Rosemount Analytical
M
ODEL
O
XYGEN MONITORS
I
NSTRUCTION MANUAL
7001D, 7002D
748039-U
OTICE
N
The information contained in this document is subject to change without notice.
Ryton® is a registered trademark of Phillips Petroleum Co.
®
Teflon
UNOX
is a registered trademark of E.I. duPont de Nemours and Co., Inc.
®
is a trademark for Wastewater Treatment Systems of Union Carbide Corp.
Manual Part Number 748039-U
December 2000
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
C
P
REFACE
SAFETY SUMMARY ..........................................................................................P1
SPECIFICATIONS - GENERAL .........................................................................P3
SPECIFICATIONS – ELECTRICAL....................................................................P3
SPECIFICATIONS - PHYSICAL.........................................................................P4
SPECIFICATIONS - ALARM..............................................................................P4
SPECIFICATIONS - SENSORS.........................................................................P5
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE.............P6
RETURNING PARTS TO THE FACTORY.........................................................P6
TRAINING ......................................................................................................P6
DOCUMENTATION............................................................................................P6
ONTENTS
COMPLIANCES .................................................................................................P7
SECTION 1. INTRODUCTION
1.1 OVERVIEW.................................................................................................1
1.2 AMPLIFIER MODULE .................................................................................1
1.3 OXYGEN SENSORS...................................................................................2
1.4 MODEL 7001D SENSOR INSTALLATION KITS.........................................4
1.5 MODEL 7002D SENSOR INSTALLATION KITS.........................................5
S
ECTION
2.1 MODEL 7001/7002 OXYGEN MONITOR....................................................9
2.
INSTALLATION
2.1.1 Facility Preparation........................................................................9
2.1.2 Location and Mounting....................................................................9
2.1.3 Electrical Connections - General Precautions................................10
2.1.3.1. Line Power Connection..................................................11
2.1.3.2. System Grounding Connections.....................................11
2.1.3.3 Sensor Cable Connections.............................................11
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
i
ONTENTS
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2.1.3.4. Output Cable Connections............................................. 12
2.1.3.5. Output Connections for Alarms...................................... 13
2.2 MODEL 7001D SENSOR MOUNTING KITS............................................. 15
2.2.1 In-Line Flow Kit PN 639900........................................................... 15
2.2.1.1 Monitoring Boiler Feedwater, High-Purity Water, or
Deaerated Sea Water................................................................. 16
2.2.1.2 Monitoring Deoxygenated Brine for Oil Well Flooding... 18
2.2.2 Submersion Kit PN 623712...........................................................19
2.2.3 In-Line Flow Kit PN 623711........................................................... 22
2.3 MODEL 7002D SENSOR INSTALLATION KITS........................................25
2.3.1 Submersion Kits 639901(Polypropylene) and PN 646626
Ryton)........................................................................... 25
2.3.2 In-Line Flow Kits PN 639902 (Polypropylene) and PN 646627
(Ryton).......................................................................... 29
2.3.3 45° Submersion Kit PIN 639903................................................... 32
2.3.4 Submersion Kit PN 623714...........................................................35
2.3.5 In-Line Flow Kit PN 623713......................................................... 38
2.3.6 Equilibrium Sensor Guard Kit PN 624741 .................................... 41
2.3.7 Equilibrium Sensor Fast Response Kit PN 624742...................... 43
2.3.8 In-Line Kit PN 624743 ( Equilibrium) ............................................ 45
SECTION 3. STARTUP AND CALIBRATION
3.1 SYSTEM STARTUP AND INITIAL CALIBRATION WITH AIR..................... 49
3.2 CALIBRATION OF MODEL 7001D............................................................. 54
3.2.1 Calibration for Measurement of Dissolved Oxygen in
High-Purity Water......................................................... 54
3.2.2 Calibration for Measurement of Dissolved Oxygen in
Deaerated Sea Water................................................... 55
3.2.3 Calibration for Measurement of Dissolved Oxygen in
Deoxygenated Brine for Oil Well Flooding.................... 55
3.3 CALIBRATION OF MODEL 7002D............................................................ 57
3.3.1 Measurements in Sea Water or Brine: Calibration with Air for
Readout of Dissolved Oxygen in Parts Per Million
by Weight (mg/liter). ..................................................... 57
3.3.2 Calibration by Chemical Analysis for Readout of Dissolved
Oxygen in Parts per Million by Weight (mg/liter)........... 58
3.3.3 Combination of Chemical Analysis and Air Calibration for
Readout of Dissolved Oxygen in Parts per Million by
Weight (mg/liter)........................................................... 58
3.3.4 Calibration with Air for Readout of Dissolved Oxygen in
Percent of Saturation.................................................... 59
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December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
