Rosemount Manual: 4081FG 2-Wire In Situ O2 Analyzer (550° to 1600°C) with FOUNDATION Fieldbus Communications-Rev 1.2 | Rosemount Manuals & Guides

Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Model 4081FG
Two-Wire In Situ Oxygen Analyzer (550° to 1600°C) with F
OUNDATION
http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.
Read all instructions prior to installing, operating, and servicing the product.
If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative for clarification.
Follow all warnings, cautions, and instructions marked on and supplied with the product.
Inform and educate your personnel in the proper installation, operation, and mainte-
nance of the product.
Install your equipment as specified in the Installation Instructions of the appropriate In- struction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s per­formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.
The information contained in this document is subject to change without notice.
Emerson Process Management
Rosemount Analytical Inc. Process Analytic Division
1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com

HIGHLIGHTS OF CHANGES

Effective April, 2001 Rev. 1.0
Page Summary
Throughout Changed all references of 38 in. (965 mm) probe to 34.625 in. (880 mm).
Page 11-2 Added drawing 1400175.
Effective December, 2001 Rev. 1.1
Page Summary
Page 1-3 Updated Product Matrix.
Effective September, 2002 Rev. 1.2
Page Summary
Page 1-8 Updated process temperature limits specification.
Model 4081FG
PREFACE........................................................................................................................ P-1
Definitions ........................................................................................................................P-1
Safety Instructions .......................................................................................................... P-2
1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1
1-1 Component Checklist of Typical System (Package Contents) .................................. 1-1
1-2 System Overview............................................................................................................ 1-1
1-3 Specifications................................................................................................................... 1-8
2-0 INSTALLATION .............................................................................................................. 2-1
2-1 Pre-Installation................................................................................................................. 2-1
2-2 Mechanical Installation ................................................................................................... 2-1
2-3 Electrical Installation.....................................................................................................2-10
2-4 Pneumatic Installation .................................................................................................. 2-11
3-0 STARTUP........................................................................................................................ 3-1
3-1 General ............................................................................................................................ 3-1
3-2 Power Up........................................................................................................................ 3-1
3-3 Reestablishing Proper Calibration Check Gas Flow Rate......................................... 3-2
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002

