Rosemount 7003M Percent O2 Analyzer-Rev H Manuals & Guides

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Rosemount Analytical

ODEL

ERCENT OXYGEN

NALYZER

NSTRUCTION MANUAL

7003M

748223-H

OTICE

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

Manual Part Number 748223-H July 1997 Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue Anaheim, California 92807-1802

ONTENTS

REF ACE

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

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

Customer Service, Technical Assistance and Field Service...............................P-6

Returning Parts to the Factory............................................................................P-6

Training ......................................................................................................P-6

Documentation....................................................................................................P-6

Compliances ......................................................................................................P-7

ECTION

1.1 Overview...................................................................................................1-1

1.2 Principle of Measurement.........................................................................1-2

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

1.4 Conditions Affecting Measurement...........................................................1-2

1.5 Features....................................................................................................1-3

ECTION

2.1 Unpacking.................................................................................................2-1

2.2 Analyzer Installation.................................................................................2-1

2.3 Sensor Installation ....................................................................................2-1

2.4 Electrical Connections..............................................................................2-3

1. I

1.4.1 Gas Composition..........................................................................1-2

1.4.2 Sample and Cal Gas Pressures...................................................1-3

1.4.3 Environmental Factors.................................................................1-3

2.1.1 Storage.........................................................................................2-1

2.3.1 Analyzer/Sensor Jumper Configuration........................................2-2

2.4.1 Sensor Cable ...............................................................................2-4

2.4.2 Power Connections......................................................................2-5

2.4.3 Current Output Connections.........................................................2-6

2.4.4 Voltage Output Connections........................................................2-7

2.4.5 Relay Contacts for Alarms or ON/OFF Controls...........................2-9

NTRODUCTION

INSTALLATION

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ECTION

OPERATION

3.1 Overview...................................................................................................3-1

3.2 Keypad Operation....................................................................................3-1

3.2.1 Changing Parameters Using the Keypad.....................................3-2

3.2.2 Single and Double Keystroke Commands...................................3-3

3.2.3 Display Prompts...........................................................................3-4

3.2.4 Error Messages ...........................................................................3-6

3.2.5 Automatic Return to RUN Mode..................................................3-7

3.2.6 Preventing Unauthorized Access.................................................3-7

3.2.7 Sensor Equilibration.....................................................................3-7

3.3 Startup ......................................................................................................3-7

3.3.1 Initial Power-Up ...........................................................................3-8

3.3.2 System Restart............................................................................3-9

3.3.3 Automatic Restart - Due to Power Interruption............................3-9

3.3.4 Manual Restart............................................................................3-9

3.4 RUN Mode................................................................................................3-9

3.4.1 Display Oxygen Concentration/Sensor Temperature ..................3-10

3.4.2 Acknowledge Alarms...................................................................3-10

3.4.3 Access Other Modes ...................................................................3-10

3.5 SETUP Mode ...........................................................................................3-10

3.5.1 Security Code..............................................................................3-12

3.5.2 Current Output Range .................................................................3-12

3.5.3 Range Endpoint Adjustments......................................................3-12

3.5.4 Zero Offset Adjustment................................................................3-14

3.6 ALARM Mode vs. ON/OFF Control Mode................................................3-14

3.6.1 Relay Configured as Alarm..........................................................3-16

3.6.2 Relay Configured as ON/OFF Controller.....................................3-16

3.6.3 Relay Contacts ............................................................................3-16

3.6.4 Fail Safe Operation......................................................................3-17

3.6.5 Relay Reset Upon Fatal Error......................................................3-17

3.6.6 Pressure Effects on Alarms.........................................................3-17

3.6.7 Setting Alarm and ON/OFF Controller Relays.............................3-17

3.6.8 Setting Alarm Setpoints...............................................................3-17

3.6.9 Setting Alarm ON and OFF Levels..............................................3-17

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ONTENTS

ECTION

4.1 Frequency of Calibration...........................................................................4-1

4.2 CALIBRATION Mode................................................................................4-1

4.3 HOLD Mode..............................................................................................4-5

4.4 DIAGNOSTICS Mode...............................................................................4-7

4.5 Adjustments and Settings.........................................................................4-11

ECTION

5.1 Principles of Operation..............................................................................5-1

5.2 Effects of Sample Conditions....................................................................5-1

5.3 Circuit Descriptions...................................................................................5-3

CALIBRATION AND ADJUSTMENTS

4.2.1 Zero Calibration............................................................................4-1

4.2.2 Span Calibration...........................................................................4-2

4.2.3 Pressure Compensation - Correction for Constant Pressure

Differences...........................................................................4-4

4.4.1 Raw Sensor Voltage.....................................................................4-8

4.4.2 Test Current Output .....................................................................4-8

4.4.3 Linearizing Current Output...........................................................4-8

4.4.4 Test Alarm Relays........................................................................4-10

THEORY

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

5.2.1 Barometric Pressure.....................................................................5-1

5.2.2 Humidity.......................................................................................5-1

5.2.3 Sample Temperature ...................................................................5-2

5.2.4 Interfering Gases..........................................................................5-2

5.3.1 Signal Board.................................................................................5-3

5.3.2 Power Supply Board.....................................................................5-3

5.3.3 Microprocessor Board..................................................................5-3

5.3.4 Alarm Circuits...............................................................................5-3

ECTION

6.1 Routine Servicing......................................................................................6-1

6.2 Troubleshooting........................................................................................6-1

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6. R

6.2.1 Symptoms....................................................................................6-1

OUTINE SERVICING AND TROUBLESHOOTING

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ECTION

7. R

EPLACEMENT PARTS

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

7.2 Replacement Parts - Model 7003M.......................................................... 7-1

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

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

7.3.2 Disposable Sensors..................................................................... 7-3

ENERAL PRECAUTIONS FOR HANDLING

ARRANTY

IELD SERVICE AND REPAIR FACILITIES

IGURES

& S

TORING HIGH PRESSURE CYLINDERS

2-1 Sensor Ordering Matrix............................................................................2-2

2-2 Model 7003M Rear Panel Connections ...................................................2-3

2-3 Power Jumpers and Fuses ......................................................................2-6

2-4 Current Output Connections ....................................................................2-8

3-1 Model 7003M Front Panel Controls and Indicators..................................3-1

3-2 Model 7003M Operation Flow Diagram....................................................3-2

3-3 SETUP Mode Flowchart...........................................................................3-11

3-4 Security Access Routine Flowchart..........................................................3-13

3-5 ALARM Mode Flowchart..........................................................................3-15

3-6 Action of Alarm Relay ON and OFF Setpoints.........................................3-18

4-1 CALIBRATION Mode and PRESSURE COMPENSATION Flowchart.....4-3

4-2 HOLD and DIAGNOSTICS Modes Flowchart..........................................4-6

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ABLES

2-1 Sensor Cables..........................................................................................2-4

2-2 Analyzer Cable Connections ....................................................................2-4

3-1 Key Functions...........................................................................................3-3

3-2 Display Indicators .....................................................................................3-3

3-3 Security Access Prompts and Responses................................................3-4

3-4 Alarm Settings Prompts and Responses..................................................3-4

3-5 Calibration Prompts and Responses........................................................3-4

3-6 System Setup Prompts and Responses...................................................3-4

3-7 System Hold and Diagnostics Codes........................................................3-5

3-8 Data Displayed in Diagnostics Mode........................................................3-5

3-9 Miscellaneous Prompts and Responses...................................................3-5

3-10 Power ON, Reset Diagnostics Errors (Fatal Errors)..................................3-6

3-11 RUN Mode Errors (Non-Fatal Errors) .......................................................3-6

3-12 Signal Board Errors ..................................................................................3-6

3-13 Microprocessor Errors That Reset The System........................................3-6

3-14 Default Settings at Power Up....................................................................3-8

3-15 RUN Mode Key Functions........................................................................3-9

3-16 SETUP Mode Key Functions....................................................................3-10

3-17 ALARM Mode Key Functions....................................................................3-16

3-18 Alarm Relay Contact Positions/Terminal Locations..................................3-16

4-1 CALIBRATION Mode Key Functions........................................................4-1

4-2 Composition of Dry Atmospheric Air.........................................................4-2

4-3 Composition of Humid Atmospheric Air....................................................4-2

4-4 Barometric Pressure Effect on Apparent Oxygen Concentration..............4-4

4-5 PRESSURE COMPENSATION Mode Key Functions ..............................4-4

4-6 HOLD Mode Key Functions......................................................................4-5

4-7 Caret Readings.........................................................................................4-7

4-8 DIAGNOSTICS Mode Key Functions.......................................................4-8

ONTENTS

RAWINGS

652542 Outline and Mounting - Panel Mount 652543 Outline and Mounting - Wall Mount 652544 Outline and Mounting - Pipe Mount 652682 Pictorial Wiring Diagram 652683 Interconnect Diagram 652699 Installation Drawing

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REFACE

AFETY SUMMARY

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 Model 7003M Percent Oxygen Analyzer should be thoroughly familiar with and strictly follow the instructions in this manual.

Save these instructions.

DANGER

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

WARNING

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

CAUTION

personal injury or property damage if the warning is ignored.

NOTE

important but not hazard-related.

is used to indicate the presence of a hazard which

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

will

can

cause

can

cause

severe

WARNING: 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.

minor

Relay contacts wired to separate power sources must be disconnected before servicing.

This instrument was shipped from the factory set up to operate on either 115 VAC 50/60 Hz, or 230 VAC 50/60 Hz, as specified by sales order. Verification that this voltage is proper for the installation is the responsibility of the purchaser. See Section 2.4.2.

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WARNING: OXYGEN LEVEL WILL NOT BE MONITORED

The instrument will not return automatically to the RUN mode from HOLD or DIAGNOSTICS modes. Operator must manually return instrument to RUN mode to continue monitoring oxygen.

WARNING: ERRONEOUS OXYGEN READINGS

If the pressure compensation function is not applied correctly, erroneous readings can be displayed. The display using span gas during calibration should be the same as the reading using the s ame gas in RUN mode if the pressure values are correctly entered.

WARNING: PARTS INTEGRITY

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

WARNING: HIGH PRESSURE GAS CYLINDERS

If gas cylinders are used for supplying drying or carrier gases, refer to "General Precautions for Handling and Storing High Pressure Gas Cylinders" in the rear of this manual.

WARNING: SENSOR NOT INTRINSICALLY SAFE

The oxygen sensors used with this analyzer are not intrinsically safe. Use of the sensors in or near flammable liquids, gases or vapors or in Class I, Division 1, Hazardous Locations should be carefully evaluated by qualified personnel at the site and is entirely the responsibility of the user.

The sensor is approved as non-incendive for use in Class I, Division 2 locations.