SECTION 4. OPERATION
4.1 ROUTINE OPERATION .............................................................................61
4.2 FREQUENCY OF CALIBRATION..............................................................61
4.3 FREQUENCY OF SENSOR RECHARGING..............................................62
ONTENTS
C
S
ECTION
5.1 ELECTROCHEMICAL THEORY................................................................ 63
5.2 PRACTICAL ASPECTS OF DISSOLVED OXYGEN MEASUREMENT ......64
5. T
5.1.1 Oxygen Sensor (Rechargeable or Non- Rechargeable) ................63
5.1.2 Equilibrium Sensor.........................................................................63
5.2.1 Variables Which Influence Measurement.......................................64
5.2.2 Interrelation of Measurement Units................................................66
5.2.3 Readout of Dissolved Oxygen in Parts by Weight..........................67
5.2.4 Readout of Dissolved Oxygen in Percent Saturation.....................68
HEORY
SECTION 6. SENSOR MAINTENANCE
6.1 RECHARGEABLE SENSORS.....................................................................71
6.1.1 Recharging Sensor........................................................................71
6.1.2 Rejuvenating Cathode...................................................................74
6.1.2.1 Cell Separator Kit (PN 637358).......................................75
6.2 NON-RECHARGEABLE SENSORS............................................................75
S
ECTION
7. S
ERVICE
7.1. SYSTEM CHECKOUT.................................................................................77
7.2 CHECKING SENSOR AND CABLE.............................................................78
7.3 CHECKING NON-RECHARGEABLE SENSOR AND CABLE......................81
7.4 CHECKING ELECTRONICS........................................................................ 82
S
ECTION
8.1 REPLACEMENT PARTS – MODELS 7001D AND 7002D..........................83
748169 I
748597 I
ENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS
G
ARRANTY
W
IELD SERVICE AND REPAIR FACILITIES
F
748039-U Rosemount Analytical December 2000
8. R
NSTRUCTION SHEET
NSTRUCTION SHEET
EPLACEMENT PARTS
, 624737 H
ENSOR CONVERSION
, S
EADER KIT
ODEL
– M
– R
7002D
ECHARGEABLE TO NON-RECHARGEABLE
Model 7001D, 7002D Oxygen Monitors
iii
ONTENTS
C
F
IGURES
1-1. Model 7001D Oxygen Monitor................................................................. 2
1-2. Model 7002D Oxygen Monitor................................................................. 2
1-3. Rechargeable Sensor.............................................................................. 3
1-4. Rechargeable Sensor with Gland ............................................................ 3
1-5. Non-Rechargeable Sensor....................................................................... 4
2-1. Power Supply Board Connector Locations .............................................. 11
2-2. Connections for Potentiometric Recorder with Non-Standard Span ........ 14
2-3. Typical Example of Oxygen Monitor Connected in Series with Several
Current-Activated Devices............................................................ 14
2-4. Rechargeable Sensor with In-Line Flow Kit 639900 – Sectional View..... 15
2-5. Rechargeable Sensor with In-Line Flow Kit 639900 – Outline and
Mounting Dimensions................................................................... 15
2-6. In-Line Flow Kit 639900 - Typical Panel-Mounted Installation................ 16
2-7. In-Line Flow Kit 639900 - Typical Power Plant Installations..................... 17
2-8. In-Line Flow Kit 639900 - Typical Installation for Oil Well Flooding.......... 18
2-9. Non-Rechargeable Sensor with Submersion Kit 623712 – Sectional
View.............................................................................................. 19
2-10. Non-Rechargeable Sensor with Submersion Kit 623712 – Outline
and Mounting Dimensions............................................................ 20
2-11. Non-Rechargeable Sensor Submersion Kit 623712 – Typical
Installation .................................................................................... 21
2-12. Non-Rechargeable Sensor with In-Line Pressure Compensation
Kit 623711 – Sectional View......................................................... 22
2-13. Non-Rechargeable Sensor with In-Line Flow Kit 623711 – Outline
and Mounting Dimensions............................................................ 23
2-14. Non-Rechargeable Sensor with In-Line Pressure Compensation
Kit 623711 – Typical Installation................................................... 24
2-15. Rechargeable Sensor with Submersion Kit 639901 or 646626 –
Sectional View.............................................................................. 25
2-16. Rechargeable Sensor with Submersion Kit 639901 or 646626 –
Outline and Mounting Dimensions................................................ 26
2-17. Rechargeable Sensor with Submersion Kit 639901 or 646626 –
Preferred Mounting Orientation .................................................... 27
2-18. Rechargeable Sensor with Submersion Assembly 639901 or 646626
– Typical Installation During Plant Construction ........................... 27
2-19. Rechargeable Sensor with Submersion Assembly 639901 or 646626
– Typical Installation In An Existing Plant..................................... 28
2-20. Rechargeable Sensor with In-Line Flow Kit PN 639902 or 646627
– Sectional View........................................................................... 29
2-21. Rechargeable Sensor with In-Line Flow Kit PN 639902 or 646627
– Outline and Mounting Dimensions............................................. 30
2-22. Rechargeable Sensor with In-Line Flow Kit PN 639902 or 646627
– Preferred Orientation................................................................. 31
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December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
ONTENTS