TABLE OF CONTENTS

4-0 OPERATION ...................................................................................................................4-1
4-1 General ............................................................................................................................ 4-1
4-2 Program Menu ................................................................................................................4-4
4-3 Diagnostics Menu ........................................................................................................... 4-8
4-4 CALCHECK MENU ...................................................................................................... 4-12
4-5 SIMULATE SWITCH .................................................................................................... 4-15
4-6 SECURITY SWITCH .................................................................................................... 4-15
5-0 MAINTENANCE AND SERVICE .................................................................................. 5-1
5-1 MODEL 4081 ELECTRONICS REPLACEMENT ........................................................... 5-1
5-2 OXYGEN PROBE REPLACEMENT ............................................................................. 5-2
6-0 TROUBLESHOOTING .................................................................................................... 6-1
6-1 GENERAL........................................................................................................................ 6-1
6-2 PROBE LIFE.................................................................................................................... 6-1
6-3 FAULT INDICATIONS .................................................................................................... 6-2
6-4 IDENTIFYING AND CORRECTING FAULT INDICATIONS ....................................... 6-3
7-0 RETURN OF MATERIAL .............................................................................................. 7-1
8-0 REPLACEMENT PARTS ............................................................................................... 8-1
9-0 APPENDICES ................................................................................................................. 9-1
10-0 INDEX............................................................................................................................ 10-1
11-0 DRAWINGS AND SCHEMATICS............................................................................... 11-1
Rosemount Analytical Inc. A Division of Emerson Process Management i
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Figure 1-1. Typical System Package ....................................................................................... 1-2
Figure 1-2. Two-Wire In Situ Oxygen Analyzer Fieldbus Connections .................................... 1-7
Figure 1-3. Typical System Installation .................................................................................... 1-7
Figure 2-1. Probe Installation Details ....................................................................................... 2-2
Figure 2-2. Optional Adapter Plate........................................................................................... 2-2
Figure 2-3. Optional Probe Mounting Flange ........................................................................... 2-3
Figure 2-4. Horizontal Probe Installation .................................................................................. 2-4
Figure 2-5. Adjusting Probe Insertion Depth ............................................................................ 2-5
Figure 2-6. Flat Surface Mounting Dimensional Information.................................................... 2-7
Figure 2-7. Pipe Mounting Dimensional Information................................................................ 2-8
Figure 2-8. Display Positioning Assembly................................................................................ 2-9
Figure 2-9. Oxygen Probe Terminal Block ............................................................................. 2-11
Figure 2-10. Model 4081 Transmitter Terminal Block.............................................................. 2-11
Figure 2-11. Oxygen Probe Gas Connections ......................................................................... 2-12
Figure 2-12. Air Set, Plant Air Connection ............................................................................... 2-12
Figure 3-1. Normal Operation Display...................................................................................... 3-1
Figure 3-2. Faulted Operation Display ..................................................................................... 3-1
Figure 3-3. Proper Calibration Check Gas Flow Rate.............................................................. 3-2
Figure 4-1. Normal Operation Display...................................................................................... 4-1
Figure 4-2. Model 4081 Transmitter Menu Tree ...................................................................... 4-2
Figure 4-3. Infrared Remote Control (IRC)............................................................................... 4-3
Figure 4-4. CODE..................................................................................................................... 4-4
Figure 4-5. DISPLAY CODE ................................................................................................... 4-5
Figure 4-6. CELL T HI ............................................................................................................ 4-5
Figure 4-7. RESET MAX CELL T.......................................................................................... 4-6
Figure 4-8. SET O Figure 4-9. SET HI BOTTLE O Figure 4-10. SET LO BOTTLE O
Figure 4-11. SET CODE............................................................................................................ 4-8
Figure 4-12. SHOW FAULT ...................................................................................................... 4-8
Figure 4-13. T/C mV................................................................................................................... 4-9
Figure 4-14. O
Figure 4-15. CELL IMPEDANCE............................................................................................. 4-10
Figure 4-16. PREVIOUS SLOPE ............................................................................................ 4-10
Figure 4-17. PREVIOUS CONSTANT .................................................................................... 4-11
Figure 4-18. MAX CELL T ...................................................................................................... 4-11
Figure 4-19. IN MANUAL? ...................................................................................................... 4-12
Figure 4-20. ACCEPT HIGH O Figure 4-21. ACCEPT LOW O
Figure 4-22. PURGING ............................................................................................................ 4-14
Figure 4-23. SLOPE ................................................................................................................. 4-14
Figure 4-24. CONSTANT ......................................................................................................... 4-14
Figure 4-25. Simulate and Security Switch Positions .............................................................. 4-15
Figure 5-1. Two-Wire In Situ Oxygen Analyzer Exploded View............................................... 5-0
Figure 5-2. Oxygen Probe Terminal Block ............................................................................... 5-3
Figure 6-1. Slope vs. Impedance ............................................................................................. 6-1
Figure 6-2. Speed of Response ............................................................................................... 6-2
Figure 6-3. Faulted Operation Display ..................................................................................... 6-2
Figure 6-4. Model 4081 Transmitter Terminal Block ................................................................ 6-3
Figure 6-5. Fault 1, Open Thermocouple ................................................................................. 6-4
Model 4081FG
LIST OF ILLUSTRATIONS
FILTER TIME......................................................................................... 4-6
2
CELL mV ........................................................................................................ 4-9
2
............................................................................................ 4-7
2
........................................................................................... 4-7
2
............................................................................................. 4-13
2
.............................................................................................. 4-13
2
ii Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
LIST OF ILLUSTRATIONS (CONTINUED)
Figure 6-6. Fault 2, Reversed Thermocouple .......................................................................... 6-4
Figure 6-7. Fault 3, Shorted Thermocouple ............................................................................. 6-5
Figure 6-8. Fault 4, High Probe Temperature .......................................................................... 6-5
Figure 6-9. Fault 5, O
Figure 6-10. Fault 6, Cell Impedance Too High ......................................................................... 6-6
Figure 6-11. Fault 7, Reversed O
Table 1-1. Product Matrix........................................................................................................ 1-3
Table 1-2. Accessories............................................................................................................ 1-4
Table 1-3. Mounting Adapter................................................................................................... 1-4
Table 4-1. Model 4081 Transmitter Parameters ..................................................................... 4-8
Table 8-1. Replacement Parts List.......................................................................................... 8-1
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
Cell Open............................................................................................. 6-6
2
Cell ...................................................................................... 6-7
2

LIST OF TABLES

Rosemount Analytical Inc. A Division of Emerson Process Management iii
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Model 4081FG
iv Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
The purpose of this manual is to provide information concerning the components, func­tions, installation and maintenance of this particular NGA 2000 module.
Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
PREFACE

DEFINITIONS

Highlights an operation or maintenance procedure, practice, condition, state­ment, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an essential operating procedure, condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

Highlights an operation or maintenance procedure, practice, condition, state­ment, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
The number in the lower right corner of each illustration in this publication is a manual illus­tration number. It is not a part number, and is not related to the illustration in any technical manner.
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
FOR THE WIRING AND INSTALLATION
The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non­EU states should also comply with the following unless superseded by local or National Standards.
1. Adequate earth connections should be made to all earthing points, internal and external,
where provided.
2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.
The integrity of all earth terminals must be maintained at all times.
3. Mains supply cords should comply with the requirements of IEC227 or IEC245.
Model 4081FG
IMPORTANT

SAFETY INSTRUCTIONS

OF THIS APPARATUS
4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.
5. All cable glands used should be of such internal dimensions as to provide adequate cable
anchorage.
6. To ensure safe operation of this equipment, connection to the mains supply should only be
made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.
7. Where equipment or covers are marked with the symbol to the right, hazard-
ous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then only by trained service personnel.
8. Where equipment or covers are marked with the symbol to the right, there is a
danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Cer­tain surfaces may remain hot to the touch.
9. Where equipment or covers are marked with the symbol to the right, refer to
the Operator Manual for instructions.
10. All graphical symbols used in this product are from one or more of the follow-
ing standards: EN61010-1, IEC417, and ISO3864.
P-2 Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
1

DESCRIPTION AND SPECIFICATIONS

Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
SECTION 1
1-1 COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
A typical Rosemount Two-Wire In Situ Oxygen Analyzer should contain the items shown in Figure 1-1. Record the part number, serial num­ber, and order number for each component of your system in the table located on the first page of this manual. Also, use the product ma­trix in Table 1-1 to compare your order number against your unit. The first part of the matrix de­fines the model. The last part defines the vari­ous options and features of the analyzer. Ensure the features and options specified by your order number are on or included with the unit.