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REFACE

PECIFICATIONS

CCURACY

PERATING RANGE

0 to 25% oxygen (endpoints set by user)

INEARITY

(with constant sample temperature after sensor zero offset correction)

ERO STABILITY

PAN STABILITY

OISE

ESPONSE TIME

90% of reading in 20 seconds at 25°C

- P

ERFORMANCE

0.25% oxygen

0.25% oxygen/week at 25°C

0.25% oxygen/24 hours at 25°C

0.25% oxygen

EMPERATURE EFFECTS

32 to 110°F (0 to 44°C): 60 to 90°F (15 to 32°C): other 30°F (16°C) ranges:

PECIFICATIONS

OUNTING

Standard: Panel Mount Optional: Wall Mount, Pipe Mount

IMENSIONS

5.7 x 5.7 x 7.6 inches (14 x 14 x 19 cm) HxWxD

EIGHT

Approximately 3.0 pounds (1.36 kg)

NCLOSURE

ABS Plastic, Black, NEMA Type 4X, IP65

MBIENT HUMIDITY

- P

HYSICAL

6% reading

3% reading

+4% reading

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95% relative humidity, non-condensing (maximum)

MBIENT TEMPERATURE

14 to 122°F (-10 to 50°C)

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PECIFICATIONS

ENSOR CABLE

2 twisted pairs, specified length up to 1000 feet (305 m) maximum

OWER CABLE

3 conductor, Type SJT, 18 AWG minimum

ONNECTION CONDUIT

Power: 1/2 inch Sensor: 3/4 inch

PECIFICATIONS

OWER REQUIREMENTS

115/230 VAC ±10%, 50/60 Hz ±3 Hz

ISPLAY

3-1/2 digit liquid crystal (LCD)

IGNAL OUTPUT

Isolated 4 to 20 or 0 to 20 mA (selectable)

- P

HYSICAL (CONTINUED

- E

LECTRICAL

)

600 ohms maximum load

LARM RELAY CONTACTS

Two Form C Relays SPDT, resistive load, independently adjustable Deadband adjustable over full range

LARM RELAY CONTACTS RATINGS

General Purpose (Ordinary) Locations: 115 VAC, 3.0 A (resistive), 230 VAC, 1.5 A resistive Class I, Division 2 Locations: CSA: 120 VAC, 3.0 A (non-inductive) 240 VAC, 1.5 A (non-inductive). FM: 28 VDC (resistive) (Ci = 0, Li = 0) Groups A&B: 150 mA Group C: 400 mA Group D: 540 mA

ECORDER OUTPUT

Isolated 4 to 20 mA

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PECIFICATIONS

YPES

Rechargeable and Disposable

ROCESS CONNECTIONS

Refer to flow chamber (if supplied)

AMPLE PRESSURE

0 to 50 psig (0 to 345 kPa)

AMPLE TEMPERATURE

32 to 110°F (0 to 44°C)

MBIENT TEMPERATURE

32 to 110°F (0 to 44°C)

MBIENT HUMIDITY

95% relative humidity, non-condensing (maximum)

LSO REFER TO INSTRUCTIONS SUPPLIED WITH SENSOR

- S

ENSORS

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USTOMER SERVICE

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

ETURNING PARTS TO THE FACTORY

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

Number.

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

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

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

, T

ECHNICAL ASSIST ANCE AND FIELD SERVICE

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

RAINING

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

OCUMENTATION

The following Model 7003M Percent Oxygen Analyzer instruction materials are available. Contact Customer Service or the local representative to order.

748223 Instruction Manual (this document)

Current Operator and Service Training Schedule

Rosemount Analytical Inc.

Phone: 1-714-986-7600

FAX: 1-714-577-8006

contact

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COMPLIANCES

The Model 7003M Percent Oxygen Analyzer and Models 4000 and 5000 series sensors are suitable for use in Class I, Groups A, B, C, and D, Division 2 locations per North American electrical codes. Factory Mutual Research (FM) approved under J.I. 1T5AO.AX. Canadian Standards Association (CSA) certified under file LR 93812.

REFACE

APPROVED

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NTRODUCTION

1.1 OVERVIEW

The Model 7003M Percent Oxygen Analyzer continuously monitors the concentration of oxygen in a gaseous sample. It consists of a sensor and the analyzer. The sensor is housed in a chamber assembly and is connected to the analyzer by a shielded multi-conductor cable.

The Model 7003M Percent Oxygen Analyzer provides direct digital readout, isolated current output, automatic temperature compensation circuitry, and dual relay contact closures for alarms or ON/OFF control devices as standard features. The alarm ranges can be selected independently from the output range, eliminating the need to readjust alarm setpoints if the range is changed.

The analyzer has six modes of operation:

MODE FUNCTION

RUN (see Section 3.4) Normal monitoring SETUP (see Section 3.5) Changing parameters ALARM/CONTROL (see Section 3.6) Set alarms or ON/OFF controllers CALIBRATION (see Section 4.2) Gas calibration/pressure inputs HOLD (see Section 4.3) Retain last output value DIAGNOSTICS (see Section 4.4) Electronics checks

The Model 7003M Percent Oxygen Analyzer is housed in a NEMA 4X (CSA enclosure

4), corrosion resistant housing suitable for panel, pipe or wall mounting. The analyzer has a microprocessor controlled keyboard for operation. Signals from

the remote oxygen and temperature sensors are processed to compute real time oxygen concentration corrected for temperature, constant pressure differences and residual sensor current. The oxygen concentration is compared with user-set alarm parameters, and also generates an isolated 4 to 20 or 0 to 20mA signal. Data is stored in a memory circuit that retains the data in case power is removed.

The analyzer is shipped from the factory configured for operation on either 115 VAC or 230 VAC, 50/60 Hz as specified by the customer when ordered.

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1.2 PRINCIPLE OF MEASUREMENT

Measurement is based on the electro-chemical reaction between oxygen and the sensor cathode which produces a low level electrical current. The sensor signal is proportional to the partial pressure of oxygen present at the membrane. This signal and a thermistor signal are received by the analyzer and processed by the electronics to output a calibrated oxygen signal that is compensated for temperature.

1.3 SENSORS

Rosemount Analytical offers rechargeable and disposable oxygen sensors which can be used with the Model 7003M. These sensors are supplied in kits: Submersion, inline flow, fast response, and a cell separation kit. Sensors are available constructed of polypropylene or Ryton. See Section 7.3 Replacement Parts - Sensors, for additional information.

1.4 CONDITIONS AFFECTING MEASUREMENT

Oxygen measurement is affected by the following:

Composition of the sampled gas

•

Sample and calibration gas pressures

•

Environment of sensor, cable and analyzer

•

Each must be considered when calibrating and operating the analyzer to obtain accurate measurements.

1.4.1 G

AS COMPOSITION

Any substance in the sample that significantly interferes or "poisons" the sensor oxygen reading should be removed by a chemical and/or mechanical sample handling system (see Section 5.2). If ambient air is not used as the span gas, the composition of calibration gases should also be representative of the sample.

The sample and calibration gases must meet certain specifications (see Specifications in Preface) to ensure accurate measurement. Physical parameters that affect measurement include:

Pressure

•

Humidity

•

Temperature

•

Gas composition

•

Also refer to Section 5.2 for additional information about how gas conditions affect the oxygen measurement.

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NTRODUCTION

1.4.2 S

AMPLE AND CAL GAS PRESSURES

The sample and calibration gases may be at different pressures as long as the pressure of each remains constant. Any variation in the pressure of either gas will result in an incorrect output reading of the same proportion.

Two methods of sample calibration are recommended:

1. Calibrate at the sample pressure, or

2. Calibrated at a different pressure, and enter the two pressure in the analyzer (Section 4.2.3)

Refer to Section 5.2 for a more detailed discussion of the relationship between gas pressures and apparent oxygen concentration.

1.4.3 E

NVIRONMENTAL FACTORS

If radio frequency interference (RFI) normally occurs in the operating environment, the sensor cable should be electrically shielded during installation.

1.5 FEATURES

UPPRESSED RANGES

When setting the Model 7003M to a suppressed output range (15 to 25%, etc.), note that the absolute accuracy, drift, and noise of the oxygen measurement will remain the same for all ranges (see Specifications in Preface).

ALAR M M

ODE

ALARM Mode is not self-resetting. Operator must press ACK to bring relays back to their no-alarm state. Used when immediate operator action is required.

Note: Operator Can Bypass Alarm Relays When relays are set to ALARM Mode (Section 3.6.1) and an alarm condition

has occurred, pressing the ACK key will turn off the relay switch, whether the oxygen level is out of range or not. If you do not want an operator to be able to bypass the relay switches in this way, set the instrument to ON/OFF

-CONTROL Mode.

ON/OFF-C

ONTROLLER MODE

ON/OFF-CONTROLLER Mode is self-resetting. Pressing ACK has no effect on relay coils. Used when automated action is required.

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NSTALLATION

2.1 UNPACKING

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 7003M Percent Oxygen Analyzer are operational.

2.1.1 S

2.2 ANALYZER INSTALLATION

2.3 SENSOR INSTALLATION

TORAGE

The sensors and analyzer unit may be shipped together or separately. The sensors are shipped assembly and charged, ready for use.

If rechargeable sensors are stored longer than six months, they may need to be recharged or rejuvenated if performance is marginal. Disposable sensors are not rechargeable.

Refer to documentation supplied with sensors for more information.

The Model 7003M Percent Oxygen Analyzer is designed to meet NEMA Type 4X (CSA enclosure 4) requirements, provided that the cutouts in the bottom of the enclosure are fitted with approved conduit fittings or are properly sealed by the user with Hoffman plugs (PN A-S050) or equivalent.

The Model 7003M is supplied with the Panel Mounting Kit PN 652527 as standard. Optional Wall Mount Kit PN 652539 and Pipe Mount Kit PN 652529 are available. Refer to the Outline and Mounting drawings provided in the rear of this manual.

Note: Refer to Figure 2-1 Sensor Ordering Matrix, and verify that the sensor to be

used corresponds with the application. If an incorrect sensor is used, calibration may be impossible or incorrect. If a different type of sensor is to be used, the rocker switch (SW1) on the Signal Board may have to be changed (see Section 2.3.1).

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Install the sensor in an area where temperature is relatively constant, taking care to avoid changes in exposure to sunlight or due to sudden drafts. A room-temperature environment is preferable. The flow chamber/sensor kit contains detailed mounting and sample flow information. Add distilled or deionized water to the sensor to the maximum level indication on the sensor reservoir. Let sensor stand for approximately 15 minutes and check for leaks around the base of the reservoir, and at the seams and corners. If a leak is found, contact the factory before proceeding. Drain the sensor.

4000 Rechargeable Sensor 5000 Disposable Sensor

1 Polypropylene 2 Ryton (rechargeable only) 9 Special (consult factory)

1 Submersion 2 In-Line Flow 3 Fast Response (rechargeable only) 9 Special (consult factory)

Position

4000 3

→

1234

Positions 1 through 4 = Sensor Type Position 5 = Material of Construction (Sensor and Flow Assembly) Position 6 = Flow Assembly Configuration

Example 400013 is a Rechargeable sensor, constructed of polypropylene, mounted in a Fast-Response Flow Chamber Assembly.

IGURE

2.3.1 A

2-1. S

NALYZER/SENSOR JUMPER CONFIGURATION

ENSOR ORDERING MATRIX

The Model 7003M is configured to match the type of sensor ordered with the analyzer. If the Signal Board or Sensor is repaired or replaced, verify rocker switch SW 1 on the Signal Board is properly set.

2-2

Rechargeable Sensor: Close positions 1, 4, and 5 Disposable Sensor: Close positions 2, 4, and 6

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2.4 ELECTRICAL CONNECTIONS

Observe all precautions stated in this manual and in the drawings provided at the back of this manual before installation.