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2-23. 45° Rechargeable Sensor with Submersion Kit 639903 – Sectional
View ..............................................................................................32
2-24. 45° Rechargeable Sensor with Submersion Kit – Outline and Mounting
Dimensions ...................................................................................33
2-25. 45° Rechargeable Sensor with Submersion Kit – Typical Installation
In UNOX System...........................................................................34
2-26. Non-Rechargeable Sensor with Submersion Kit PN 623714 –
Sectional View...............................................................................35
2-27. Non-Rechargeable Sensor with Submersion Kit 623714 – Outline and
Mounting Dimensions....................................................................36
2-28. Non-Rechargeable Sensor with Submersion Kit 623714 –
Typical Installation.........................................................................37
2-29. Non-Rechargeable Sensor with In-Line Flow Kit PN 623713 –
Sectional View...............................................................................38
2-30. Non-Rechargeable Sensor with In-Line Flow Kit PN 623713 –
Outline and Mounting Dimensions ................................................39
2-31. Non-Rechargeable Sensor with In-Line Flow Kit 623713 –
Typical Installation.........................................................................40
2-32. Equilibrium Sensor with Guard Kit 624741 – Sectional View....................41
2-33. Equilibrium Sensor with Guard Kit 624741 – Outline and Mounting
Dimensions ...................................................................................42
2-34. Equilibrium Sensor with Fast Response Kit 624742 – Sectional View.....43
2-35. Equilibrium Sensor with Fast Response Kit 624742 – Outline and
Mounting Dimensions....................................................................44
2-36. Equilibrium Sensor with In-Line Flow Kit 624743 – Sectional View..........45
2-37. Equilibrium Sensor with In-line Flow Kit 624743 – Outline and
Mounting Dimensions....................................................................46
2-38. Equilibrium Sensor with In-Line Flow Kit 624743 – Prefe rred Orientation 47
3-1. Display Board Controls and Adjustments.................................................50
3-2. Isolated Current Output Board..................................................................51
3-3. Solubility of Oxygen in Water of Various Degrees of Salinity ...................56
5-1. Rechargeable Oxygen Sensor – Sectional View......................................64
5-2. Solubility of Oxygen in Air-Saturated Water as a Function of
Temperature..................................................................................68
6-1. Oxygen Sensor – Exploded View.............................................................73
6-2. Location of Cell Separator in Oxygen Sensor...........................................75
7-1. Expected Display Reading vs. Substitute Resistance (Model 7001D)......79
7-2. Expected Display Reading vs. Substitute Resistance (Model 7002D.......80
T
ABLES
7-1. Rechargeable Sensor Problems Troubleshooting Guide............................81
7-2. Non-Rechargeable Sensor Problems Troubleshooting Guide....................81
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
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ONTENTS
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DRAWINGS (LOCATED IN REAR OF MANUAL)
620434 Schematic, Isolated V/I Board
622617 Outline and Mounting Dimensions, Oxygen Monitor
622227 Interconnect Diagram, Oxygen Monitor
622530 Schematic, Display Board
622538 Schematic, Power Supply Board
vi
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
P
REFACE
S
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
7001D, 7002D Oxygen Monitors should be thoroughly familiar with and strictly follow
the instructions in this manual. Save these instructions.
DANGER is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored
WARNING is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
NOTE is used to indicate installation, operation, or maintenance information which is
important but not hazard-related.
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.
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. For operation
on 230 VAC 50/60 Hz, see Section 2.3.1.
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
P1
REFACE
P
!
Tampering or unauthorized substitution of components may adversely affect
safety of this product. Use only factory documented components for repair
WARNING: PARTS INTEGRITY
P2
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
SPECIFICATIONS - GENERAL
REFACE
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C
ATALOG NUMBER MODEL
192601
C
ATALOG NUMBER MODEL
192602
F
RONT PANEL DISPLAY MODEL
0 to 199.9 parts-per-thousand-million (p/109 ) by weight, displayed as ppb
F
RONT PANEL DISPLAY MODEL
0 to 19.9 parts-per-thousand-million (p/106 ) by weight, displayed as ppm
AMBIENT TEMPERATURE
-20°F to 122°F (-29°C to 50°C)
A
MBIENT HUMIDITY
Up to 95% relative humidity, non-condensing
S
YSTEM LINEARITY
For constant sample temperature: ±1% of fullscale
S
AMPLE TEMPERATURE
32°F to 110°F (0°C to 44°C)
7001D
7002D
7001D
7002D
1
S
PECIFICATIONS
P
OWER REQUIREMENTS (SWITCH SELECTABLE
107 to 127 VAC 50/60 Hz @ 0.2 Ampere
214 to 254 VAC 50/60 Hz @ 0.1 Ampere
D
ISPLAY
Digital liquid crystal (LCD)
O
UTPUT (POTENTIOMETRIC, SELECTABLE RANGE
0 to 200, 0 to 100 or 0 to 50 ppb, fullscale
S
ELECTABLE FULLSCALE VOLTAGE
0 to 10 volts, 0 to 5 volts, or 0 to 1 volt
P
OTENTIOMETRIC OUTPUT
Minimum load is 2K ohms
I
SOLATED CURRENT OUTPUT (OPTIONAL
Field selectable 0 to 20 mA or 4 to 20 mA over same range as
potentiometric output
Maximum load for current output is 600 ohms
– E
LECTRICAL
)
)
)
1
Rated specifications are for an operating temperature of 25°C.