1-2 SYSTEM OVERVIEW

a. Scope
This Instruction Bulletin is designed to sup­ply details needed to install, start up, oper­ate, and maintain the Rosemount Two-Wire In Situ Oxygen Analyzer. The analyzer con­sists of an oxygen probe and Model 4081 Transmitter. Integral signal conditioning electronics outputs a digital F fieldbus signal representing an O2 value. An infrared remote control (IRC) allows access to setup, calibration, and diagnostics. This same information, plus additional details, can be accessed via fieldbus digital communications.
OUNDATION
OUNDATION
b. F
FOUNDATION fieldbus is an all digital, se­rial, two-way communication system that inter-connects field equipment such as sen­sors, actuators, and controllers. Fieldbus is a Local Area Network (LAN) for instruments used in both process and manufacturing automation with built-in capacity to distrib­ute the control application across the net­work. The fieldbus environment is the base level group of digital networks in the hierar­chy of planet networks.
The fieldbus retains the desirable features of the 4-20 mA analog system, including a standardized physical interface to the wire, bus powered devices on a single wire, and intrinsic safety options, and enables addi­tional capabilities, such as:
Increased capabilities due to full digital communications
Reduced wiring and wire terminations due to multiple devices on one set of wires
Increased selection of suppliers due to inter-operability
Reduced loading on control room equipment with the distribution of some control and input/output functions to field devices
Speed options for process control and manufacturing applications
Fieldbus Technology
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Model 4081FG
1
7
6
2
3
5
1. Instruction Bulletin
2. Model 4081 Transmitter
3. Oxygen Probe
4. Adapter Plate with Mounting Hardware and Gasket (Optional)
5. Infrared Remote Control (IRC) (Optional)
6. Reference Air Set (Optional)
7. Pipe Mounting Kit (Optional)
4
29760001
Figure 1-1. Typical System Package
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
1
IB-106-4081 Rev. 1.2
Model 4081FG
Table 1-1. Product Matrix
4081FG Model 4081FG In Situ Oxygen Analyzer with FOUNDATION Fieldbus Communications
Model 4081FG Oxygen Analyzer - Instruction Book
Code Sensing Probe Length
1 20 in. (508 mm) probe, 1/4 in. tube fittings
2 26 in. (660 mm) probe, 1/4 in. tube fittings
3 38 in. (965 mm) probe, 1/4 in. tube fittings
Code Probe Outer Tube Material - Maximum Operating Temperature
1 Alumina - 2912°F (1600°C) maximum - 1.25 NPT mounting
2 Inconel 600 - 1832°F (1000°C) maximum - 1.25 NPT mounting
Code Mounting Adapter - Stack Side
0 No adapter plate required uses 1.25 NPT (“0” must also be chosen under “Mounting Adapter” probe side)
1 New flanged installation - Square weld plate with studs (matches “Mounting Adapter” probe side)
2 Model 450 mounting (“4” must also be chosen under “Mounting Adapter” probe side)
3 Competitor's Mount (“5” must also be chosen under “Mounting Adapter” probe side)
Code Mounting Adapter - Probe Side
0 No adapter plate
1 ANSI 2 in. 150 lb flange to 1.25 NPT adapter
(6 in. dia. Flange, 4.75 in. BC with 4 x 0.75 in. dia. holes)
2 DIN to 1.25 NPT adapter (184 mm flange, 145 mm BC with 4 x 18 mm dia. holes)
3 JIS to 1.25 NPT adapter (155 mm flange, 130 mm BC with 4 x 13 mm dia. holes)
4 Model 450 to 1.25 NPT adapter
5 Competitor’s mounting flange
Code Electronics & Housing - Intrinsically Safe, NEMA 4X, IP65
1 4081 F
2 4081 F
3
4 4081 F
5 4081 F
6
4081FG2100111211 Example
OUNDATION
OUNDATION
OUNDATION
4081 F Suite
OUNDATION
OUNDATION
4081 F
OUNDATION
Control Suite
Code Housing Mounting
0 Surface or wall mounting
1 1/2 to 2 in. pipe mounting
Fieldbus Electronics - CENELEC EEx ia IIC T5 with Control Suite
Fieldbus Electronics - CSA pending, with Control Suite
Fieldbus Electronics-FM Class I, Div. I, Groups B,C,D with Control
Fieldbus Electronics - CENELEC EEx ia IIC T5 without Control Suite
Fieldbus Electronics - CSA pending, without Control Suite
Fieldbus Electronics-FM Class I, Div. I, Groups B,C,D without
Code Communications
0 No remote control
1 Infrared Remote Control (IRC) (LCD display through cover)
Code Calibration Accessories
1 No hardware
2 Reference air flowmeters and pressure regulator
Code Armored Cable Length
00 No cable
11 20 ft (6 m)
12 40 ft (12 m)
13 60 ft (18 m)
14 80 ft (24 m)
15 100 ft (30 m)
16 150 ft (45 m)
17 200 ft (61 m)
18 300 ft (91 m)
19 400 ft (122 m)
20 500 ft (152 m)
September, 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Table 1-2. Accessories
Part No. Description
1A99135H01 Armored cable, bulk, uncut, no connectors 100’ minimum.
1A99135H02 Unarmored cable, bulk, uncut, no connectors 100’ minimum.
Order as separate items.
Table 1-3. Mounting Adapter
Type Description
Plate with studs Bolt circle diameter, number and arrangement of studs, stud thread, stud height
above mounting plate.
Plate without studs Bolt circle diameter, number and arrangement of holes, thread, depth of stud
mounting plate with accessories.
Where possible specify SPS number; otherwise provide details of the existing mounting plate.
Model 4081FG
c. System Description
The Rosemount Two-Wire In Situ Oxygen Analyzer is designed to measure the net concentration of oxygen in an industrial pro­cess; i.e., the oxygen remaining after all fu­els have been oxidized. The oxygen probe is permanently positioned within an exhaust duct or stack and performs its task without the use of a sampling system. The Model 4081 Transmitter is mounted remotely and conditions the oxygen probe outputs.