All electrical connections to the analyzer are made on the Power Supply Board connection panel (see Figure 2-2 and drawing 652683), which is accessed by removing the rear cover.

WARNING: ELECTRICAL SHOCK HAZARD

Do not operate without rear cover secured. 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 the National Electrical Code (ANSI/NFPA-70) and/or any applicable national or local codes.

NSTALLATION

WARNING: ENCLOSURE INTEGRITY

Unused cable conduit entries must be securely sealed by non-flammable closures to provide enclosure integrity in compliance with personnel safety and environmental protection requirements. For watertight installation conforming to the requirements of NEMA Type 4X, use Hoffman plugs (PN A-S050) or equivalent to seal any unused openings.

1 +12V 2 -12V 1 ANODE 2 TEMP SENSE 3 NC 4 NC 5 EPOL 6 GND 7 Tx 8 Rx 9 RET 1 COM 2 NC 3 NO 4 COM 5 NC 6 NO 7 ISO GND 8 ISO CUR9 ISO CUR+

ALARM CONTACT RA T ING: 3A 120 VAC

1.5A 240 VAC 3A 30 VDC

AC POWER

AL 1

AL 2

HOT NEUT GND

L1 L2

FUSE RATING: 115V: 1/4A 250V 230V: 1/8A 250V

IGURE

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EAR PANEL CONNECTIONS

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Provide three separate 1/2 inch conduits as follows:

Power cable

•

Sensor cable

•

Alarm cables

•

2.4.1 S

ENSOR CABLE

The sensor cable used with the Model 7003M may be of any length up to a maximum of 1000 feet (305 m). (See Table 2-1.)

The signal cable should be routed through a conduit (customer-supplied) in permanent installations or in cases where the sensor is located more than a few feet from the control unit. (See Table 2-2.)

Note: In humid environments, temperature changes can cause moisture to

condense in the conduit, resulting in signal noise and corrosion. To minimize the effect of condensation, put desiccant (available locally) inside the conduit before sealing it.

CABLE PART NUMBER LENGTH

191748 10 Feet (3.1 m) 193265-SPECL Any specified length up to 1000 Feet (305 m)

ABLE

2-1. S

ENSOR CABLES

F CONDUIT USED

1/2 inch NPT female connection on bottom of control unit. (Conduit customersupplied.

F NO CONDUIT USED

Use cable connector assembly (PN 856831) to provide watertight seal. Assembly includes: Aluminum inner sealing grommet for connector compression nut.

ABLE

2-2. A

ONNECT SENSOR CABLE

NALYZER CABLE CONNECTIONS

1. Ensure that power is disconnected and remove rear cover.

2. Install the conduit or cable clamp in the left opening in the bottom rear of the case.

3. Install the sensor cable in the instrument through the cable clamp and tighten the nut on the plug to create a seal around the cable.

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NSTALLATION

4. Refer to Figure 2-2. Using a flat-blade screwdriver, connect the wires of the sensor cable to the TB2-1, TB2-2, TB2-5 and TB2-6 on the rear panel of the analyzer.

5. Replace the rear cover if no other connections are to be made. Do not overtighten the cover retaining screws to avoid stripping the threads in the plastic case.

2.4.2 P

OWER CONNECTIONS

Electrical power is supplied to the analyzer via a customer-supplied three conductor cable, type SJT, minimum 18 AWG. Refer to the installation drawing in the rear of this manual.

UMPERS AND FUSES

To verify the jumper location for the specified power (115 or 230 VAC) or if the analyzer is to be connected to a different power source, refer to Figure 2-3 and set jumpers and fuse as follows:

WARNING: ELECTRICAL SHOCK HAZARD

Disconnect power to analyzer before continuing.

1. Remove the rear cover from the analyzer.

2. Remove Power Supply Board.

3. Verify and/or set Jumpers E1, E2, E3, and E4 per Figure 2-3.

4. Verify that fuse (F1) is correct for power.

5. Re-install Power Supply Board.

6. Replace the rear cover if no other connections are to be made. Do not overtighten the cover retaining screws to avoid stripping the threads in the plastic case.

ONDUIT CONNECTIONS

Route the power cable through conduit and into the central opening in the bottom of the case. The inlet hole is sized for standard 1/2 inch conduit fittings

WARNING: ENCLOSURE NOT GROUNDED

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

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ERCENT OXYGEN ANALYZER

IGURE

F1 E3 E4 E2 E1

1/4 AMP 115 VAC

2-3. P

ONNECT POWER CABLE

OWER JUMPERS AND FUSES

Power Supply Board

115 VAC

Jumpers: E1 - E2 E3 - E4

Fuse: 1/4 Am

115 VAC

Jumpers: E2 - E4 Fuse: 1/8 Amp

F1 E3 E4 E2 E1

1/8 AMP 230 VAC

Connect power wiring to the compression type connectors on the rear panel (Figure 2-

2) as follows:

1. Loosen the connector screw.

2. Strip insulation back approximately 1/4 inch (6.35 mm), twist stranded wires together. DO NOT tin braid wire or the connection can work loose.

3. Insert wire into connector about 1/4 inch (6.25 mm), ensuring that wires do not touch any other wire or connector.

4. Tighten screw.

2.4.3 C

URRENT OUTPUT CONNECTIONS

CAUTION: TOTAL OUTPUT RESISTANCE

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

Refer to Figure 2-4. Isolated current output (0 to 20 or 4 to 20 mA) is standard on the Model 7003M. To convert from current output to voltage output, see Section 2.4.4.

1. Disconnect power to the analyzer. Remove rear cover.

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NSTALLATION

2. Connect the shielded recorder cable leads to the rear panel of the analyzer (Figure 2-2):

TB3-8 negative (-) TB3-9 positive (+)

Note: TB3-7 has no connection.

3. Connect the other end of the output cable to terminals of the output device. Ensure that polarity is correct. Connect the shield to a suitable ground point.

Note: Current output terminals are not grounded. Ground the current loop at

some point within the circuit to minimize noise or other undesirable interactions.

4. Replace the rear cover. Do not overtighten cover retaining screws, to avoid stripping the threads in the plastic case.

5. To connect recorder(s), see Figure 2-4.

2.4.4 V

OLTAGE OUTPUT CONNECTIONS

CAUTION: TOTAL OUTPUT RESISTANCE

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

Refer to Figure 2-4. To convert the voltage output to current output see Section 2.4.3. To monitor the signal output with a voltage recorder or other voltage device, the

standard current output must be converted into a voltage by connecting a resistor in parallel with the output device as follows:

1. Determine the resistor value (R) required:

R1 ohms = (fullscale voltage, volts)/(0.02 amps)

2. Disconnect power; remove the rear cover.

3. Connect resistor (1/4 watt or greater) of value R between TB3-8 and TB3-9 (Figure 2-4).

4. Connect leads of a shielded recorder cable to the rear panel of the analyzer (Figure 2-2):

TB3-8 negative (-) TB3-9 positive (+)

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ODEL

Note: TB3-7 has no connection.

ERCENT OXYGEN ANALYZER

5. Connect other end of output cable to terminals of output device. Ensure that polarity is correct.

6. Replace the rear cover. Do not overtighten cover retaining screws, to avoid stripping the threads in the plastic case.

7. For the low end point to be 0 volts, set the current output range to 0 to 20mA when setting up the instrument (Section 3.5.2).

TB3

RECORDER

S - +

7 8 9

NEG (-) POS (+)

RECORDER

S - +

NEG (-) POS (+)

ONE RECORDER

RECORDER

S - +

MULTIPLE

RECORDERS

IGURE

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Rosemount Analytical

URRENT OUTPUT CONNECTIONS

July 1997

748223-H

NSTALLATION

2.4.5 R

ELAY CONTACTS FOR ALARMS OR

ON/OFF-C

ONTROLS

Note: Whenever "Alarm" is used, it refers to either alarm or ON/OFF Control,

depending on how the relays are connected and configured by the customer.

ATINGS

Two sets of alarm relay contacts are provided for actuation of customer-supplied alarm and/or ON/OFF-Control functions. (see analyzer specifications in Preface).

OWER FAILURE

Removal of AC power from the analyzer, as in a power failure, removes power from both relay coils. The Model 7003M should operate on a different AC power source than the Alarm relay contacts.

ADIO FREQUENCY INTERFERENCE

(RFI)

If alarm contacts are connected to any device that causes radio frequency interference (RFI), an arc suppressor (PN 858728) should be used to minimize RFI.

ONNECTING DEVICES TO RELAY CONTACTS

WARNING: RELAY CONTACTS

Relay contacts wired to separate power source must be disconnected before servicing.

Connect alarm or ON/OFF-Control devices to the relay contacts as follows:

1. Disconnect power; remove rear cover of analyzer.

2. Connect leads from the external alarm or ON/OFF Control system (see Figure 2-

2). TB3-1 Alarm 1 Com

TB3-2 Alarm 1 NC TB3-3 Alarm 1 NO TB3-4 Alarm 2 Com TB3-5 Alarm 2 NC TB3-6 Alarm 2 NO

3. Connect other end of output cable to terminals of alarm device.

4. Replace the rear cover. Do not overtighten cover retaining screws, to avoid stripping the threads in the plastic case.

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ERCENT OXYGEN ANALYZER

Note: For installation in a Class I, Division 2 location, refer to the Specifications

in the Preface section, and the approval label on the analyzer for Factory Mutual limitations on contact ratings.

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PERATION

3.1 OVERVIEW

It is recommended that the operator read the entire manual through before first operating the instrument.

The operator can generally operate the Model 7003M using the flow chart in Figure 32 after the display symbols and modes of operation are understood.

3.2 KEYPAD OPERATION

During each particular keystroke sequence, the analyzer will recognize only certain keys. If an unrecognized key is pressed, the instrum ent will either not respo nd or will display "SrY" ("Sorry") and return to RUN Mode.

Generally, to escape from any routine, press ENTER repeatedly until the instrument returns to the RUN Mode and the oxygen concentration is displayed.

IGURE

748223-H

3-1. M

ODEL

7003M F

Rosemount Analytical

ALARM1

ALARM2

MODEL 7003M

DISPLAY ACK

PERCENT OXYGEN

RONT PANEL CONTROLS AND INDICATORS

ALARM1ALARM

CAL ENTER

ANALYZER

°°°°

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3.2.1 C

HANGING PARAMETERS WITH THE KEYPAD

All operation parameters are set with the keypad. When the instrument is waiting for operator input, the display will flash a digit. At this point, if the number itself can be changed, the operator can generally increase the number (UP arrow) or decrease it (DOWN arrow) at this time. An exception is when the operator is restricted to preselected choices (e.g., output current ranges, see Section 3.5.2).

When changing a value, an arrow key can be pressed for a moment, and the display will change by one digit. If it is held down, the display will change, slowly at first, then rapidly.

If the display has a digit flashing and will not change, check the range of that parameter. For example, an alarm setpoint cannot be set higher than 25%.

When the number desired is displayed, press ENTER. The Model 7003M will accept that number and continue with the next step of that routine.