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
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SPECIFICATIONS - PHYSICAL
E
NCLOSURE
ABS Plastic, Black, NEMA Type 4X, IP65
M
OUNTING
Standard: Panel Mount
Optional: Wall Mount, Pipe Mount
DIMENSIONS
5.7 x 5.7 x 7.6 inches (14 x 14 x 19 cm) HxWxD
WEIGHT
Approximately 4.2 pounds (1.9 kg)
E
NCLOSURE CLASSIFICATION
General purpose
Optional air purge designed to NFPA-496 Type Z
M
AXIMUM DISTANCE BETWEEN OXYGEN MONITOR AND SENSOR
1000 feet (304.8 meters)
1
2
S
PECIFICATIONS
A
LARM MODEL
- A
7001D
LARM
0 to 200, 0 to 100 or 0 to 50 ppb, fullscale
A
LARM MODEL
7002D
0 to 20, 0 to 10 or 0 to 2 ppm, fullscale
A
LARM CONTACTS
Two independently adjustable SPDT relay contact actuations
A
LARM RELAY CONTACTS RATINGS(RESISTIVE LOAD
)
Maximum switching voltage: 250 VAC, 30 VDC
Maximum switching current: 3A
D
EADBAND
Adjustable from less than 1% to 20% of range at any setpoint
R
EPEATABILITY
±0.1% of range
1
The optional air purge, when installed along with user supplied components, is designed to equip the instrument
enclosure with Type Z protection per Standard ANSI/NFPA 496-1986. This reduces the classification within the
enclosure from Class I, Division 2 (normally non-hazardous) to non-hazardous, thus permitting installation in a location
classified Class I, Groups A, B, C, D, Division 2. This method of protection is recognized in Article 500-1 of the National
Electrical Code (NEC, ANSI/NFPA 70).
2
The oxygen sensors and interconnecting cable used with the Models 7001D and 7002D Oxygen Monitors are non-
incendive in normal operation and comply with the requirements of Articles 501-3 (b)(1) c and 501-4 (b), Exception of the
National Electrical Code, ANSI/NFPA 70-1987, for installation in Class I, Groups A,B,C,D, Division 2 classified locations.
P4
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
SPECIFICATIONS - SENSORS
REFACE
P
T
YPES
- 7001D
Rechargeable, Polypropylene - PN 623246
Non-Rechargeable, Polypropylene - PN 623740
T
YPES
- 7002D
Rechargeable, Polypropylene - PN 623245
Rechargeable, Ryton – PN 190404
Non-Rechargeable, Polypropylene - PN 623741
S
TABILITY
±1% of fullscale at any given temperature per 24 hours
T
EMPERATURE COMPENSATION
32°F to 110°F (0°C to 44°C) ±6% of reading
60°F to 90°F (15°C to 32°C) ±3% of reading
For any 30°F (16°C) range ±4% of reading
R
ESPONSE TIME
90% in 20 seconds for rechargeable and non-rechargeable sensors
90% in 60 seconds for equilibrium sensor
S
AMPLE PRESSURE
0 to 50 psig (0 to 345 kPa)
1
A
LSO REFER TO INSTRUCTIONS SUPPLIED WITH SENSOR
1
With atmospheric discharge of sample.
.
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
P5
REFACE
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CUST OMER SERVICE, TECHNICAL ASSIST ANCE AND FIELD SERVIC E
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
R
ETURNING PARTS TO THE FACTORY
Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call: 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 sender, freight collect.
When returnin g any pro duct o r compon ent t hat has be en expo sed to a toxic, corrosi ve
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
USA
TRAINING
A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the Current Operator and Service Training Schedule contact
the Technical Services Depart men t at:
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
D
OCUMENTATION
The following Model 7001D, 7002D Oxygen Monitors instruction materials are
available. Contact Customer Service or the local representative to order.
748039 Instruction Manual (this document)
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December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
REFACE
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COMPLIANCES
The Model 7001D and 7002D Oxygen Monitors are designed to comply with applicable
American standards for protection against electrical shock, mechanical and fire hazards in
non-hazardous locations. The instrument(s) must be installed in accordance with the
provisions of the National Electrical Code (NEC), ANSI/NFPA 70, and/or any applicable
national or local code(s), and, operated and maintained in the recommended manner.
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
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REFACE
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NOTES
P8
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
I
NTRODUCTION
1
1.1 OVERVIEW
Model 7001D and 7002D Oxygen Monitors (Figure 1-1) automatically and continuously
measure the concentration of dissolved oxygen in water or non-aqueous solution. The
determination is based on measurement of the electrical current developed by an
amperometric sensor in contact with the sample.
The monitors provide direct readout, on a front-panel display, of dissolved oxygen. The
Model 7001D readout is in parts per thousand million (ppb) by weight, while the Model
7002D readout is in parts per m illion (ppm) by weight. Alarms and a potentiome tric output
are standard features. The full scale range of the alarms and the potentiometric output are
each independently selectable. Thus, the range of the potentiometric output may be
changed without the need to readjust alarm setpoints.
The oxygen monitor system consists of a sensor, a chamber, and an amplifier module. The
sensor is housed within the chamber and is connected to the amplifier by a multi-conductor
shielded cable.
1.2 AMPLIFIER MODULE
The amplifier module conditions the sensor output signal to provide direct readout of
dissolved oxygen in parts per thousand million (ppb) (Model 7001D) or parts per million
(ppm) (Model 7002D) by weight. It also contains current-measuring circuitry, operating
controls, digital display, alarms and signal output provisions.
The module is designed for panel mounting. An accessory kit (PN 622622) permits the
amplifier module to be mounted on a vertical or horizontal pipe. An accessory kit (PN
652117) permits wall (surface) mounting. An optional air purge is designed to meet
requirements for NFPA 496 Type Z air purge (see specifications) .
An accessory board (PN 621023) provides a field-selectable 0 to 20 milliampere or 4 to 20
milliampere isolated current output.