The equipment measures oxygen percent­age by reading the voltage developed across an electrochemical cell, which con­sists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. The millivolt output voltage of the cell is given by the following Nernst equation:
EMF = KT log
10(P1/P2
) + C
Where:
1. P
is the partial pressure of the oxygen
2
in the measured gas on one side of the cell.
2. P
is the partial pressure of the oxygen
1
in the reference air on the opposite side of the cell.
3. T is the absolute temperature.
4. C is the cell constant.
5. K is an arithmetic constant.
NOTE
For best results, use clean, dry, in­strument air (20.95% oxygen) as the reference air.
NOTE
The probe uses a Type B thermocou­ple to measure the cell temperature.
When the cell is at 550°C to 1600°C (1022°F to 2912°F) and there are unequal oxygen concentrations across the cell, oxy­gen ions will travel from the high oxygen partial pressure side to the low oxygen par­tial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade.
The output is proportional to the inverse logarithm of the oxygen concentration. Therefore, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the Rosemount Two-Wire In Situ Oxygen Ana­lyzer to provide exceptional sensitivity and accuracy at low oxygen concentrations.
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
1
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
Oxygen analyzer equipment measures net oxygen concentration in the presence of all the products of combustion, including water vapor. Therefore, it may be considered an analysis on a “wet” basis. In comparison with older methods, such as the portable apparatus, which provides an analysis on a “dry” gas basis, the “wet” analysis will, in general, indicate a lower percentage of oxygen. The difference will be proportional to the water content of the sampled gas stream.
d. System Configuration
The equipment discussed in this manual consists of two major components: the oxy­gen probe and the Model 4081 Transmitter.
Oxygen probes are available in three length options, providing in situ penetration appro­priate to the size of the stack or duct. The options on length are 20 in. (508 mm), 26 in. (660 mm), or 38 in. (965 mm).
The Model 4081 Transmitter is a two-wire transmitter providing an output proportional to the measured oxygen concentration. A customer-supplied 24 VDC power source is required to provide power to the electronics. The transmitter accepts millivolt signals generated by the probe and produces the outputs to be used by other remotely con­nected devices. The output is a FOUNDA­TION fieldbus digital communication signal.
e. System Features
1. The cell output voltage and sensitivity increase as the oxygen concentration decreases.
2. High process temperatures eliminate the need for external cell heating and increase cell accuracy.
3. FOUNDATION fieldbus is standard.
4. Easy probe replacement due to the lightweight, compact probe design.
5. Remote location of the Model 4081 Transmitter removes the electronics from high temperature or corrosive environments.
6. Power is supplied to the electronics through the FOUNDATION fieldbus digital signal line for intrinsic safety (IS) purposes.
7. Infrared remote control (IRC) allows inter-facing without exposing the electronics.
8. An operator can operate and diagnos­tically troubleshoot the Two-Wire In Situ Oxygen Analyzer in one of two ways:
(a) Infrared Remote Control. The IRC
allows access to fault indication menus on the Model 4081 Trans­mitter LCD display. Calibration can be performed from the IRC key­pad.
(b) FOUNDATION fieldbus Interface.
The transmitter’s output carries a signal containing the oxygen level encoded in digital format. This digital output can also be used to communicate with the oxygen analyzer and access all of the oxy­gen analyzer status information.
9. Selected Distributed Control Systems ­The use of distributed control systems requires input/output (I/O) hardware and AMS Security codes are provided (by infrared remote control) to prevent unintended changes to analyzers adja­cent to the one being accessed.
10. A calibration check procedure is pro­vided to determine if the Rosemount Two-Wire In Situ Oxygen Analyzer is correctly measuring the net oxygen concentration in the industrial process.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Model 4081FG
f. Handling the Analyzer
The probe was specially packaged to pre­vent breakage due to handling. Do not re­move the padding material from the probe until immediately before installation.
It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to pre­vent possible equipment damage.
The oxygen probe is designed for in­dustrial applications. Treat with care to avoid physical damage. The probe contains components made from ce­ramic, which are susceptible to shock when mishandled. THE WARRANTY DOES NOT COVER DAMAGE FROM MISHANDLING.
temperatures, environmental considera­tions, convenience, and serviceability Figure 1-2 shows the FOUNDATION Field­bus communications interface. A typical system installation is illustrated in Figure 1-3.
A source of instrument air is required at the oxygen probe for reference air use. Since the Two-Wire In Situ Oxygen Analyzer is equipped with an in-place calibration fea­ture, provisions should be made for con­necting calibration check gas tanks to the oxygen probe during calibration.
