable to Oxygen Monitor

Diffuser

Model 7003D

Chain to Deck Level

Sensor/Submersion Assembly

Capped Pipe Clamped to

Union (loose to act as swivel)

Chain to Deck Level

Sensor/Submersion Assembly

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

2-16 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

SECTION 3

STARTUP AND CALIBRATION

Prior to startup and calibration, familiarization with Figure 3-1 on page 3-3 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 on page 3-3):

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 on page 3-2).

2. Turn on line power.

Instruction Manual

3-2 CALIBRATION

Sensor - Residual Current Zeroing

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 3-2a below or 3-2b on page 3-2, as appropriate.

a. Calibration 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 O labeled as such. U.S. Government standards require only that cylinders labeled "air" contain between 19% and 23% oxygen.

and N2, and is not necessarily

748054-L

May 2003

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 performance 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 on page 1-1.

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Calibration 3-1

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.

Instruction Manual

748054-L May 2003

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 % O

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.

2 in sample

Model 7003D

tion. 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

EXAMPLE:

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

b. Calibration 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. Wait 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 posi-

3. 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.

4. When setpoints and deadbands have been selected, set alarm switches S4 and SS to the AUTO position, to activate the alarms.

5. To test external alarm devices, temporarily set alarm switch S4 or S5 in the ON position. The associated alarm is then unconditionally on.

3-2 Startup and Calibration Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

LOW ALARM INDICATOR LED CR1

LOW ALARM SETPOINT ADJUST R43

LOW ALARM DEADBAND ADJUST R44

SENSOR CONVERSION HEADER J5

AUTO OFF ON

LOW ALARM SWITCH S4

RANGE SWITCH S7

CAL CONTROL R14

OUTPUT VOLTAGE SWITCH S2

OUTPUT/ALARM SWITCH S3

19.99 25 CAL

OFF ON

E OUT

LARM

Instruction Manual

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May 2003

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

HIGH ALARM SWITCH S5

Figure 3-1. Display Board

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Calibration 3-3

Instruction Manual

748054-L May 2003

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 on page 3-3), 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 on page 2-2). Secure the leads so that they will not contact any board or component.

3. Turn power ON. On the Display Board (Figure 3-1 on page 3-3), 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 below) so that current output device indicates the low range-limit desired for

ZERO R1

SPAN R2

R 1

R 2

R5 R6

CR2

O G

1 2 3 4

Model 7003D

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 on page 2-2). 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 below), adjust SPAN control R2 for reading of 20 milliamps on current output device.

U1 J1

I G O

Figure 3-2. Isolated Current Output Board

3-4 Startup and Calibration Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

Instruction Manual

748054-L

May 2003

SECTION 4

OPERATION

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 there is no leak in the system, another 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 6 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 61a on page 6-1. 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.

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.

Rosemount Analytical Inc. A Division of Emerson Process Management Operation 4-1

Instruction Manual

748054-L May 2003

Model 7003D

4-2 Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

SECTION 5

THEORY

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 on page 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 below). Oxygen in the

THERMISTOR

CAP

O-RINGS

MEMBRANE

Instruction Manual

748054-L

May 2003

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

BODY

FILL PORT

ANODE

CATHODE

Figure 5-1. Rechargeable Oxygen Sensor - Sectional View

Rosemount Analytical Inc. A Division of Emerson Process Management Theory 5-1

Instruction Manual

748054-L May 2003

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:

Model 7003D

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)

partial pressure H kPa)

0 = 20 mm Hg ( 2.7

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

partial pressure O mm Hg = 151 mm Hg (20.1 kPa)

= (740-20) x 0.2095

5-2 Theory Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

ROUTINE SERVICE AND TROUBLESHOOTING

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.

Instruction Manual

748054-L

May 2003

SECTION 6

the gold cathode should be rejuvenated as described in Section 6-1b on page 6-3.

In event of "spiking," i.e., non-oxygen-related transient response, the accessory Cell Separator Kit is recommended. Refer to Section 6-1c on page 6-

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.

a. Recharging 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.

Rechargeing Procedure

For this procedure refer to Figure 6-1 on page 6-2.

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.

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 6-1a below. If output still remains low, or the other symptoms exist,

Rosemount Analytical Inc. A Division of Emerson Process Management Routine Service and Troubleshooting 6-1

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 cath-

Instruction Manual

748054-L May 2003

ode should be rejuvenated as described in Section 6-1b on page 6-3.

b. Any deposited material, typi-

cally 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

CAP

MEMBRANE

RETAINER

CELL SEPARATOR (Accessory)

HOLDER

O-RING

Model 7003D

retainer. Remove and discard the old membrane.

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

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

MEMBRANE CONTAMINATION

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

BREATHER HOLE

WASHER

CATHODE

O-RING

DIAPHRAGM

DIAPHRAGM SCREW

Figure 6-1. Rechargeable Sensor – Exploded View

6-2 Routine Service and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

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 level flush with the top of the sidewall.

Instruction Manual

748054-L

May 2003

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.

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

Sensor is ready for operation. Connect cable. If sensor does not operate properly refer to Section 6-3 on page 6-4.

If normal operation is not obtained with the specified recharging procedure, perform rejuvenation, as detailed in Section 6-1b below.

b. Rejuvenating 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

Rosemount Analytical Inc. A Division of Emerson Process Management Routine Service and Troubleshooting 6-3

Instruction Manual

748054-L May 2003

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 area lightly 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.

Model 7003D

The condition may be corrected by installing a separator disk which mechanically separates the cathode and anode (see Figure 6-1 on page 6-2). 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.

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.

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.

c. Cell Separator Kit

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 reaction products which 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 transient response.

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 6-1 and Section 6-2.

System problems can be isolated to the sensor or the amplifier by the following procedure:

1. Disconnect AC power from the instrument.

6-4 Routine Service and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

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

3. On TB2 (Figure 2-1 on page 2-2) 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 on page 3-3).

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 6-3a below or 6-3b on page 7.

Instruction Manual

748054-L

May 2003

a. Checking Rechargeable Sensor and

Cable

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, 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 on page 6-6. This table is a compilation of the most common sensor problems.

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

Rosemount Analytical Inc. A Division of Emerson Process Management Routine Service and Troubleshooting 6-5

Instruction Manual

748054-L May 2003

Model 7003D

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Abnormally high oxygen readings (unable to calibrate)

Abnormally low oxygen readings (unable to calibrate)

Sensor noisy (motion sensitive) Upscale reading with known oxygen-

free sample Slow response (sluggish) Contaminated electrolyte1 Rejuvenate/recharge sensor

Hole in sensor membrane Replace membrane Gold cathode loose Replace sensor Open thermistor Replace sensor High internal cell resistance Rejuvenate/recharge sensor

Membrane too loose Contaminated electrolyte1 Clean/recharge sensor

Thermistor shorted Replace sensor Membrane loose Replace membrane Low electrolyte level Fill properly Cathode contaminated

Gold cathode loose Replace sensor

Rejuvenate/recharge sensor

Tighten cap or replace membrane

Table 6-1. Rechargeable Sensor Troubleshooting Guide

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

rejuvenation procedure is required.

6-6 Routine Service and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

748054-L

Model 7003D

May 2003

between any two leads should be at least

b. Checking Non-Rechargeable Sensor

and Cable

To check the cable disconnect it from the monitor and the sensor. The resistance

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 oxygenfree sample (greater than 0.1% O2 or equivalent) Slow response (sluggish) Contaminated electrolyte1 Replace sensor

Sensor contaminated

100 M ohms. A continuity check on any lead should produce a reading of less than 15 ohms per thousand feet.

Adjust sensor zero control Check linearity with standards

Table 6-2. Non-Rechargeable Sensor Troubleshooting Guide

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

rejuvenation procedure is required.