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
1
NTRODUCTION
I
IGURE
F
1-1. M
ODEL
7001D O
LOW
SET PT
Model 7001D Oxygen Monitor
PPB
XYGEN MONITOR
LOW
SET PT
PPM
LOW
SET PT
LOW
SET PT
Model 7002D Oxygen Monitor
IGURE
F
1-2. M
ODEL
7002D O
XYGEN MONITOR
1.3 OXYGEN SENSORS
Rosemount Analytical offers rechargeable and disposable oxygen sensors which can be
used with the Model 7001D and 7002D. See Figures 1-3, 1-4 and 1-5. See Sections 2.4 Sensors, Rechargeable, 2.5 - Sensors - Non-Rechargeable and 7.3 - Sensors,
Replacement Parts for additional information. Sensors are ordered separately from kits.
The available kits are: Submersion, In-Line Flow, and Fast Response (Section 1.4).
The rechargeable oxygen sensors are available in polypropylene or RYTON with the
associated hardware available in PVC or RYTON. The non-rechargeable oxygen sensors
are available in polypropylene with associated hardware in PVC.
2
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
NTRODUCTION
I
Polypropylene bodied sensors are more resistant to service where conditions are more
extreme and hydrocarbons may be present in the sample stream. RYTON bodied sensors
are most resistant to organics, but have specific limitations in resistance to certain organic
compounds1.
Model 7001D Sensors
Rechargeable with Gland, Polypropylene 623246
Non-Rechargeable, Polypropylene 623740
Model 7002D Sensors
Rechargeable with Gland, Polypropylene 623245
Rechargeable with Gland, Ryton 190404
Rechargeable Equilibrium with Gland 624750
Rechargeable 45°
623373
Non-Rechargeable, Polypropylene 623741
IGURE
F
IGURE
F
1
'RYTON is resistant to 30% sulfuric acid, 85% phosphoric-acid, 30% sodium hydroxide, gasoline, aliphatic alcohols, esters, ethers, and ketones as well as to aromatic
amines. It is not particularly suited for service in strong oxidizing agents, aliphatic amines, chlorinated hydrocarbons, or aro matic nitrites, aldehydes, and nitro compounds.
1-3. R
1-4. R
ECHARGEABLE SENSOR
Integral Gland
with O-Rings
ECHARGEABLE SENSOR WITH GLAND
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
3
NTRODUCTION
I
IGURE
F
1-5. NON-R
ECHARGEABLE SENSOR
1.4 MODEL 7001D SENSOR INSTALLATION KITS
Note:
Sensor installation kits DO NOT include a sensor.
Fast Response Liquid Flow Kit PN 639900 (Rechargeable, Polypropylene)
Used with rechargeable sensor PN 623246, this kit is designed for ppb level dissolved
oxygen in water applications. The sample enters the chamber through a nozzle and
impinges directly on the sensor membrane for fast response, then discharges at
atmospheric pressure. Nominal flow is 250 to 500 cc/min.
Typical sample streams include: high purity water, such as boiler feedwater; deaerated sea
water feed in evaporative desalination processes; and deoxygenated brine, as used in oil
well flooding.
Fast Response Liquid Flow Kit PN 623711 ( Non- Rechargeable, Polypropylene)
Designed for use with non-rechargeable oxygen sensor (PN 623740) when a flowing liquid
stream with discharge of the effluent from the flow chamber at atmospheric pressure is
being measured. This requirement means that upstream sample pressure reduction must
be performed on the process sample from a pressurized source before it is presented to the
flow chamber for analysis by the sensor. Sample input flow rate should be selected in the
range of 50 to 100 cc/min and care must be taken with downstream pressure drops to
prevent back pressurization of the sensor. Typical applications are the same as Kit 639900.
4
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
NTRODUCTION
I
Submersion Kit PN 623712 (Non-Rechargeable, Polypropylene)
Used with non-rechargeable sensor 623740 for liquid phase oxygen measurements. It is
intended for use when the liquid phase sensor is to be inserted through a vessel wall as in
the monitoring of a process vessel head space or when a large diameter process is being
monitored directly by insertion of the sensor through the pipe. This kit exposes the sensor
membrane, diaphragm and compensator directly to the sample, with no flow chamber, while
protecting the connector from contact with the sample.
1.5 MODEL 7002D SENSOR INSTALLATION KITS
Note:
Sensor installation kits DO NOT include a sensor.
Submersion Kit PN 639901 (Rechargeable, Polypropylene)
Submersion Kit PN 646626 (Rechargeable, RYTON)
Used with rechargeable sensor PN 623245 (polypropylene) or PN 190404 (Ryton), one of
the principal applications of the submersion assembly is use in wastewater treatment
aeration tanks. In this application the most satisfactory location is at the side of the aeration
tank, either on the diffuser side or on the opposite side. Most installations are made with
the sensor located above the diffuser. Because air bubbles or debris could become trapped
on the active area of the electrode, the sensor (which is not position sensitive) should be
mounted at right angles to flow. Installations made in this way have given many months of
continuous service with the only operating requirement being an occasional calibration
check.
Typical applications for these kits are monitoring natural waters, treated water, wastewater,
non-aqueous process streams and sewage treatment processes. The submersion
assembly permits placing the sensor at depth in a tank, open channel or stream, at a
maximum pressure of 50 psig (345 kPa), equivalent to a water depth of approximately 100
feet (approximately 30 m).
Pressure Compensated In-Line Flow Kit PN 639902 (Rechargeable, Polypropylene)
Pressure Compensated In-Line Flow Kit PN 646627 (Rechargeable, RYTON)
Used with sensor PN 623245 (polypropylene) or PN 190404 (Ryton), some typical
applications for these kits are monitoring neutral waters, treated water, and wastewater.