If the calibration check gas bottles are to be permanently connected, a check valve is required next to the calibration fittings on the integral electronics.
This check valve is to prevent breathing of calibration check gas line and subsequent flue gas condensation and corrosion. The check valve is in addition to the stop valve in the calibration check gas kit.
g. System Considerations
Prior to installing your Rosemount Two-Wire In Situ Oxygen Analyzer, make sure you have all the components necessary to make the system installation. Ensure all the com­ponents are properly integrated to make the system functional.
After verifying that you have all the compo­nents, select mounting locations and deter­mine how each component will be placed in terms of available line voltage, ambient
NOTE
The electronics of the Model 4081 Transmitter is rated NEMA 4X (IP65) and is capable of operating at tem­peratures up to 65°C (149°F).
NOTE
Retain the packaging in which the Rosemount Two-Wire In Situ Oxygen Analyzer arrived from the factory in case any components are to be shipped to another site. This packag­ing has been designed to protect the product.
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
1
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
TWO-WIRE IN SITU
OXYGEN ANALYZER
CALIBRATION CHECK
GAS LINE
Figure 1-2. Two-Wire In Situ Oxygen Analyzer Fieldbus Connections
GASES
STACK
REFERENCE
AIR LINE
OmV
2
SIGNAL
MODEL 4081
TRANSMITTER
TEMPERATURE
mV SIGNAL
DUCT
DIGITAL OUTPUT
FIELDBUS
(TWISTED PAIR)
INTRINSIC
SAFETY
BARRIER
(OPTIONAL)
FIELDBUS
COMPUTER TERMINAL
29760002
OXYGEN
PROBE
MODEL 4081
TRANSMITTER
OPTIONAL ADAPTER PLATE
FLOWMETER
FIELDBUS
DIGITAL SIGNAL
PRESSURE
REGULATOR
Figure 1-3. Typical System Installation
INSTRUMENT AIR SUPPLY (REFERENCE AIR)
29760003
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
1-3 SPECIFICATIONS
Net O
Range ...................................................... 0 to 25% O2 Fully Field Selectable via the FOUNDATION
2
Fieldbus Interface
Lowest Limit................................................... 0.05% O
Highest Limit.................................................. 25.00% O
2
2
Accuracy.............................................................. ±1.5% of reading or 0.05% O2, whichever is greater
System Response to Calibration Check Gas...... Initial response in less than 3 seconds
T90 in less than 10 seconds
Probe
Lengths................................................................ 20 in. (508 mm)
26 in. (660 mm)
34.625 in. (880 mm)
Temperature Limits
Process Temperature Limits ......................... 550° to 1400°C (1022° to 2552°F)
Operation to 1600°C (2912°F) with reduced cell life.
Ambient ......................................................... -40° to 149°C (-40° to 300°F) Ambient
Mounting and Mounting Position......................... Vertical or Horizontal
Materials of Construction - Process Wetted Parts
Inner Probe ............................................. Zirconia
Outer Protection Tube............................. Alumina [1600°C (2912°F) limit]
Inconel 600 [1000°C (1832°F) limit]
Probe Junction Box................................. Cast aluminum
Speed of Installation/Withdrawal......................... 1 in. (25.4 mm) per minute
Hazardous Area Certification .............................. Intrinsically safe per EN50 014 (1977), clause 1.3
(pending)
Reference Air Requirement................................. 100 ml per minute (0.2 scfh) of clean, dry instrument air;
1/4 in. tube fittings
Calibration Check Gas Fittings............................ 1/4 in. tube fittings
Cabling ................................................................ Two twisted pairs, shielded
Electronics
Enclosure ............................................................ IP65 (NEMA 4X), weatherproof, and corrosion-resistant
Materials of Construction .................................... Low copper aluminum
Ambient Temperature Limits ............................... -20° to 65°C (-4° to 149°F)
Relative Humidity ................................................ 95% with covers sealed
Inputs (from O
Probe) ........................................ Two wires - O2 signal, Two wires - type B thermocouple
2
Output ................................................................ FOUNDATION Fieldbus digital signal
Fieldbus Logic Function Blocks
Two AI Blocks: Execution Rate .................... 75mS
PID Block: Execution Rate ........................... 150mS
Fieldbus Segment Power Consumption ............. 30mA max, 30VDC max
Hazardous Area Certification .............................. Cenelec EEx ia IIC T4 or T5(2) (pending)
NEC Class I Div.I Group B,C,D (pending) Fisher-Rosemount has satisfied all obligations coming from the European legislation to harmonize the product requirements in Europe.
Power Transient Protection ................................. IEC 801-4
Shipping Weight .................................................. 10 lbs (4.5 kg)
Infrared Remote Control
Power Requirements........................................... Three AAA batteries
Hazardous Area Certification .............................. Cenelec EEx ia IIC Class I, Div. I, Group A, B, C, D
(1)
Thermocouple and O2 probe cell are both unpowered, developing a millivolt emf, and are considered a “simple ap­paratus” by certifying agencies.
(2)
Dependent on ambient temperature limits.
Model 4081FG
(1)
1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
2
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
SECTION 2