RUN MODE

Display Oxygen Temperatur e

DISPLAY ACK

Acknowledge Alarm

Reveal Security Code

SETUP MODE

CAL + ENTER

ENTER SECURITY

CODE

Set New Security

ACK

FLOW

ZERO GAS

Code

Select 0-20 or 4-20mA

Set Concentrati on for Minimum Output Current

(0 or 4mA)

Set Concentrati on for Maximum Output Current

(20mA)

Set Residual Current Offset

ENTER ACK

ENTER

ALARM MODE

ALARM1*

ENTER SECURITY

ENTER

CODE

ALARM 1*

Toggle

ON/OFF

Disable Alarm

Change "ON" Setpoint

Change "OFF" Setpoint

CALIB. MODE

CAL

ENTER SECURITY

CODE

ENTER

Return to

RUN Mode

PRESSURE

COMPENSATION

ROUTINE

CAL

ENTER

Set Span Concentration

DISPLAY + ACK

Set Sample Pressure

Set Span Gas Pressure

HOLD MODE

ENTER SECURITY

CODE

ENTER

Return to

RUN Mode

DIAGNOSTICS

MODE

Select Displayed Parameter

ALARM 1*

ON/OFF

ENTER

DISPLAY

Toggle

Change Current Output

Return to

RUN Mode

*Press ALARM 2 to set Alarm 2.

IGURE

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7003M O

Return to

RUN Mode

July 1997

Return to

RUN Mode

PERATION FLOW DIAGRAM

Return to

RUN Mode

748223-H

PERATION

3.2.2 S

INGLE AND DOUBLE KEYSTROKE

Most procedures involve a sequence of single keystrokes by which the operator presses one key at a time. Some of the more frequently used single-key commands are:

KEY FUNCTION HOW TO USE IT

ACK Acknowledges an alarm condition Press once to silence alarms

Press to display °C; press again to display

DISPLAY

ARROW keys

CAL Access CALIBRATION mode

ENTER End command sequence

ALARM1 Access ALARM 1 mode

ALARM2 Access ALARM 2 mode

CAL + ENTE R Access SETUP mode UP ARROW +

DOWN ARROW DISPLAY + ACK Access DIAGNOSTICS mode

DISPLAY + ACK Access security ID code

Switch between %O2 and °C

Increase/Decrease displayed value

Access HOLD mode.

O2. Output signals are not affected. Press once to change value by one digit.

Hold key down to change value quicker. Press to calibrate. (If security is enabled,

prompts for ID code first) Press to enter value or to end a command

sequence Press to check, set or disable Alarm 1 or

ON/OFF-Control re lay s Press to check, set or disable Alarm 2 or

ON/OFF-Control re lay s From RUN mode, press CAL and ENTER

keys simultaneously. From RUN mode, press UP ARROW and

DOWN ARROW keys simultaneously. From HOLD mode, press DISPLAY and

ACK keys simultaneously. From RUN mode, press DISPLAY and

ACK keys simultaneously.

ABLE

748223-H

3-1. K

INDICATOR CARET/STATUS DESCRIPTION

%O2 Caret O N Oxygen percentage displayed

ALARM1,2 Caret OFF Normal condition ALARM1,2 Caret blinking Alarm condition

- Caret ON

3-2. D

EY FUNCTIONS

Caret ON

ISPLAY INDICATORS

Sensor temperature displayed, °C

Displays current output in mA (DIAGNOSTICS mode only)

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3.2.3 D

ISPLAY PROMPTS

The Model 7003M prompts the operator for inputs and also indicates the function in progress. For example, when entering the calibration mode, the prompt "CAL" is displayed for one second after the CAL key is pressed. Display acronyms are listed in Tables 3-3 through 3-9.

CODE DEFINITION

id enter security code prompt no invalid security code entered - access denied YES access granted or security code entered is correct

ABLE

3-3. S

ECURITY ACCESS PROMPTS AND RESPONSES

CODE DEFINITION

A-1 setpoints for Alarm 1 - ALARM function A-2 setpoints for Alarm 2 - ALARM function C-1 setpoints for Alarm 1 - ON/OFF - Controller function C-2 setpoints for Alarm 2 - ON/OFF - Controller function

ABLE

On value in which to initiate an Alarm Action (On-setpoint) OFF value in which to terminate an Alarm Action (Off-setpoint) dis Alarm is now disabled

3-4. A

LARM SETTINGS PROMPTS AND RESPONSES

CODE DEFINITION

CAL initiate a span calibration PPr enter process pressure value CPr enter calibration pressure value GAS Initiate a zero offset calibration (gas)

3-5. C

ALIBRATION PROMPTS AND RESPONSES

CODE DEFINITION

Set enter system setup mode 4-0 define the current output as 4-20 or 0-20 mA CLo % concentration that 0/4 mA represents (calibration low) CHi % concentration that 20 mA represents (calibration high)

ABLE

3-4

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YSTEM SETUP PROMPTS AND RESPONSES

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PERATION

CODE DEFINITION

A-1 toggle ON/OFF check of relay coil for Alarm 1 A-2 toggle ON/OFF check of relay coil for Alarm 2 D-2 performing non-intrusive test Internal RAM (16#00#..16#FF#) D-3 performing non-intrusive test on Internal RAM (16#4000#..16#5FFF) D-4 performing non-intrusive test on EEPROM (16#B600#..16#B7FF#) D-5 performing non-intrusive test on PROM (16#C000#..16#FFFF#) F-2 failed D-2 test F-3 failed D-3 test F-4 failed D-4 test F-5 failed D-5 test hld entering system Hold OFF alarm relay is de-energized (normally-closed) On alarm relay is energized (normally-open) tSt entering on-line test diagnostics mode

ABLE

3-7. S

YSTEM HOLD AND DIAGNOSTICS CODES

CODE DEFINITION

caret lit displayed

sensor membrane voltage from ADC

Temp sensor thermistor voltage from DC

minus sign milliamps sent to current output

3-8. D

ATA DISPLAYED IN

DIAGNOSTICS M

ODE

CODE DEFINITION

Sry invalid keypad function (Sorry) run current function completed - entering RUN Mode

3-9. M

ISCELLANEOUS PROMPTS AND RESPONSES

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3.2.4 E

RROR MESSAGES

If an error condition occurs, E-# (non-fatal error) or F-# (fatal error) will flash on the display. Tables 3-10 through 3-13 list error codes and corrective actions. Pressing "ACK" or "ENTER" will acknowledge any alarm and the error message will disappear.

CODE DEFINITION

F-1 Invalid PROM (16#C000#..16#FFFF#) checksum detected F-2 Internal RAM (16#00#..16#FF#) failed testing F-3 External RAM (16#4000#..16#5FFF) failed testing F-4 EEPROM (16#B600#.. 16#B7FF#) bulk erase failure F-5 Signal Board not connected F-6 thru F-9 EEPROM write failure

ABLE

3-10. P

OWER

ON, R

ESET DIAGNOSTICS ERRORS (FATAL ERRORS

CODE DEFINITION

E-1 5 volts power supply above 5.5 V E-2 5 volts power supply below 4.5 V

)

ABLE

E-3 12 volts power supply above 13.2 V E-4 12 volts power supply below 10.8 V E-5 sensor output too low for calibration E-6 sensor missing E-8 E-9

3-11. RUN M

sample temperature is below 1°C sample temperature is above 44°C

ODE ERRORS (NON-FATAL ERRORS

)

CODE DEFINITION

HI LO

sample temperature is above 50°C sample temperature is below 0°C

Ahi excessive sensor signal

3-12. S

IGNAL BOARD ERRORS

CODE DEFINITION

COP Computer Operating Properly error (error detected) iot Invalid Op code Trap (internal computer command is invalid)

ABLE

3-6

E-0 power interruption occurred

3-13. M

Rosemount Analytical

ICROPROCESSOR ERRORS THAT RESET THE SYSTEM

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PERATION

3.2.5 A

UTOMATIC RETURN TO

RUN M

ODE

If no keys are pressed for f ive minutes, the instrument will autom atically return to the RUN Mode, except when in Zero Offset, HOLD, or DIAGNOSTICS Modes.

CAUTION: OXYGEN WILL NOT BE MONITORED

The instrument will remain in HOLD or DIAGNOSTICS Modes until the operator returns it to the RUN Mode or other operation.

3.2.6 P

REVENTING UNAUTHORIZED ACCESS

The Model 7003M is equipped with a security feature to prevent unauthorized tampering with the instrument settings. The instrument is shipped from the factory with the security feature disabled. It can be enabled or disabled at any time.

Security access is not required to:

Display sensor data

•

Acknowledge alarms

•

Reveal security code

•

Security access is required to:

Calibrate with span gas

•

Access options and diagnostics

•

Change operation parameters

•

Enable or disable alarms and ON/OFF-Control

•

Disable or change the security code

•

After the security code is entered, the operator can change any instrument setting and can go back and forth to the RUN Mode without having to enter the code again.

If security is enabled, and the instrument is left in the RUN Mode for five minutes, security will automatically be re-activated. With in this five minute period, an yone can access the functions without re-entering the security code.

3.2.7 S

ENSOR EQUILIBRIUM

When a new sensor is installed, power up the instrument and let the sensor stabilize for about 5 hours before calibrating it.

If the oxygen sensor is calibrated at a relatively high oxygen concentration, such as with ambient air (typically 20.95%) and then is exposed to a low oxygen level, a longer equilibrium time period may be re quired f or the sens or to equilibra te. This time perio d depends on the monitoring concentration level and how long the sensor was operated at the higher level.

3.3 START-UP

Before proceeding, the operator should be familiar with the keypad and indicators (Section 3.2).

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ERCENT OXYGEN ANALYZER

Operational checks and adjustments are not normally required, provided that the sensor, inter-connection cable and analyzer have been properly installed. The analyzer continually performs self-checking routines during operation.

Calibration with ambient air is recommended after start-up and at regular intervals (see Section 4.2.2)

The following sections provide instructions for initial start-up and subsequent standardization of the analyzer.

3.3.1 I

NITIAL POWER-UP

1. Ensure that the proper sensor and sensor cable are connected to the analyzer.

2. Apply power to the analyzer. The following internal tests are performed:

RAM Read/write test ROM "Checksum" test

EEPROM Read/write test

3. If an error code flashes, refer to the error code lists in Tables 3-10 through 3-13. Press ACK to continue with the startup procedure.

After internal tests are passed, the software version is displayed for a few seconds, and the analyzer goes directly into RUN mode. "RUN" is briefly displayed, then current oxygen level.

Error codes E-0 (power failure) and E-5 (not calibrated) typically occur upon powerup.

4. Monitor the oxygen output or display until the level stabilizes (typically 5 hours). The alarms and current output levels can be set immediately if desired.

5. Once the sensor has stabilized, the analyzer is operational and is ready for subsequent operations. Refer to Table 3-14 for the default settings present upon power-up.