The kits may also be used when the Model 7002D is set up to monitor non-aqueous
process streams. The in-line pressure-compensated flow chamber used permits mounting
the sensor in a variable-pressure liquid sample stream, at pressures up to 50 psig (345
kPa). The typical application is in-line monitoring, with the flow assembly connected directly
into the process stream pipeline. An alternative application involves discharge to
atmospheric pressure where discharge rates are high.
The sensor responds to partial pressure of oxygen in the flowing sample. If total pressure
changes, the oxygen partial pressure changes proportionally, and the sensor responds
accordingly.
45
°°°°
Submersion Kit PN 639903 (Rechargeable, Polypropylene)
Used with rechargeable sensor 635747, this configuration was designed for use with the
UNOX™ process for secondary treatment of sewage, developed by the Linde Division of
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
5
NTRODUCTION
I
Union Carbide Corporation. The method involves introduction of pure oxygen into
wastewater in a closed tank system. It is intended for use when the liquid phase sensor is
to be inserted through a vessel wall as in the monitoring of a process vessel head space or
when a large diameter process is being monitored directly by insertion of the sensor through
the pipe. The kit includes a 45° submersion assembly.
System characteristics impose special requirements:
1. Avoiding entrapment of bubbles on the sensor membrane is particularly important.
Bubbles are pure oxygen, and thus would cause greater readout errors than the air
bubbles present in conventional aeration systems. To minimize bubble entrapment,
sensor membrane must be inclined at 45°. The sensor is functionally identical to those
provided in the other sensor kits, but differs physically. While the typical sensor has a
cylindrical body, the body of the special sensor incorporates a 45° elbow. Thus, with the
submersion chamber mounted on the bottom of a vertical pipe (Figure 2-12A), the
sensor membrane has the required 45° inclination.
2. The use of a closed tank imposes dimensional limitations on the sensor mounting
arrangement. Design of the submersion assembly permits insertion of the sensor into a
closed tank through a vertical standpipe with minimum inside diameter of 6.0 inches/152
mm. The standpipe has a flange seat at the top of the tank and extends downward into
the tank, below the liquid level.
In-Line Flow Kit PN 623713 (Non-Rechargeable, Polypropylene)
Used with sensor PN 623741 this configuration can be used for the same applications as kit
PN 639901, discussed in the previous Section.
The flow chamber used with this kit serves the same purpose as the fast-response-liquid
and fast-response-gas flow chambers for rechargeable sensors.
This kit is designed for analysis of liquid oxygen samples when a stream with discharge of
the effluent from the flow chamber at atmospheric pressure is being measured. This
requirement means that upstream sample pressure reduction must be performed on the
process sample from a pressurized source before it is presented to the flow chamber for
analysis by the sensor. Sample input flow rate should be selected in the range of 50 to 100
cc/min and care must be taken with downstream pressure drops to prevent back
pressurization of the sensor.
Submersion Kit PN 623714 ( Non-Rechargeable, Polypropylene)
Used with sensor PN 623741, this configuration can be used for the same applications as
kit PN 639901, discussed in the previous Section.
The submersion assembly used with this kit serves the same purpose as the submersion
assembly for rechargeable sensors except that no cable accessory is available.
This kit is intended for use when the liquid phase sensor is to be inserted through a vessel
wall as in the monitoring of a process vessel head space or when a large diameter process
is being monitored directly by insertion of the sensor through the pipe.
6
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
NTRODUCTION
I
Guard Kit PN 624741 ( Equilibrium)
Used with sensor 624750, typical applications are monitoring industrial municipal treated
water and waste waters, especially secondary treatment of sewage. The guard assembly
used in this kit protects the membrane from possible damage due to floating solids and
severe agitation in sample streams commonly found in these applications.
Fast Response Kit PN 624742 (Equilibrium)
Used with sensor 624750, this kit is designed for use when a flowing liquid stream with
discharge of the effluent from the flow chamber at atmospheric pressure is being measured.
Sample input flow rate should be selected in the range of 2-5 cc/min.
The sample enters the chamber through a nozzle and impinges directly on the sensor
membrane for f ast response, then discharges at atmospheric pressure. The nominal flow
rate is 2 to 5 cc/sec. The sensor and flow chamber is designed to have minimum volumes
and thus provide fast response in spite of the low flow rates.
Pressure Compensation In-Line Kit PN 624743 ( Equilibrium)
Used with sensor 624750, this kit permits mounting the sensor in a variable pressure liquid
sample stream, at pressures up to 50 psig (345 kPa). The typical application is in-line
monitoring with the flow assembly connected directly into the process stream pipeline. An
alternative application involves discharge to atmospheric pressure where discharge rates
are high.
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
7
NTRODUCTION
I
NOTES
8
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
I
NSTALLATION
2
Section Two is divided into three parts: Installation of Model 7001/7002D Oxygen Monitor,
Installation of Oxygen Sensor Kits for Model 7001D Monitor and Installation of Oxygen
Sensor Kits for Model 7002D Monitor. Applicable installation instructions' are placed at the
end of each part.
The monitor is shipped set up to operate with a rechargeable sensor. To convert the
instrument to operate with a non-rechargeable or equilibrium sensor, refer to Instructions
748597 or 748169, placed at the back of this manual.