INSTALLATION

2-1 PRE-INSTALLATION
a. Inspect
Carefully inspect the shipping container for any evidence of damage. If the container is damaged, notify the carrier immediately.
b. Packing List
Confirm all items shown on the packing list are present. Notify Rosemount Analytical immediately if items are missing.
Before installing this equipment, read the “Safety instructions for the wiring and installation of this apparatus” at the front of this Instruction Bulletin. Failure to follow the safety instruc­tions could result in serious injury or death.
2-2 MECHANICAL INSTALLATION
Avoid installation locations near steam soot blowers.
the process gas temperature falls within a range of 550° to 1600°C (1022° to 2912°F). Figure 2-1 provides mechani­cal installation references.
2. Check the flue or stack for holes and air leakage. The presence of this con­dition will substantially affect the accu­racy of the oxygen reading. Therefore, either make the necessary repairs or install the probe up-stream of any leakage.
3. Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance ac­cess to the probe. Allow adequate clearance for probe removal (Figure 2-1).
b. Installing Oxygen Probe
The probe was specially packaged to prevent breakage due to handling. Do not remove the padding material from the probe until immediately before in­stallation.
1. Ensure all components are available to
a. Locating Oxygen Probe
1. The location of the oxygen probe in the stack or flue is important for maximum accuracy in the oxygen analyzing proc­ess. The probe must be positioned so the gas it measures is representative of the process. Best results are normally obtained if the probe is positioned near the center of the duct (40-60% insertion). Longer ducts may require several ana­lyzers since the O stratification. A point too near the wall of the duct, or the inside radius of a bend, may not provide a representative sample because of the very low flow conditions. The sensing point should be selected so
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
can vary due to
2
Leave the probe inner protective cover in place until installation. This is re­quired to protect the ceramic cell dur­ing movement.
install the probe.
NOTE
2. If using an optional adapter plate (Figure 2-2) or an optional mounting flange (Figure 2-3), weld or bolt the component onto the duct. The through hole in the stack or duct wall and re­fractory material must be 2 in. (50.8 mm) diameter, minimum.
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Model 4081FG
Figure 2-1. Probe Installation Details
A
B
C
NOTE: DIMENSIONS ARE
IN INCHES WITH MILLIMETERS IN PARENTHESES.
DIMENSION
BTHREAD 0.625-11 M-16x2 M-12x1.75
CDIA. 4.75 (121) 5.71 (145) 5.12 (130)
METAL WALL
STACK OR DUCT
A
WELD OR BOLT ADAPTER PLATE TO STACK OR DUCT. JOINT MUST BE AIR TIGHT.
PLATE DIMENSIONS
ANSI
4512C34G01
A 6.00 (153) 7.5 (191) 6.50 (165)
2.50 (63.5) MIN. DIA.
JOINT MUST
BE AIR TIGHT
DIN
4512C36G01
MASONRY WALL
STACK
3.00 SCHEDULE 40 PIPE SLEEVE
SUPPLIED BY CUSTOMER
JIS
4512C35G01
WELD PIPE TO
ADAPTER PLATE
3.50 (89)
O.D. REF
29750002
Figure 2-2. Optional Adapter Plate
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
2
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
TAP 1.25 NPT
B
A
C
FLANGE DIMENSIONS
ANSI
DIMENSION
ADIA. 6.00 (153) 7.28 (185) 6.10 (155) 9.00 (229)
BDIA. 0.75 (20) 0.71 (18) 0.59 (15) 0.50 (13)
CDIA. 4.75 (121) 5.71 (145) 5.12 (130) 7.68 (195)
5R10158H01
DIN
5R10158H02
0.50 (12.7)
NOTE: DIMENSIONS ARE IN
INCHES WITH MILLIMETERS IN PARENTHESES.
JIS
5R10158H03
MODEL 450
5R10158H04
29750003
Figure 2-3. Optional Probe Mounting Flange
3. If the optional adapter plates are not used, a 2 in. NPT, schedule 40, pipe nipple (Figure 2-4) should be welded to the stack or duct wall.
When a 2 in. NPT to 1.25 NPT adapter is threaded to the welded pipe nipple, the adapter provides the pipe threads needed for the probe’s process fitting.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Model 4081FG
STACK OR DUCT
METAL WALL
WELD PIPE TO
METAL WALL
2.0 IN. (51 mm) MIN. DIA.
REFRACTORY
SCHEDULE 40
STACK OR DUCT METAL WALL
ADAPTER
2 IN. NPT
PIPE
1.25 NPT
CUSTOMER
SUPPLIED ADAPTER
INSULATE IF EXPOSED
TO AMBIENT WEATHER
CONDITIONS
2 IN. NPT
SCHEDULE 40
PIPE
CALIBRATION
CHECK
GAS LINE
REFERENCE
AIR LINE
SYSTEM
CABLE
29750004
Figure 2-4. Horizontal Probe Installation
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
2
REFRACTORY
STACK OR
DUCT METAL
PROBE LENGTH
A
WAL L
1.5 + A
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
DIMENSION A -- 1-5/8, 2-1/2, 3, OR 4 IN. 1.25 NPT SCHEDULE 40 PIPE NIPPLE
2 IN., 1.25 NPT
PIPE COUPLING
29750005
Figure 2-5. Adjusting Probe Insertion Depth
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Model 4081FG
4. Where high particulate or slag is in the flue gas stream, it may be desirable to inset the probe in the refractory as shown in Figure 2-5. Use pipe cou­plings and nipples to adjust the probe insertion depth.