Mode: Alarm State: DisabledAlarm 1 Setpoints: On: 0.0 Off : 0.1% Mode: Alarm State: DisabledAlarm 2

Setpoints: On: 0.0 Off : 0.1% Range Current Output Range 4-20 mA

Security Disabled Pressure Residual Zero Offset 0

Calibration Status Not Calibrated

ABLE

3-8

3-14. D

Rosemount Analytical

EFAULT SETTINGS AT POWER-UP

0% of scale: 0% Oxygen

100% of scale: 25% Oxygen

Calibration: 76.0 cm Hg

Process: 76.0 cm Hg

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PERATION

3.3.2 S

YSTEM RESTART

The Model 7003M will attempt to restart itself in the event of a power interruption, power surge or other outside interference to micropr ocessor operati on (Section 3.3.3) .

The analyzer can also be manually restarted if the RAM or EEPROM becomes corrupted (3.3.4).

3.3.3 A

UTOMATIC RESTART

UE TO POWER FAILURE

- D

If a power failure or other event occurs that affects operation of the microprocessor the system will attempt to re-start itself. If it is su ccessful, th e instrume nt will continu e to operate normally, except that the appropriate error code will be displayed until the ACK button in pressed. See Section 5.3.3 for circuit description.

3.3.4 M

ANUAL RESTART

1. Turn power to analyzer OFF.

2. Wait 30 seconds, and turn the power to the analyzer ON.

3. While the software revision is being displayed and the self-tests are being performed, press DISPLAY and ACK simultaneously.

"dYn" is displayed.

4. Press ENTER to clear the RAM and EEPROM.

The display will go blank, then continue with the SETUP routine. Continue with Section 3.5.1, step 2.

3.4 RUN MODE

Refer to Figure 3-2 and Table 3-15. The RUN mode is the norm al mo de of operation, from which the operator can:

Display oxygen concentration and sensor temperature

•

Acknowledge alarms

•

Display security code

•

Access other modes

•

KEY DISPLAY WHAT HAP PE NS

DISPLAY Number change Toggles between O2 reading and temperature ACK Clears message Acknowledges Alarms ALARM 1 "A-1" then ON To Alarm 1 SETUP mode ALARM 2 "A-2" then ON To Alarm 2 SETUP mode UP ARROW "SrY" "run" Stays in RUN mode DOWN ARRO W "SrY" "run" Stays in RUN mode CAL "CAL" then ON To CALIBRATION mode ENTER "SrY" "run" Stays in RUN mode CAL + ENTER "SEt" then ON Moves to SETUP mode UP + DOWN "hLd" then ON Moves to HOLD mode DISPLAY + ACK "123" Shows the security code

ABLE

748223-H

3-15. RUN M

ODE KEY FUNCTIONS

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3.4.1 D

ISPLAY OXYGEN CONCENTRATION/SENSOR TEMPERATURE

Press DISPLAY once to display sensor temperature. Press DISPLAY again to display oxygen concentration.

3.4.2 A

CKNOWLEDGE ALARMS

If an alarm setpoint has been reached, "A-1" or "A-2" will flash with a concentration value. Acknowledging the alarm will stop the flashing display and turn off the relay switch.

To Acknowledge Alarm -

Press ACK key. If relays are configured as ON/OFF

controllers, pressing the ACK key has no effect.

3.4.3 A

CCESS OTHER MODES

The following lists which key(s) to press to access various modes:

SETUP = CAL+ENTER ALARM = ALARM1 (or ALARM2) CALIBRATION = CAL HOLD = UP and DOWN ARROWS DIAGNOSTICS = DISPLAY+ACK (from HOLD)

3.5 SETUP MODE

Refer to Figure 3-3 and Table 3-16. From the SET-UP mode the operator can:

Change security code

•

Set output current range (0-20mA or 4-20mA)

•

Set output concentration range endpoints

•

Adjust zero offset

•

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK "<4>-0" / "4-<0> Selects 4-20 or 0-20 mA operation ALARM 1 Nothing Nothing ALARM 2 Nothing Nothing

ABLE

UP ARROW DOWN ARROW

10.8 →10.9

10.9 →10.8 CAL Nothing Nothing ENTER various to "run" Moves to the next step or goes to RUN mode

3-16. SETUP M

ODE KEY FUNCTIONS

Changes the number displayed Changes the number displayed

3-10

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748223-H

SET-UP Mode

CAL ENTER

PERATION

Flashing

Flashing May not be displayed each time.

Flashing

ALARM1

ALARM2

%O2

°°°°

SECURITY ACCESS ROUTINE

(see Figure 3-4)

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

%O2

°°°°

%O2

°°°°

%O2

°°°°

%O2

°°°°

%O2

°°°°

Prompts for Security Code. If left at 000, code will be disabled. Use Arrow keys to set Security Code.

Select either 4-20mA or

ACK

0-20mA Output

ENTER

Flashing

Flash for 2 seconds

(Hi range output selection)

Flash for 2 seconds

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

%O2

°°°°

%O2

°°°°

%O2

°°°°

%O2

°°°°

%O2

°°°°

Prompts for zero offset

%O2

°°°°

%O2

°°°°

Prompts for low end output. (i.e., 0% O2 would be the low range representing O2 level of 0 or 4mA.

Set Span output level = 20mA

ENTER

IGURE

748223-H

3-3. SETUP M

ODE FLOWCHART

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ERCENT OXYGEN ANALYZER

3.5.1 S

ECURITY CODE

Refer to Figure 3-4.

EVEAL CURRENT SECURITY CODE

From RUN mode, hold down DISPLAY and ACK keys simultaneously.

HANGE CURRENT SECURITY CODE

1. From RUN mode, press CAL and Enter simultaneously.

2. SET, id are briefly displayed. Then "000" is displayed with the right digit flashing.

Note If RUN and CAL are not press exactly at the same time, "SRY", or "RUN"

will appear, and the analyzer will return to RUN mode.

3. If the security code has been disabled, skip to step 4. Use the ARROW keys to enter the current security code, then press ENTER.

4. If the correct code is entered, YES, SET, id will be displayed briefly, the code will flash. If the incorrect code is entered the analyzer will return to RUN mode.

5. Use the ARROW keys to set the new security code (or "000" to disable), press enter.

6. Continue with the next set-up routine, or hold down ENTER until "run" appears (the instrument is back in RUN mode).

3.5.2 C

URRENT OUTPUT RANGE

- 0-20MA

4-20MA

Following the last procedure, "4-0" is displayed with either digit flashing. "4" indicated 4-20mA (default), and "0" indicates 0-20mA.

1. Press ACK until the desired range is flashing, press ENTER.

2. Continue with the next SET-UP routine, or hold ENTER key to return instrument to RUN mode.

3.5.3 R

ANGE ENDPOINT ADJUSTMENTS

The oxygen values corresponding to minimum and maximum output current must be set. Default is 0% for 0 or 4mA and 25% for 20mA. Endpoints must be within the range of the instrument and must be at least 1% oxygen apart.

ET OXYGEN LOW CONCENTRATION ENDPOINT

Following the last procedure, "CLo" is displayed briefly, followed by the oxygen concentration last stored to correspond to minimum output current.

Note If "CLo" is set to a value greater than "CHi", "CHi" will be automatically

reset to a value 1% greater than "CLo".

Use the ARROW keys to set the low oxygen concentration (0 to 24%), press ENTER.

3-12

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748223-H

PERATION

"CHi" is displayed briefly, followed by the latest oxygen concentration stored corresponding to maximum output current.

ET OXYGEN HIGH CONCENTRATION ENDPOINT

"CHi" cannot be set to a value equal to or less than "CLo". Use the ARROW keys to set the high oxygen concentration (1 to 25%), press ENTER. Continue with next SET-UP routine or hold ENTER to return to RUN mode.

RUN

SET-UP Mode

CAL ENTER

ALARM CA L

WAS SECURITY ID

ENTERED <5 MIN.

AGO

ENTER ID

ENTER

CORRECT

HOLD Mode

YES

OPERATOR GIVEN

ACCESS TO

SELECTED MODE

YES

IGURE

748223-H

3-4. S

ACCESS DENIED

Returns to RUN mode

ECURITY ACCESS ROUTINE FLOWCHART

July 1997

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3-13

ODEL

7003M P

ERCENT OXYGEN ANALYZER

3.5.4 Z

ERO OFFSET ADJUSTMENT

Following the last procedure, the current zero offset value will be flashing.

Note When flowing zero gas over the sensor, ensure that there are no leaks and

the gas actually has zero oxygen concentration. Otherwise, significant errors will result. Zero offset adjustment is generally not required. Errors are more often due to incorrect zero gas oxygen concentration than residual current of the oxygen sensor.

The zero offset adjustment allows the operator to compensate for any residual sensor current. Adjustment range is 0-5% equivalent oxygen.

Sensor Current = Current from Oxygen + Residual Current

Note Adjusting the zero offset affects the output of the Model 7003M. Therefore,

if the zero offset is changed, the system must be re-calibrated with span gas.

ERO OFFSET IS NOT TO BE CHANGED

Press ENTER to return analyzer to RUN mode, and skip the remainder of this procedure.

ERO OFFSET IS TO BE REMOVED

1. Press the UP ARROW until the maximum value is displayed.

2. Press ENTER and re-calibrate with span gas per Section 4.2.2.

ERO OFFSET TO BE ADJUSTED

1. Expose the sensor to 100% oxygen-free nitrogen or other inert gas and allow the sensor signal to stabilize (2-5 hours depending on sample conditions).

2. Use the DOWN ARROW to bring the displayed value to zero (for maximum offset).

3. Press ENTER to return to RUN mode.

4. Re-calibrate with span gas per Section 4.2.2.

3.6 ALARM MODE VS. ON/OFF-CONTROL MODE

Refer to Figure 3-5 and Table 3-17. From the ALARM or ON/OFF-Control Mode, the operator can:

Set alarm ON and OFF setpoints.

•

3-14

Select alarm or ON/OFF-Control function for relays

•

Disable alarm(s)

•

Rosemount Analytical

July 1997

748223-H

ALARM/CONTROLLER MODE

PERATION

To Disable Alarm

Indicates Alarm is disabled

Flashes Alarm Configuration

ALARM1

ALARM2

Flashing

ALARM1

ALARM2

Prompts "ON" Setpoint

Displays "ON" Setpoint

ACK

%O2

°°°°

ALARM

ALARM1

ALARM2

Note: Alarms are disabled when instrument is received. Alarm 2 uses identical sequence.

%O2

°°°°

SECURITY ACCESS ROUTINE

(see Figure 3-4)

ALARM1

ALARM2

%O2

°°°°

ALARM1

ALARM2

ALARM1

ALARM2

%O2

°°°°

ALARM1

ALARM2

%O2

°°°°

%O2

°°°°

STANDARD ALARM

Adjust Alarm ON Setpoint

ENTER

%O2

°°°°

Flashes Control Configuration

ALARM

Change Relay configuration

ALARM1

ALARM2

%O2

°°°°

ALARM1

ALARM2

ALARM1

ALARM2

%O2

Prompts for OFF Setpoint

°°°°

%O2

°°°°

ENTER

ALARM1

ALARM2

New values/functions will not be stored until instrument returns to RUN mode with relay activated.