The sensors are shipped assembled and charged, ready for use in either the rechargeable
non-rechargeable, or equilibrium configuration. The non-rechargeable sensor is not
reworkable. The rechargeable and equilibrium sensors may be recharged or rejuvenated if
its performance is marginal due to long storage or other unusual conditions. Refer to
Section 6 for the correct recharging method. When operating fresh from the box, or after a
recharge/rejuvenation procedure, the rechargeable sensor may require recharging as
frequently as every three months. There is no known specific cause for service limitation of
the non-rechargeable sensor; therefore, no storage or service life levels can be accurately
set.
2.1 MODEL 7001/7002 OXYGEN MONITOR
2.1.1 F
Outline and mounting diagrams for the amplifier module are given in DWG 622617. Outline
and mounting dimensions for the alternative oxygen sensor installation kits are provided in
Section 2.2 (Model 7001D) and Section 2.3 (Model 7002D). Electrical connections are
shown in DWG 622227.
2.1.2 L
The amplifier module is designed to meet NEMA-4X requirements, and may be mounted
outdoors. Permissible ambient temperature range is -20 to +122°F (-29 to + 50°C).
Panel mount the amplifier, or use the accessory wall-mount kit (PN 652117) or accessory
pipe-mount kit (PN 622622).
Mount the sensor in an environment within the permissible range of 32°F to 110°F (0°C to
44°C). Installation instructions for the alternative oxygen sensor installation kits are
provided in Section 2.2 (Model 7001D) and Section 2.3 (Model 7002D).
ACILITY PREPARATION
OCATION AND MOUNTING
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
9
NSTALLATION
!
!
I
Sensor and amplifier are interconnected by a multi-conductor shielded cable. The cable is
available in 20 foot length (PN 193661) or 21 feet to 1000 feet (PN 193662, specify length).
2.1.3 E
Wiring diagrams, schematics and other engineering drawings are placed in numerical order
at the back of this manual.
LECTRICAL CONNECTIONS
ENERAL PRECAUTIONS
- G
WARNING: ELECTRICAL SHOCK HAZARD
Do not operate without doors and internal circuit panel secure. Servicing
requires access to live parts which can cause death or serious injury. Refer
servicing to qualified personnel.
For safety and proper performance this instrument must be connected to a
properly grounded three-wire source of power. Electrical installation must be
made in accordance with any applicable national or local codes.
Alarm switching relay contacts wired to separate power source must be
disconnected before servicing.
WARNING: ENCLOSURE INTEGRITY
Unused cable conduit entries must be securely sealed by flameproof closures to
provide enclosure integrity in compliance with personnel safety and
environmental protection requirements. The plastic closures provided are for
shipping protection only. When installing instrument, observe all notes on
drawing 622617 (in rear of this manual).
CAUTION: CONDUIT GROUNDING
The non-metallic enclosure does not provide grounding between conduit
connections. Use grounding-type bushings and jumper wires.
NOTE
Electrical installation must be made in accordance with the National Electrical
Code and/or any applicable local or national codes.
NOTE
For watertight installation conforming to the requirements of NEMA-4X,
approved watertight hubs and closures must be used.
10
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
NSTALLATION
I
2.1.3.1 Line Power Connection
Models 7001D and 7002D monitors provide switch-selectable operation on either 107 to
127 VAC or 214 to 254 VAC, 50/60 Hz power. Open the door (refer to Figure 3-1). Loosen
the retainer screw that holds the display board and pivot the display board to access the
power supply board. Verify that the line voltage selector switch is set to indicate the proper
nominal line voltage: 115 or 230 VAC.
Electrical power is supplied to the monitor via a customer-supplied three-conductor cable,
type SJT with 18 AWG minimum wire size. Route power cable through conduit and into
appropriate opening in monitor enclosure. Connect power cable leads to terminal strip TB5
on the power supply board, as shown in Figure 2-1 and DWG 622227.
2.1.3.2. System Grounding Connections
Within the analyzer, a ground terminal (GND) is provided on the power supply board. Refer
to Figure 2-1. This terminal must be connected, via the ground lead of the three-conductor
power cable to a good earth ground.
2.1.3.3 Sensor Cable Connections
The sensor cable is supplied, as ordered, in any length up to a maximum of 1000 feet (305
m). If a long cable is used, it should be routed to the amplifier through appropriate conduit.
Connect the amplifier end of the cable to terminal strips TB1 and TB2 on the power supply
board, as shown in Figure 2-1 and DWG 622227.
Connect the remaining end of the cable to the sensor when installation of the sensor kit is
complete.
Isolated V/I Board
(Option)
(see Figure 3-2)
Recorder
TB3
Sensor
TB2
R
1
R4
R3
R8
R9
POWER SUPPLY BOARD 622537
J1
R5 R6
U2
C2
U3
30K
THERM
U4
C4
C5
I G O
TB2
U6
O
G
I
CR2
1 2 3 4
TB1
C1
U1 J1
CR
C3
I
G
O
U5
3K/10K
THERM
SHLD
CATH
AM
TB3
CR2
U5
O
G
I
U1
U3
O
G
I
O
O
G
I
I
G
U2 U4
SHIELD
+VOLTAGE OUT
-VOLTAGE OUT
+CURRENT OUT
-CURRENT OUT
CR3
CR4
CR1
C2 C1
O
I
K2
G
F1
K1
TB4
NO
COM
ALARM
NC
NO
COM
ALARM
NC
TB5
C3
GND
NEUTRAL/L2
HOT/L1
T1
Voltage Select Switch
S1
S1
AC Power
TB5
Current Output
TB3
IGURE
F
2-1. P
748039-U Rosemount Analytical December 2000
OWER SUPPLY BOARD CONNECTOR LOCATIONS
Model 7001D, 7002D Oxygen Monitors
11
NSTALLATION
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2.1.3.4. Output Cable Connections
WARNING
Do not route potentiometric output or current output cables through the same
conduit as the power cable or alarm output cable, to avoid shock hazard and AC
pickup.