5. Use rags or other material to seal around the probe during insertion. This prevents hot gases from escaping or cold air from entering the stack or duct.
6. Initially insert the probe to a depth of 3 in. (76.2 mm) or ½ the depth of the stack or duct refractory, whichever is greater.
After initial insertion, do not insert the probe at a rate exceeding 1 in. per mi­nute (25.4 mm per minute) or damage to the probe may result due to thermal shock.
the probe. Ensure the electrical conduit is routed below the level of the terminal block housing. This drip loop minimizes the possibility that moisture will accu­mulate in the housing.
9. If insulation was removed to access the duct work for probe mounting, make sure the insulation is replaced after­ward. See Figure 2-4.
If the ducts will be washed down dur­ing outage, MAKE SURE to power down the probes and remove them from the wash area.
c. Locating Model 4081 Transmitter
1. Ensure the Model 4081 Transmitter is easily accessible for maintenance and service and for using the infrared re­mote control (if applicable).
7. After initial insertion, insert the probe at a rate of 1 in. (25.4 mm) per minute until the probe is fully inserted.
8. Install anti-seize compound on the pipe threads and screw the probe into the process flange or adapter.
NOTE
Use anti-seize compound on threads to ease future removal of probe.
The electrical conduit port should be facing down for a horizontal probe in­stallation. See Figure 2-4. In vertical probe installations, orient the probe so the system cable drops vertically from
Do not allow the temperature of the Model 4081 Transmitter to exceed 65°C (149°F) or damage to the unit may result.
2. The ambient temperature of the trans­mitter housing must not exceed 65°C (149°F). Locate the electronics in an area where temperature extremes, vi­bration, and electromagnetic and radio frequency interference are minimal.
3. Locate the Model 4081 Transmitter within 150 ft (45.7 m) of the oxygen probe due to wiring and signal considerations.
2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
2
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
d. Installing Model 4081 Transmitter
1. Ensure all components are available to install the Model 4081 Transmitter.
2. Choose a method or location to mount the transmitter.
(a) Flat Surface Mounting. The trans-
mitter may be mounted on a flat
COVER
LOCK
CIRCUIT
END
6.32
(160.5)
6.35
(161.3)
TERMINAL END
THREADED CAP (2 PLACES)
surface using the threaded mount­ing holes located on the bottom of the transmitter housing. Refer to Figure 2-6 for installation refer­ences.
(b) Pipe Mounting. An optional pipe
mounting bracket is available for this type of installation. Refer to Figure 2-7 for installation references.
TERMINAL BLOCK (TB)
TERMINAL END
CAP OMITTED FOR CLARITY
(THIS VIEW)
1.32
(33.5)
O-RING
(2 PLACES)
NOTE: DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN PARENTHESES.
3.68
(93.5)
Figure 2-6. Flat Surface Mounting Dimensional Information
3/4-14 NPT (2 PLACES)
SURFACE
BY OTHERS
0.839
(21.31)
FLAT SURFACE MOUNTING
PAD HOLE PATTERN
1/4-20 THREADS (4 PLACES)
0.839 (21.31)
26020003
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
6.35
(161.3)
COVER LOCK
6.9
(175.3)
Model 4081FG
TERMINAL BLOCK (TB)
CIRCUIT
6.32
(160.5)
1.00
(25.4)
0.375 (9.525) DIA. (4 MOUNTING
HOLES)
1.405
(35.687)
2.81
(71.374)
END
1.32 (33.5)
C
L
3.87
(98.3)
3.25
(82.55)
7.5
(190.5)
6.5
(165.1)
C
L
TERMINAL END
3/4 -14 NPT 2 PLACES
3/4-14 FNPT
(2 PLACES)
5/16-18 NUT
4.00
(101.6)
TERMINAL END CAP OMITTED FOR CLARITY IN THIS VIEW.
2 IN. PIPE/WALL MOUNTING BRACKET (OPTION)
U-BOLT (2 PLACES)
%
1/4-20 THREADS
BRACKET HOLE PATTERN
FOR WALL MOUNTING
NOTE:
DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.
*SCREWS FURNISHED WITH
Figure 2-7. Pipe Mounting Dimensional Information
5/16 WASHER
U-BOLT
MOUNTING KIT ONLY. NOT FURNISHED WITH ANALYZER/TRANSMITTER.
BOTTOM VIEW
1/4-20 SCREW*
29760016
2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
2
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
3. For correct viewing orientation, the dis­play may be changed 90 degrees, us­ing the following procedure:
(a) Refer to Figure 2-8. Loosen the
cover lock screw until the cover lock is disengaged from the knurled surface on the threaded circuit end cap.
(b) Remove the circuit end cap.
(c) Remove the three screws retaining
the display board in place.
(d) Lift and rotate the display board 90
degrees either way.
(e) Reposition the display board on
the standoffs. Install and tighten all three screws.
(f) Install the circuit end cap and
tighten the cover lock screw to se­cure the cover lock in place.
CIRCUIT
END CAP
SCREW
COVER LOCK
SCREW
DISPLAY
BOARD
90
O
90
O
Figure 2-8. Display Positioning Assembly
HOUSING
29760004
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
Model 4081FG

2-3 ELECTRICAL INSTALLATION

All wiring must conform to local and national codes.
Disconnect and lock out power before connecting the unit to the power supply.
Install all protective equipment covers and safety ground leads after installa­tion. Failure to install covers and ground leads could result in serious injury or death.
To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, con­nection to the main electrical power supply must be made through a circuit breaker (min 10 A) which will discon­nect all current-carrying conductors during a fault situation. This circuit breaker should also include a me­chanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 947.
a. General
The power supply and signal wiring should be shielded. Also, make sure the signal wiring is grounded at the Model 4081 Transmitter end only. Do not ground the signal loop at more than one point. Twisted
pairs are recommended. Ground the trans­mitter housing to an earth ground to prevent unwanted electromagnetic interference (EMI) or radio frequency interference (RFI).
NOTE
For optimum EMI/RFI immunity, shield the FOUNDATION fieldbus signal ca­ble and enclose in an earth grounded metal conduit.
Never run signal or sensor wiring in the same conduit, or open tray, with power cables. Keep signal or sensor wiring at least 12 in. (0.3 m) away from other electrical equipment and 6.5 ft (2 m) from heavy electrical equipment.
It is necessary to prevent moisture from entering the Model 4081 Transmitter hous­ing. The use of weather-tight cable glands is required. If conduit is used, plug and seal connections on the transmitter housing to prevent moisture accumulation in the termi­nal side of the housing.
Moisture accumulation in the transmit­ter housing can affect its performance and may void its warranty.
b. Oxygen Probe Signal Connections
1. Two signals represent the O and the cell temperature. The probe provides these values to the Model 4081 Transmitter for processing and signal conditioning.
2. Wiring connections for the probe are shown in Figure 2-9.
value
2
2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model 4081FG
2
TERMINAL BLOCK
CONDUIT
FACTORY-INSTALLED
JUMPER
TERMINAL
BLOCK (TB1)
PROBE
CABLE
SHIELD
GROUND
4
3
12
Instruction Manual
IB-106-4081 Rev. 1.2
September, 2002
CELL - (WH)
THERMOCOUPLE - (RD)
CELL + (BK)
7
6
5
THERMOCOUPLE + (GY)
EARTH
GROUND
11
12
TERMINALS
FIELDBUS
13
DIGITAL (-)
14 15
FIELDBUS
16
DIGITAL (+)
8
9
10
THERMOCOUPLE + (GY)
THERMOCOUPLE - (RD)
CELL - (WH)
CELL + (BK)
26020004
Figure 2-9. Oxygen Probe Terminal Block
c. Model 4081 Transmitter and F
OUNDATION
Fieldbus Signal Connections
1. Two signals representing the O
value
2
and the cell temperature are supplied to the Model 4081 Transmitter from the oxygen probe.
2. Wiring connections for the Model 4081 Transmitter are shown in Figure 2-10.
NOTE
The ground arrangement shown in Figure 2-10 limits the amount of noise introduced into the electronics.
3. Connect wire shields to terminal 1. Connect earth ground as shown.
CELL AND THERMOCOUPLE
CONDUITS
NOTE:
RUN CELL AND THERMOCOUPLE SIGNALS IN SEPARATE CONDUIT FROM .FIELDBUS
Figure 2-10. Model 4081 Transmitter
Terminal Block

2-4 PNEUMATIC INSTALLATION

a. General
Reference air is required for O and calibration check gas is required during a calibration check. Refer to Figure 2-11 for the gas connections on the oxygen probe.
b. Reference Air Package
After the oxygen probe is installed, connect the reference air set. Install the reference air set according to Figure 2-12.
c. Instrument Air (Reference Air)
Instrument air is required for reference. Use 10 psig (68.95 kPa gage) minimum,
FIELDBUS DIGITAL
29760005
calculation,
2
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11
Instruction Manual
IB-106-4081 Rev. 1.2 September, 2002
225 psig (1551.38 kPa gage) at 0.2 scfh (100 ml/min.); less than 40 parts-per-million total hydrocarbons. Regulator outlet pres­sure should be set at 5 psi (35 kPa).
d. Calibration Check Gas
Two calibration check gas concentrations are used with the Two-Wire In Situ Oxygen Analyzer: Low Gas - 0.4% O
- 8% O Do not use 100% nitrogen. See Figure 2-11 for the probe connections. Set both calibra­tion check gases at the same flow rate: 5 scfh (2.5 L/min).
, each with the balance in nitrogen.
2
and High Gas
2
Model 4081FG
1/4 TUBE FITTING
(REFERENCE AIR PORT)
1/4 TUBE FITTING
(CALIBRATION CHECK
Figure 2-11. Oxygen Probe Gas Connections
GAS PORT)
REFERENCE
AIR VENT
26020006
4.81 (122.17)
FLOW SET
POINT KNOB
0.125-27 NPT FEMALE
OUTLET CONNECTION
1
2
1.19 (30.22)
DRAIN VALVE
OUTLET
10.0
(254)
REF
3.12 (79.25) MAX
3
(SUPPLIED BY CUSTOMER)
1/4” TUBE
2.250 (57.15)
2.0
(50.80)
1.50
(38.10)
1 FLOWMETER 0.2-2.0 SCFH 771B635H08
2 2" PRESSURE GAGE 0-15 PSIG 275431-006
3 COMBINATION FILTER-REG. 0-30 PSIG 4505C21G01
TO PROBE
NOTE: DIMENSIONS ARE IN INCHES WITH
0.25-18 NPT FEMALE INLET CONNECTION
2 MOUNTING HOLES
3.19 (81.03) LG
THROUGH BODY FOR
0.312 (7.92) DIA BOLTS
REF AIR SET
263C152G05
MILLIMETERS IN PARENTHESES.
8.50
(215.90)
MAX
INSTRUMENT AIR SUPPLY 10-225 PSIG MAX PRESSURE
SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYGEN PROBE.
26020034
Figure 2-12. Air Set, Plant Air Connection
2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Loading...
+ 78 hidden pages