IGURE

3-5. ALARM M

ODE FLOWCHART

748223-H

%O2

°°°°

July 1997

Adjust Alarm OFF Setpoint

Rosemount Analytical

3-15

7003M P

ODEL

DISPLAY Nothing Nothing ACK "dIS" Disables alarms ALARM 1 "C-1" / "A-1" Toggles between alarm and controller m ode ALARM 2 "C-2" / "A-2" Toggles between alarm and controller m ode UP ARROW DOWN ARROW CAL Nothing Nothing

ENTER "OFF" / "run"

ERCENT OXYGEN ANALYZER

KEY DISPLAY WHAT HAPPENS

10.8 →10.9

10.9 →10.8

Changes alarm setpoint Changes alarm setpoint

Moves to the "OFF" setpoint step or goes back to RUN mode

ABLE

3.6.1 R

3-17. ALARM M

ELAY CONFIGURED AS ALARM

ODE KEY FUNCTIONS

Relays are configured as alarms (ALARM Mode) when immediate operator action is required.

When alarms are selected, "A-1" and "A-2" are displayed in the ALARM mode set-up procedure.

When an alarm condition occurs, the caret blinks, the relay activates, and the display flashes. Press the ACK key to acknowledge the alarm, de-energize the relay coil and stop the alarm actions.

3.6.2 R

ELAY CONFIGURED AS

ON/OFF-C

ONTROLLER

Relays are configured as ON/OFF-Controllers (ON/OFF-Controller mode) when a noncritical, non-hazardous automated action is desired, or when it is important that the relay output not be bypassed by the operator.

When ON/OFF-Controllers are selected, "C-1" and/or "C-2" is displayed in the ALARM mode set-up procedure.

When an ON/OFF-Controller alarm condition occurs, Alarm 1 or 2 caret blinks and the relay coil is energized. However, the display does not flash, and the ACK key is inactive. Alarm conditions are automatically reset when the sensor indicates that an alarm condition no longer exists.

3.6.3 R

ELAY CONTACTS

The relay contacts are:

RELAY TERMINAL LOCATIONS

POS ALARM1

NO (Normally open) TB3-3

nc (Norm ally closed) TB3-2

COM (Common) TB3-1

Relay positions are with power removed.

ABLE

3-16

3-18. A

Rosemount Analytical

LARM RELAY CONTACT POSITIONS/TERMINAL LOCATIONS

July 1997

ALARM2

Tb3-6 TB3-5 TB3-4

748223-H

PERATION

3.6.4 F

AIL SAFE OPERATION

The relays are setup to operated in "Fail Safe" configuration. In this configuration the relay coils are powered when the unit is NOT in an alarm condition. When an alarm condition occurs, power is removed from the relay coils.

If a power failure occurs, power will be removed from the relays and an alarm condition will be indicated to the device connected to the relays.

3.6.5 R

ELAY RESET UPON FATAL ERROR

If a fatal error is detected, the unit will attempt to reset itself which will make both relays go into alarm mode. If the microprocessor is able to continue its operation, the relays will then be reset to their normal operating position.

3.6.6 P

RESSURE EFFECTS ON ALARMS

If the sample pressure changes, the partial pressure of oxygen, and thus the reading, will change and the alarm relays will not actuate at the same oxygen levels as they were set when the interment was last calibrated. See Section 5.4.2 for a more detailed description of pressure effects.

3.6.7 S

ETTING ALARM AND

ON/OFF-C

ONTROLLER RELAYS

Wherever "Alarm" is referred to in this section, the term "ON/OFF-Controller" can be substituted, unless specifically called out. Also, any reference to A1 or Alarm 1 also applies to Alarm 2, and to ON/OFF-Controllers 1 and 2.

3.6.8 S

ETTING ALARM SETPOINTS

This procedure can be used to:

Verify alarm relay setpoints

•

Change setpoints

•

Enable alarms

•

Disable alarms

•

Perform the following procedure for each Alarm setpoint, as required. Figure 3-6 illustrates how relays are energized and de-energized in High and Low Alarm configurations.

3.6.9 S

ETTING ALARM

AND

OFF L

EVELS

Refer to flowchart Figure 3-5. From RUN mode, press ALARM 1. A-1, YES, A-1 (or C-1), ON flash briefly; the alarm ON setpoint is displayed with the

right digit blinking. A-1 indicates relay 1 acts as an ALARM; C-1 indicates relay one acts as an ON/OFF-

Control.

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ERCENT OXYGEN ANALYZER

To change the relay action from ALARM to ON/OFF Control function

(or vise

versa) press ALARM 1. C-1 or A-1 will flash indicating a new mode.

To disable ALARM 1

To set the ON setpoint for ALARM 1

- Press ACK. "DIS" will flash briefly and return to RUN mode.

- Use the ARROW keys, press ENTER. OFF is

flashed briefly, then the alarm OFF setpoint is displayed with the right digit flashing.

To set the OFF setpoint for ALARM 1

- Use the ARROW keys, press ENTER. The

instrument displays "run" and returns to RUN mode

HIGH Alarm

set for 8.24% O

8.24%

8.10%

ACTIVATES DE-ACTIVATES

ALARM ON

SETPOINT

OFF SETPOINT

OFF

IGURE

set for 8.10% O

3-6. A

LOW Alarm

8.24%

8.10%

ACTIVATES DE-ACTIVATES

CTION OF ALARM RELAY

TIME

ALARM ON

OFF SETPOINT

SETPOINT

TIME

AND

OFF S

OFF

DEADBAND

ETPOINTS

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Rosemount Analytical

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ALIBRATION AND ADJUSTMENTS

4.1 FREQUENCY OF CALIBRATION

When a new sensor is installed, adjust the zero offset current (4.2.1) and calibrate the instrument with span gas (4.2.2). Span the instrument weekly at first and note the stability. Use this information to determine the regular calibration f requency required by this particular application.

4.2 CALIBRATION MODE

Refer to Figure 4-1 and Table 4-1. From the CALIBRATION Mode, the operator can:

Calibrate with span gas

•

Enter sample and span gas pressures

•

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK Nothing Nothing ALARM 1 Nothing Nothing ALARM 2 Nothing Nothing UP ARROW DOWN ARROW CAL "PPr" Moves to pressure compensation mode ENTER "run" Drop s back to RUN mode

ABLE

4.2.1 Z

4-1. CALIBRATION M

ERO CALIBRATION

Each oxygen sensor produces a constant residual electrical current in the absence of oxygen due to characteristics of the sensor. Typically this current is less that 0.1% apparent oxygen. It is different for each sensor, but will remain constant for the life of that sensor. The instrument can be zeroed by adjusting the residual current per Section 3.5.4. After this procedure is performed once, the zero should not need adjusting again during the life of the sensor.

10.8 →10.9

10.9 →10.8

ODE KEY FUNCTIONS

Changes calibration factor Changes calibration factor

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Rosemount Analytical

4-1

ODEL

7003M P

ERCENT OXYGEN ANALYZER

4.2.2 S

PAN CALIBRATION

1. Expose the sensor to ambient air1 and let the oxygen reading and sensor temperature stabilize.

2. Press CAL to enter the CALIBRATION mode. Enter the security code if required.

3. CAL flashes and oxygen concentration is displayed with the right digit flashing. Output is held at last reading until returned to RUN mode.

4. Use the ARROW keys to set the instrument to the concentration of the calibration gas. See Tables 4-2 and 4-3 if using ambient air as span gas.

5. Press ENTER to return to the RUN mode.

6. If the ratio between the concentration value entered and the sensor voltage is excessive, an error message will be flashed.

7. If the sample gas and the calibration gas are each at constant pressure, continue with Section 4.2.3 and enter the pressure of each.

Oxygen 20.946% Nitrogen 78.084% Argon 0.934%

0.002

0.004

0.033%

0.001

Water Vapor 0.000% Other Gases Balance

760 mm Hg; 0% Relative Humidity

ABLE

4-2. C

OMPOSITION OF DRY ATMOSPHERIC AIR

PERCENT COMPOSITION ( .002%) A@

GAS

C20

°°°°

C25

°°°°

C30

°°°°

Oxygen 20.641% 20.510% 20.338% 20.115% Water Vapor 1.683 2.307 3.126 4.187 Other Gases Balance Balance Balance Balance

760 mm Hg; 100% Relative Humidity

ABLE

We recommend using ambient air in calibration, regardless of the range. Only when monitoring at 0 to 1% range, can

the accuracy of the instrument be slightly improved by using a gas of lower concentration (e.g., 1%) for calibration. If bottled air is used, verify the oxygen concentration against National Bureau of Standards certified calibration gas. The true oxygen concentration in cylinders is often different from the concentration indicated on the cylinder label.

CRC Handbook of Chemistry and Physics, R. Weast, ed., Chemical Rubber Co., Boca Raton, FL: CRC Press, 1987, p.

F-148.

Computed from data in CRC Handbook of Chemistry and Physics, p. D-190.

4-3. C

OMPOSITION OF HUMID ATMOSPHERIC AIR

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Rosemount Analytical

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748223-H

CALIBRATION MODE

(

)

CAL

ALIBRATION AND ADJUSTMENTS

STANDARD CALIBRATION PROCEDURE

Example if using in Air

ALARM1

ALARM2

ALARM1

ALARM2

%O2

°°°°

SECURITY ACCESS ROUTINE

see Figure 3-4

ALARM1

ALARM2

ALARM1

ALARM2

CURRENT %O

%O2

°°°°

%O2

°°°°

READING

%O2

°°°°

ALARM1

ALARM2

PRESSURE COMPENSATION SEQUENCE (i.e., CAL at atmospheric pressure, put sensor in different process pressure.)

ENTER

%O2

Flash for 2 seconds (Process Pressure)

°°°°

ALARM1

ALARM2

ENTER

ALARM1

ALARM2

%O2

°°°°

%O2

°°°°

Input Process Pressure in cm Hg

ENTER

ALARM1

ALARM2

ALARM1

ALARM2

%O2

Flash for 2 seconds

°°°°

(Calibration Pressure)

%O2

°°°°

Input Calibration Pressure in cm Hg

ENTER

ALARM1

ALARM2

%O2

°°°°

IGURE

4-1. CALIBRATION M

LOWCHART

748223-H

ODE AND

PRESSURE COMPENSATION

July 1997

Rosemount Analytical

4-3

ODEL

7003M P

ERCENT OXYGEN ANALYZER

BAROMETRIC

PRESSURE

cm Hg (in. Hg)

APPARENT O

PARTIAL PRESSURE

cm Hg (Dry Air)

73 (28.7) 15.3 20.24% 74 (29.1) 15.5 20.52 75 (29.5) 15.7 20.80 76 (29.9) 15.8 20.95 77 (30.3) 16.1 21.36 78 (30.7) 16.3 21.63

ABLE

4-4. B

AROMETRIC PRESSURE EFFECT ON APPARENT OXYGEN

ONCENTRATION

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK Nothing Nothing ALARM 1 Nothing Nothing ALARM 2 Nothing Nothing UP ARROW DOWN ARROW

10.8 →10.9

10.9 →10.8

CAL Nothing Nothing ENTER "CPr" / "run"

O2 CONCENTRATION WITH NO PRESSURE

CORRECTION

Changes pressure value Changes pressure value

Moves to calibration pressure input or goes back to RUN mode

ABLE

4.2.3 P

4-5. PRESSURE COMPENSATION M

RESSURE COMPENSATION

IFFERENCES

ORRECTION FOR CONSTANT PRESSURE

- C

ODE KEY FUNCTIONS

Refer to Figure 4-1 and Table 4-5. If the sample and calibration gases are each at constant pressure, the following procedure should be used to correct for the pressure difference between them. However, the instrument does not monitor pressure and will not correct the output if either sample or calibration gas pressure changes. (See Section 5.2).