Rosemount Analytical Inc. A Division of Emerson Process Management Routine Service and Troubleshooting 6-7

Instruction Manual

748054-L May 2003

Model 7003D

6-8 Routine Service and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

SECTION 7

REPLACEMENT PARTS

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

Instruction Manual

748054-L

May 2003

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

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

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 7-1

Instruction Manual

748054-L May 2003

7-3 REPLACEMENT PARTS - SENSORS

a. Rechargeable Sensors

Sensor:

MATERIAL PART NUMBER

Polypropylene 623371 Polypropylene 623370 (use with Fast Response Kit)

Ryton 190408 Ryton 190409 (use with Fast Response Kit)

Sensor Kits (Sensor not included):

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

Sensor Kits (Sensor included):

Model 7003D

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 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

b. Non-Rechargeable Sensors

Sensor:

MATERIAL PART NUMBER

Polypropylene 623742

Sensor Kits (Sensor not included):

DESCRIPTION PART NUMBER USE WITH SENSOR

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

Sensor Kits (Sensor included):

DESCRIPTION PART NUMBER

Submersion, Polypropylene 500011 In-Line Flow, Polypropylene 500012

Instruction Manual

748054-L

May 2003

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 7-3

Instruction Manual

748054-L May 2003

Model 7003D

7-4 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003D

8-1 RETURN OF MATERIAL

If factory repair of defective equipment is required, proceed as follows:

1. Secure a return authorization from a Rosemount Analytical Inc. Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted.

Rosemount CSC will provide the shipping address for your instrument.

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

2. Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs during shipping.

3. In a cover letter, describe completely:

• The symptoms that determined the

equipment is faulty.

• The environment in which the equip-

ment was operating (housing, weather, vibration, dust, etc.).

• Site from where the equipment was

removed.

• Whether warranty or non-warranty

service is expected.

• Complete shipping instructions for the

return of the equipment.

4. Enclose a cover letter and purchase order

and ship the defective equipment according to instructions provided in the Rosemount Return Authorization, prepaid, to the address provided by Rosemount CSC.

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

Instruction Manual

748054-L

May 2003

SECTION 8

RETURN OF MATERIAL

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

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

8-2 CUSTOMER SERVICE

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

8-3 TRAINING

A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service Training Schedule contact the Technical Ser- vices Department at:

Rosemount Analytical Inc.

Customer Service Center

1-800-433-6076

Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 8-1

Instruction Manual

748054-L May 2003

Model 7003D

8-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7001D, 7002D, 7003D

CONVERTING RECHARGEABLE SENSOR TO

NON-RECHARGEABLE SENSOR

Instruction Sheet

748597-G

October 2000

To convert a Model 7001D, 7002D or 7003D Oxygen Monitor which has been used with a rechargeable oxygen sensor so that it can be used with a non-rechargeable oxygen sensor, it is necessary to modify the display board of the instrument. This modification changes the gain of the monitor to match the output current available from the non-rechargeable oxygen sensor. A header kit appropriate to each model is provided for use in the modification. To perform the modification to your instrument, select the appropriate instruction below.

7001D

1. Remove the existing header in J3 on the display board. Mark it and save for possible future re-conversion to use of a rechargeable sensor.

2. Install the 14 pin header from the kit (P/N

623731) into J2 on the display board. Refer to Figure 1. Verify that pin 1 on the header is installed in the pin 1 socket on the display board.

3. Install the 16 pin header from the kit into J3 on the display board. Verify that pin 1 on the header is installed in the pin 1 socket on the display board.

7002D

1. Remove the existing header in J4 on the display board. Mark it and save for possible future re-conversion to use of a rechargeable sensor.

2. Install the 14 pin header from the kit (P/N

623732) into J2 on the display board. Refer to Figure 1. Verify that pin 1 on the

header is installed in the pin 1 socket on the display board.

3. Install the 16 pin header from the kit into J4 on the display board. Verify that pin 1 on the header is installed in the pin 1 socket on the display board.

Figure 1. Models 7001D and 7002D Display

7003D

1. Remove the existing header in J5 on the

2. Install the 14 pin header from the kit (P/N

Figure 2. Model 7003D Display Board

Board

display board. Mark it and save for possible future re-conversion to use of a rechargeable sensor.