If a recorder, controller, or other output device is used, connect it via a number 22 or
number 24 AWG two-conductor shielded cable. Route the output cable through conduit to
the amplifier module, and into the case through the appropriate opening shown in DWG
622617, Sheet 2.
Potentiometric Output
1. Connect leads of shielded recorder cable to VOLTAGE OUT + and VOLTAGE OUT -
terminals of TB3 on Power Supply Board, Figure 2-1. Connect shield to SHD terminal.
2. Connect other end of output cable to terminals of recorder or other potentiometric
device.
a. For devices with spans of 0 to 1, 0 to 5, or 0 to 10 volts, connect cable directly to
input terminals of the, device, making sure polarity is correct.
b. For devices with intermediate spans, i.e., between the specified values, connect
cable to device via a suitable external voltage divider, as shown in Figure 2-2.
Isolated Current Output Accessory
1. Verify that the accessory current output board (Isolated V/I Board), if used, is properly
in place in its connector. See Figure 2-1. If originally ordered with the oxygen monitor,
the board is factory installed.
2. Connect leads of shielded cable to CURRENT OUT + and CURRENT OUT - terminals
of TB3 on Power Supply Board, Figure 2-1. Connect shield to SHD terminal.
3. Connect other end of output cable to input terminals of recorder or other
current-actuated device, making sure polarity is correct. If two or more
current-actuated devices are to be used, they must be connected in series. Refer to
Figure 2-3.
12
CAUTION: TOTAL RESISTANCE
Total resistance of all output devices and associated interconnection cable must
not exceed 600 ohms.
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
NSTALLATION
I
4. Since neither the CURRENT OUT + nor the CURRENT OUT - terminal is grounded,
the current loop should be grounded at some point within the circuit. The ground po int
should be chosen to minimize noise or other undesirable interactions.
2.1.3.5 Output Connections for Alarms
Alarm Output Connections
The alarm output provides two sets of relay contacts for actuation of alarm and/or
process-control functions. Leads from the customer-supplied external alarm system
connect to terminals on TB4, as shown in DWG 622227.
If the alarm contacts are connected to any device that produces radio frequency
interference (RFI), it should be arc-suppressed. Arc suppressor (PN 858728) is
recommended. When possible, the oxygen monitor should operate on a different AC power
source to minimize RFI.
Alarm Relay Characteristics
The HI ALARM and LO ALARM outputs are provided by two identical single-pole
double-throw relays. Relay contacts are rated at (resistive):
3A, 250 VAC
3A, 30 VDC
Removal of AC power from the analyzer, as in a power failure, de-energizes both relays.
Hi Alarm Relay
The HI ALARM relay coil is energized when the display moves upscale through the value
that corresponds to the setpoint plus deadband. This relay coil is de-energized when
display moves downscale through the value that corresponds to setpoint minus deadband.
Lo Alarm Relay
The LO ALARM relay coil is energized when the display moves downscale through the
value that corresponds to setpoint minus deadband. This relay coil is de-energized when
the display moves upscale through the value that corresponds to setpoint plus deadband.
Alarm Reset
The HI ALARM and LO ALARM functions both incorporate automatic reset. When the
display reading goes beyond the pre-selected limits, the corresponding relay is energized.
When the display reading returns within the acceptable range, the relay is automatically
de-energized.
Fail Safe Applications
By appropriate connection to the double-throw relay contacts it is possible to obtain either a
contact closure or a contact opening for an energized relay. The de-energized relay then
748039-U Rosemount Analytical December 2000
Model 7001D, 7002D Oxygen Monitors
13
NSTALLATION
Positi
Mini
ibl
O
P
(Verif
R1
R2
I
provides a contact opening or contact closure, respectively. It is important for fail safe
applications that the user understand what circuit conditions are desired in event of power
failure and the resultant relay de-energized. Relay contacts should then be connected
accordingly.
otentiometric
Recorder
IGURE
F
2-2. C
S
is correct)
1K Ohm
Input
Terminals
y polarity
e
utput Cable from
Oxygen Monitor
on of Recorder
Output Selector Plug
100 mV
Voltage Divider
(Customer Supplied)
10 mV
1 V
mum Permiss
Resistance for R1 + R2
10K Ohm
100K Ohm
ONNECTIONS FOR POTENTIOMETRIC RECORDER WITH NON-STANDARD
PAN
Oxygen
Monitor
mA
+
-
+
Recorder
-
+
Controller
-
IGURE
F
14
2-3. T
S
+
Remote
Indicator
-
YPICAL EXAMPLE OF OXYGEN MONITOR CONNECTED IN SERIES WITH
EVERAL CURRENT-ACTIVATED DEVICES
December 2000 Rosemount Analytical 748039-UModel 7001D, 7002D Oxygen Monitors
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