1. From RUN mode, press CAL. CAL, YES, CAL flash briefly, then the oxygen concentration is displayed with the

right digit flashing.

2. Press CAL again. PPr flashes, then previous sample pressure setting is displayed with right digit

flashing (76.0 cm Hg is default).

3. Use ARROW keys to enter sample pressure.

4. Press ENTER to accept the value.

Computed using 20.946% oxygen at 760 m.

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Rosemount Analytical

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ALIBRATION AND ADJUSTMENTS

CPr flashes, then previous span gas pressure setting is displayed with right digit flashing (76.0 cm Hg is default).

5. Use the ARROW keys to enter pressure of the calibration gas to be used. If the sample and calibration gas will always be at the same pressure, set PPr and CPr at the same value.

6. Press ENTER to accept the value. Instrument returns to RUN mode.

4.3 HOLD MODE

Refer to Figure 4-2 and Table 4-6. In the HOLD mode:

All instrument functions are locked

•

All existing values are retained

•

The instrument stops responding to sensor signals

•

The last measured value is displayed

•

The last output value remains at the isolated current output connections

•

Alarms and ON/OFF-Controllers are held in their last state

•

No keys are recognized except entry to the diagnostic routing.

•

KEY DISPLAY WHAT HAPPENS

DISPLAY Nothing Nothing ACK Nothing Nothing ALARM 1 Nothing Nothing ALARM 2 Nothing Nothing UP ARROW Nothing Nothing DOWN ARROW Nothing Nothing CAL Nothing Nothing ENTER "run" Drops back to RUN mode DISPLAY + ACK "d-4" "tSt" Moves to DIAGNOSTIC mode

ABLE

4-6. HOLD M

ODE KEY FUNCTIONS

If the sensor cable must be disconnected, the instrument can be put in the HOLD mode, in which all existing signal levels and output current levels and output current levels are maintained. This may be useful to prevent disturbing an ON/OFF-control loop connected to the relay contacts.

1. Press the UP ARROW and DOW N ARROW at the same time to put the instrument on HOLD.

2. If the security is activated, enter the security identification (id) code and press ENTER to continue.

748223-H

July 1997

Rosemount Analytical

4-5

(

)

(

)

ODEL

7003M P

ERCENT OXYGEN ANALYZER

HOLD MODE

SECURITY ACCESS ROUTINE

see Figure 3-4

ALARM1

ALARM2

Last displayed value held

ENTER

Sensor Voltage

Display Parameters

ALARM1

ALARM2

%O2

°°°°

DIAGNOSTICS MODE

%O2

°°°°

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

ALARM1

ALARM2

CARET LIT

see Table 4-7

DISPLAY

%O2

°°°°

%O2

°°°°

%O2

°°°°

%O2

°°°°

IGURE

ALARM1

ALARM2

ALARM1

ALARM2

4-2. HOLD

Testing Relays will affect devices connected to them

ALARM

%O2

°°°°

ALARM

%O2

°°°°

AND

DIAGNOSTICS M

Return to HOLD

Adjust Parameters (see Section 4.4)

WARNING

Exit DIAGNOSTIC

ENTER

Mode

ODES FLOWCHART

ALARM1

ALARM2

ALARM1

ALARM2

ALARM

%O2

°°°°

%O2

°°°°

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Rosemount Analytical

July 1997

748223-H

ALIBRATION AND ADJUSTMENTS

Hld, YES, flash briefly, then Hld flashes alternately with the last oxygen reading. The

output signal will remain unchanged until the instrument returns to the RUN mode.

3. Press ENTER to return to the RUN mode, or continue with Section 4.4, Diagnostics Mode.

CARET

VALUE DISPLAYED

LIT

% Raw Sensor Voltage

Thermistor Voltage 2.43 No Current Output 17.43 Yes

TYPICAL

VALUE

Use ARROW keys to make adjustments.

ABLE

4-7. C

ARET READINGS

4.4 DIAGNOSTICS MODE

Refer to Figure 4-2 and Tables 4-7, 4-8. The DIAGNOSTICS mode is used to:

Check sensor circuit voltages

•

Check relays

•

Adjust the output current

•

ADJUSTABLE

Yes

NTER

DIAGNOSTICS M

ODE

If the instrument is already in HOLD mode, skip step 1 and proceed to step 2.

1. From the RUN mode, press the UP ARROW and DOWN ARROW at the same time to enter the HOLD mode.

These typical values were obtained under the following conditions:

O2 Concentration: 20.95% Sensor Temperature: 26.07°C Current Output Range: 4-20mA Range Endpoint, Low: 0% Range Endpoint, High: 25% Zero Offset Signal: None Pressure Compensation: None

Typical voltages for new sensors at 25°C:

TYPE OF SENSOR MINIMUM NOMINAL MAXIMUM

Disposable 1.05V 1.39V 1.69V Rechargeable 0.97V 1.29V 1.76V

Near the end of the life of the sensor, the sensor voltage is typically 0.53V (disposable) or 0.48V (rechargeable). At

temperatures (T) other than 25°C, multiply the voltages above by (1.025)exp(T-25).

"-" is a minus sign displayed on the left of the display between AL 1 and AL 2.

748223-H

July 1997

Rosemount Analytical

4-7

7003M P

ODEL

If the security is activated, enter the security identification (id) code and press ENTER

ERCENT OXYGEN ANALYZER

to continue. Hld, YES, flash briefly, then Hld flashes alternately with the last oxygen reading.

The output signal will remain unchanged until the instrument returns to the RUN mode.

4.4.1 R

AW SENSOR VOLTAGE

1. Press DISPLAY and ACK at the same time to enter DIAGNOSTICS mode. Tst, d-3, d-4 flash briefly, then the %O2 caret lights and the raw sensor voltage is

displayed.

2. Press ENTER at any time to return to HOLD mode. Press ENTER again to return to RUN mode.

KEY DISPLAY WHAT HAPPENS

DISPLAY "2.13" Scrolls among the DIAGNOSTIC displays ACK Nothing Nothing ALARM 1 "A-1" "On"/ "OFF" Toggles the Alarm 1 relay ON/OFF ALARM 2 "A-2" "On" / "OFF" Toggles the Alarm 2 relay ON/OFF UP ARROW DOWN ARROW

"2.13" →"2.14" "2.14" →"2.13"

Increases current output or span setting

Decreases current output or span setting CAL Nothing Nothing ENTER "hLd" Drops back to HOLD mode

ABLE

4-8. DIAGNOSTICS M

ODE KEY FUNCTIONS

4.4.2 T

EST CURRENT OUTPUT

The current output can be tested (increased or decreased using the ARROW keys) and the actual output will change. When the instrument returns to the RUN mode, the output will return to the previous value.

1. Press DISPLAY unt il t he minus sign (-) is displayed on left.

2. Use the ARROW keys to increase or decrease the current output.

4.4.3 L

INEARIZING CURRENT OUTPUT

For some samples, current output does not track the oxygen reading displayed. The operator can linearize output and store the compensating second-order polynomials in EEPROM. This data will remain and function there as long as the EEPROM is not erased. However, if a "cold boot" is performed, the operator must repeat this linearization routine.

To determine if current output linearization is necessary, do the following:

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Rosemount Analytical

July 1997

748223-H

ALIBRATION AND ADJUSTMENTS

1. Connect a separate current meter to the output terminals (any device that will display an accurate current measurement such as a computer input will suffice).

Note Do not simply connect a current measurement meter in parallel with the

usual load because this will lead to incorrect readings.

2. Place the instrument in DIAGNOSTIC mode by pressing the UP and DOWN ARROWS, followed by the DISPLAY and ACK keys. The display will show consecutively:

tSt, d-3, d-4, and oxygen input voltage

3. Press the DISPLAY key until the minus sign and a number are displayed. This reading is the current output (in milliamps) as determined by the Model 7003M.

4. Use the UP and DOWN ARROW keys to increase the display reading, and occasionally, compare the current displayed on both meters (the instrument display and the separate meter).

If the two readings are too disparate (different applications require lesser or greater tolerance), do the following 3-point calibration to linearize the current output:

1. Use the UP and DOWN ARROW keys to set the current output to a value halfway up its range. The operator may prefer to set it at a critical measurement point.

2. Press the CAL key. The instrument will flash CCA, illuminate the th ree righthand carets, and continue displaying the current output.

3. Use the UP and DOWN ARROW keys to adjust the actual current output (as noted on the separate meter) to the correct amount. Note that the instrument display does not change.

4. Press ENTER, the instrument displays

diA

, returns to the DIAGNOSTIC

mode, and continues to display the current output.

5. Use the UP and DOWN ARROW keys to adjust the current output to a lower value, representing the low range (the operator may prefer to use 4 mA to represent 0% oxygen).

6. Press CAL (the instrument displays CCL for lower current output setting), and repeat steps 3 and 4 of this procedure.

748223-H

July 1997

Rosemount Analytical

4-9

ODEL

7003M P

ERCENT OXYGEN ANALYZER

7. Use the UP and DOWN ARROW keys to adjust the current output to a value higher than the initial calibration value (step 1 of this procedure), representing the higher range (the operator may prefer to set it at 16.72mA to represent

20.9% oxygen.

8. Press CAL (the instrument d isplays CCH for high current o utput settin g), and repeat steps 3 and 4 of this procedure.

To return to the RUN mode, press ENTER twice. At any time during this procedure, the operator may press the ACK key to reset

all calibration coefficients to default values. Pressing DISPLAY at any time during this procedure will cause the instrument to display for a moment the relevant calibration efficient.

The operator may escape the current CALIBRATION and DIAGNOSTIC mode altogether by pressing ENTER twice. Note, all coefficients will return to the default values, and the current calibration procedure must be started over to linearize current output.

Note The low calibration point must be between the initial calibration point (step

1 of previous procedure) and zero, and the high calibration point must be between the initial calibration point and 20mA.

If the third point calibrated (step 8, previous procedure) is actually another low range (between the initial calibration point and CCL) it will override the original CCL but won't affect the initial calibration.

Note The current output linearizing procedure uses second order polynomials to

adjust the output linearity. The correction effect is maximized at the calibration point, and is smoothly diminished towards the endpoints.

4.4.4 T

EST ALARM RELAYS

1. Disconnect any alarm or ON/OFF-Control devices that are connected to the analyzer, before testing.

Note When alarms are tested manually, any alarm or ON/OFF-Control devices

connected to the relays will respond as they would in an alarm condition. The alarm devices may have to be disconnected from the relays for this test.

2. Toggle the relays ON and OFF using the ALARM 1 and ALARM 2 keys.

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ALIBRATION AND ADJUSTMENTS

A-1 ON or A-2 OFF is displayed. The alarm contacts can be heard opening and closing.

3. Connect any alarm or ON/OFF-Control devices that were disconnected in step 6.

4. Press ENTER to exit the DIAGNOSTICS mode. "Hld" flashes alternately with the last oxygen reading and the analyzer returns to

HOLD mode.