623733) into J5 on the display board. Refer to Figure 2. Verify that pin 1 on the header is installed in the pin 1 socket on the display board.

http://www.processanalytic.com

Electrolyte

PRODUCT:

Oxygen Sensor Electrolyte

PART NUMBER: 192580 (1 pint, 474 ml)

24 HOUR EMERGENCY TELEPHONE NUMBER:

CHEMTREC (800) 424-9300

SECTION I - GENERAL

Distributor: Rosemount Analytical Inc. 1201 N. Main St., Orrville, Ohio 44667-0901 330-682-9010

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

SECTION II – HAZARDOUS INGREDIENTS

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 Extinguishing media Special fire fighting procedures Unusual fire and explosion hazards

SECTION V – REACTIVITY DATA

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

potassium chloride/water solution electrolyte metal halide salt solution KCl + H 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

NA NA NA NA

stable none none

none none

O (5% KCl, 95% H2O)

Material Safety Data Sheet

748595-J July 1997

Is contained in the following sensors: 190404, 190408, 1904 09, 623246, 623370, 623371, 623372, 623373, 623374,

623375, 623740, 623741, 623742

http://www.processanalytic.com

Material Safety Data Sheet

748595-J July 1997

SECTION VI – HEALTH HAZARD DATA

Threshold limit value Routes of entry Effects of overexposure Emergency & first aid procedures

SECTION VII – SPILL OR LEAK PROCEDURE

Steps to be taken in case material is released or spilled

Waste disposal method

SECTION VIII – SPECIAL PROTECTION INFORMATION

Respiratory protection Ventilation Protective gloves Eye protection Other protective equipment

SECTION IX – SPECIAL PRECAUTIONS

Precautions to be taken in handling and storing

Other precautions

SECTION X – TRANSPORTATION

Must be compliance with federal, state and local regulations

NA NA NA NA

NA no special requirement

none mechanical (general) NA safety glasses suggested none

None none

Electrolyte

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 OTHERWISE RESPONSIBLE 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 AND/OR REGULATIONS.

2 of 2 MSDS - Electrolyte

Rosemount Analytical Inc. A Division of Emerson Process Management

WARRANTY

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 WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy.

LAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY 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's direct control.

Seller shall not be liable for failure to perform due to labor strikes or acts beyond

SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DE-

Instruction Manual

748054-L May 2003

Model 7003D

EMERSON PROCESS MANAGEMENT

Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd. 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947

http://www.processanalytic.com

EUROPEAN TECHNOLOGY CENTER Fisher-Rosemount GmbH & Co. Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd. Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

Rosemount 7003D O2 Monitor-Rev L Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

LIST OF DRAWINGS

PREFACE

DEFINITIONS

SAFETY SUMMARY

AUTHORIZED PERSONNEL

DOCUMENTATION

COMPLIANCES

DESCRIPTION AND SPECIFICATIONS

1-1 OXYGEN MONITOR

Model 7003D Oxygen Monitor

1-2 SENSORS

Figure 1-2. Rechargeable Sensor

Figure 1-3. Non-Rechargeable Sensor

1-3 SPECIFICATIONS

a. Performance

b. Electrical

c. Alarm

d. Physical

e. Sensor

INSTALLATION

2-1 UNPACKING AND FACILITY PREPARATION

2-2 LOCATION AND MOUNTING

2-3 ELECTRICAL CONNECTIONS

a. Line Power Connection

b. System Grounding Connection

c. Sensor Cable Connection

d. Output Cable Connection

Figure 2-1. Power Supply Board

Potentiometric Output

Isolated Current Output Accessory

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

e. Output Connections for Alarms

Alarm Output Connections

Alarm Relay Characteristics

HI ALARM Relay

LO ALARM Relay

Alarm Reset

Fail Safe Applications

Installing Sensor

Mounting Flow Chamber

Gas Connections

Pressure and Flow

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

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

Mounting Flow Chamber

Installing Sensor

Pressure and Flow

Mounting in Gaseous Sample Stream

Operating Pressure

Liquid Sample Flow

Mounting Chamber

Installing Sensor

Sensor Cable

Figure 2-9. Rechargeable Sensor with Submersion Assembly

2-5 SENSORS - NON-RECHARGEABLE

Mounting the Flow Chamber

Installing the Sensor

Gas Connections

Mounting the Submersion Assembly

Sensor Cable

Operating Pressure

STARTUP AND CALIBRATION

3-1 SYSTEM STARTUP

3-2 CALIBRATION

a. Calibration with Air

b. Calibration with Span Gas

Figure 3-1. Display Board

3-4 CURRENT OUTPUT RANGE

Figure 3-2. Isolated Current Output Board

OPERATION

4-1 ROUTINE OPERATION

4-3 FREQUENCY OF SENSOR RECHARGING