5. Press ENTER again to return to RUN m o de.

4.5 ADJUSTMENTS AND SETTINGS

All operator settings and adjustments are made using the front keypad except if the power jumpers are to be changed. Refer to the following sections:

2.4.2 Power Connections

3.5.4 Zero Offset Adjustment

4.4.1 Raw Sensor Voltage

4.4.3 Current Output Adjustment

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4-11

ODEL

OTES

7003M P

ERCENT OXYGEN ANALYZER

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748223-H

HEORY

5.1 PRINCIPLES OF OPERATION

The Model 7003M Percent Oxygen Analyzer consists of an amperometric sensor and analyzer interconnected by a multi-conductor shielded cable. The sensor responds to the partial pressure of oxygen and produces a current signal. The analyzer amplifies and processes the signal, providing readout in percent oxygen and current output.

5.1.1 E

5.2 EFFECTS OF SAMPLE CONDITIONS

5.2.1 B

5.2.2 H

LECTROCHEMICAL THEORY

With the sensor placed in the sample gas, a voltage is applied across the cathode and anode. Sample gas diffuses through the membrane and is reduced at the cathode resulting in a current proportional to the partial pressure of oxygen in the sample.

When no oxygen is present, a small residual sensor current, which can be offset during instrument setup.

AROMETRIC PRESSURE

If ambient air is used to calibrate the sensor, a change in barometric pressure can be a significant factor. At 76 cm Hg, the partial pressure of oxygen is 15.9 cm Hg (20.9% of 76 cm Hg). As atmospheric pressure deviates from 76 cm Hg, the partial pressure of oxygen will vary proportionally. The highest partial pressure that can be read by the Model 7003M is 19 cm Hg (25% oxygen at 76 cm Hg).

UMIDITY

If calibrating with humid ambient air, the effect of the partial pressure due to water vapor content should be taken into consideration. High humidity has the effect of reducing the partial pressure of oxygen without affecting the total barometric pressure.

This relationship can be expressed as :

P atm = Po2 + P

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= P other,

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where:

ERCENT OXYGEN ANALYZER

P atm = total barometric pressure, Po2 = partial pressure of oxygen,

= partial pressure of water vapor,

H20

P other = partial pressure of all gases other than oxygen and water vapor

5.2.3 S

AMPLE TEMPERATURE

The rate of oxygen diffusion through the sensor membrane varies with temperature, with a coefficient of about +3% °C (5% °F), causing a corresponding change in sensor current. The instrument continuously monitors temperature with a thermistor in the sensor body, and compensates the output for both sample temperature and membrane permeability.

Because of a slight time lag in the response of the temperature sensor, a rapid temperature change will cause a temporary change in apparent oxygen level, such as might be encountered if the sensor is suddenly exposed to direct sunlight from a shadow.

Extended use of the sensor at low temperatures will shorten the life of the sensor. As the sensor reaches the end of its useful life, distinct step changes in the oxygen reading will be evident as the oxygen level changes.

5.2.4 I

NTERFERING GASES

Gases that are reduced or oxidized in the range of 0.5 to 0.8VDC contribute to sensor current and can cause a readout error. Only a few gases have this characteristic. Common gases that should be avoided include SO

, Cl2, and oxides of nitrogen

(NOX). Low-level concentrations of hydrogen sulfide tend to contaminate the sensor, but may not seriously affect oxygen measurement.

If you suspect that any stream components are affecting the operation of the sensor, contact Rosemount Analytical Technical Services.

If contaminated, the rechargeable sensor must be rejuvenated and the disposable sensor must be replaced. Refer to the instructions supplied with the sensor.

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5.3 CIRCUIT DESCRIPTIONS

HEORY

5.3.1 S

IGNAL BOARD

The Signal Board is configured to match the type of sensor ordered with the analyzer. If the type of sensor is changed, or the Signal Board is repaired or replaced, verify the rocker switch position (SW1):

Rechargeable Sensor: Close positions 1,4, and 5 Disposable Sensor: Close positions 2,4, and 6

5.3.2 P

OWER SUPPLY BOARD

The Power Supply Board provides:

12V (non-isolated) for analog signaling function

+5V (non-isolated) for microprocessor and associated logic +24V (non-isolated) for the isolated current function +5V (isolated) for other functions for that circuit

There are isolated and non-isolated grounds on the Power Supply Board. TTTP1 is the non-isolated ground and should be used with TP6 and TP7.

5.3.3 M

ICROPROCESSOR BOARD

The Microprocessor Board is the functional center of the instrument. With the exception of the program chip, no user serviceable functions are on this assembly. If the Microprocessor Board is to be repaired or replaced, note the positions of the configuration jumpers for setting jumpers on replacement board.

An instrument timer circuit monitors instrument power for a power failure, power surge or other outside condition interfering with the microprocessor operation. When conditions return to normal, the circuit will attempt a system restart. If the microprocessor is still capable of operating, both alarm relays will be put into alarm condition, the screen will clear, and the output current will drop to 0 mA. Then the instrument will go through a normal power-up routine and will eventually return to routine operation with alarms and output restored to their normal conditions. The appropriate error code (E-0, etc.) will be displayed until the ACK button is pressed.

5.3.4 A

LARM CIRCUITS

Each alarm activation setpoint is designed to be at a different level from the deactivation setpoint:

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To prevent relay contacts from chattering if the oxygen level stays around the

•

ERCENT OXYGEN ANALYZER

setpoint.

To indicate to the microprocessor whether alarm is HIGH or LOW.

•

To allow for a time lag between the time the alarm is activated and the time it is

•

deactivated for ON/OFF-Control purposes.

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OUTINE SERVICING AND TROUBLESHOOTING

WARNING: ELECTRICAL SHOCK HAZARD

Servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel.

Relay contacts wired to separate power sources must be disconnected before servicing.

6.1 ROUTINE SERVICING

Most service and maintenance involves cleaning and recharging the sensor. Refer to the instructions supplied with the sensor for recharging and maintenance procedures.

Service is rarely required on the Model 7003M Percent Oxygen Analyzer. Repair is limited to replacement of PCB boards, EPROM and fuses. See Section 7 Replacement Parts.

6.2 TROUBLESHOOTING

Troubleshooting should be referred to qualified service technicians. Refer to Section

3.8 Circuit Descriptions as an aide in isolating a problem.

6.2.1 S

YMPTOMS

ALIBRATION ERRO R CODE DISPLAYED

Possible cause Check/Test Corrective Action

ANNOT ADJUST SIGNAL TO CALIBRATION VALUE

Possible cause Check/Test

Corrective Action

Exhausted Sensor Install know good sensor and isolate Recharge or replace sensor

Sensor voltage error Install know good sensor and verify voltage

Recharge or replace sensor

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EADINGS NOT CONSISTENT WITH CALIBRATION CURVE

Possible cause Check/Test Corrective Action

RROR CODE

DISPLAYED

E-0

Possible cause Corrective Action

ILL NOT READ LOW LEVELS OF OXYGEN

Possible cause Check/Test

Incorrect sensor used for application Verify sensor corresponds with application Install new sensor and calibrate with span gas

Sensor temperature incorrect Sensor temperature should be 0 to 50°C Install new sensor and calibrate with span gas Incorrect span gas concentration Verify span gas concentration Install new sensor and calibrate with span gas

Power interruption, power surge or other outside interference has occurred Press ACK. If this symptom occurs frequently, surgeprotection is recommended.

Ambient air leaking into system Increase sample flow rate, block off flow of gas in and out of flow chamber, and not analyzer response If signal increases with test, isolate and seal leak.

Corrective Action

If signal does not increase, replace or recharge sensor.

UDDEN CHANGE IN OUTPUT FOR NO APPARENT REASON

Sensor subjected to sudden change in conditions,

Possible cause

as when a shadow moves and exposes the sensor to an increase in temperature

Corrective Action

ESOLUTION DEGRADING WITH TIME

Possible cause

Locate sensor in an area shaded from sunlight and away from cold or warm drafts.

Sensor exposed to low temperatures. Per Section 4.4.2, check current output of sensor.

Check/Test

If the sensor is degrading, the signal will change in steps as the oxygen level changes instead of changing continuously.

Corrective Action

Relocate sensor or replace more frequently.

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EPLACEMENT PARTS

7.1 CIRCUIT BOARD REPLACEMENT POLICY

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

Because of the exchange policy covering circuit boards, the following sections on replacement parts do not include individual, circuit board mounted 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 - MODEL 7003M

WARNING: PARTS INTEGRITY

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

PART NUMBER DESCRIPTION

652630 Signal Board 652640 Power Supply Board 654605 Display/Keypad Board 655195 EPROM 655197 Microprocessor Board 777156 Fuse, 1/4 A, 120V (package of 5) 777360 Fuse, 1/8 A, 240 V (package of 5) 858728 Arc Suppressor

When replacing Microprocessor Board PN 652650, replace with Microprocessor Board PN 655197

EPROM 655195.

AND

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ERCENT OXYGEN ANALYZER

7.3 REPLACEMENT PARTS - SENSORS

7.3.1 R

ENSOR

ENSOR KITS (SENSOR

ECHARGEABLE SENSORS

MATERIAL PART NUMBER

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

INCLUDED

NOT

DESCRIPTION PART NUMBER USE WITH SENSOR

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

Fast Response, Ryton 646630 190409

ENSOR KITS (SENSOR INCLUDED

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

ECHARGE KIT

Recharge Kit (10 recharges) 191755

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EPLACEMENT PARTS

7.3.2 D

ENSOR

ENSOR KITS (SENSOR

ENSOR KITS (SENSOR INCLUDED

ISPOSABLE SENSORS

MATERIAL PART NUMBER

Polypropylene 623742

INCLUDED

NOT

DESCRIPTION PART NUMBER USE WITH SENSOR

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

DESCRIPTION PART NUMBER

Submersion, Polypropylene 500011 In-Line Flow, Polypropylene 500012

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ENERAL PRECAUTIONS FOR HANDLING AND

TORING 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 extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent.

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

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

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

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

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

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

4125 E

AST LA PALMA AVENUE

Rosemount Analytical Inc.

• A J

, C

NAHEIM

ULY

ALIFORNIA

1997 • 748525-C • P

92807-1802 • 714-986-7600 • FAX 714-577-8006

RINTED IN

USA

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ARRANTY

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

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

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

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

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

Rosemount Analytical

4125 E

AST LA PALMA AVENUE

• A

EBRUARY 1997 • 7485189-C • PRINTED IN USA

Rosemount Analytical Inc.

NAHEIM

, C

ALIFORNIA

92807-1802 • 714-986-7600 • FAX 714-577-8006

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IELD SERVICE AND REPAIR FACILITIES

Field service and repair facilities are located worldwide.

U.S.A.

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

National Response Center

1-800-654-7768

INTERNATIONAL

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

FACTORY

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

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

RETURNING PARTS TO THE FACTORY

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

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

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

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

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

4125 E

AST LA PALMA AVENUE

• A

Rosemount Analytical Inc.

, C

NAHEIM

ULY 1997 • 748190-G • PRINTED IN USA

ALIFORNIA

92807-1802 • 714-986-7600 • FAX 714-577-8006

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Rosemount 7003M Percent O2 Analyzer-Rev H Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual