Instruction Manual
IM-106-360, Original Issue
February 2005
SBX 1000
In-Situ Oxygen Transmitter
http://www.raihome.com
Instruction Manual
IM-106-360, Original Issue
February 2005
SBX 1000
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Quick Start Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Manual Calibration Quick Reference Guide . . . . . . . . . . . . . . . . . . . iv
Technical Support Hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
SECTION 1
Description and
Specifications
SECTION 2
Installation
SECTION 3
Configuration and
Startup
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Handling the SBX 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
System Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Selecting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Connect Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Connect O
Pneumatic Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Calibration Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Reference Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Terminal Block Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Verify Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Startup Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Operating Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Signal and Logic I/O Signal . . . . . . . . . . . . . . . . . . . . 2-8
2
SECTION 4
Calibration
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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
SBX 1000
Instruction Manual
IM-106-360, Original Issue
February 2005
SECTION 5
Using the Membrane
Keypad
SECTION 6
Maintenance/Service
SECTION 7
Troubleshooting
Keypad Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Test Gas Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Calibration Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Display LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
SBX 1000 Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Remove Probe from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Install Probe on Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Electronics Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Terminal Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Heater Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Contact and Thermocouple Replacement . . . . . . . . . . . . . . . . . . . 6-9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Loose Integrated Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Identifying and Correcting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Alarm Descriptions and Corrective Actions . . . . . . . . . . . . . . . . . . 7-5
Incorrect Oxygen Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
SECTION 8
Return of Materials
SECTION 9
Replacement Parts
SECTION 10
Optional Accessories
APPENDIX A
Safety Data
INDEX
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Common Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
SBX 1000 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
SBX 1000 Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
O2 Calibration Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Reference Air Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Mounting Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Ceramic Fiber Products Material Safety Data Sheet . . . . . . . . . . . . . A-15
High Pressure Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
TOC-2
Instruction Manual
IM-106-360, Original Issue
February 2005
SBX 1000 In-Situ Oxygen Transmiter
SBX 1000
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
specifications. The following instructions MUST be adhered to
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
product.
• If you do not understand any of the instructions, contact your
Rosemount Analytical representative
• Follow all warnings, cautions, and instructions
supplied with the product.
• Inform and educate your personnel in the proper installation,
operation, and maintenance of the product
• Install your equipment as specified in the Installation Instructions
of the appropriate Instruction 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
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.
to ensure they continue to operate within their normal
and integrated
prior to installing, operating, and servicing the
for clarification.
marked on and
.
to install,
.
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The information contained in this document is subject to change without
notice.
SBX 1000
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
Instruction Manual
IM-106-360, Original Issue
February 2005
PREFACE
DEFINITIONS
The purpose of this manual is to provide information concerning the
components, functions, installation and maintenance of the SBX 1000.
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.
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 operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
NOTE
Highlights an essential operating procedure, condition, or statement.
SYMBOLS
NOTE TO USERS
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.
ii
Instruction Manual
IM-106-360, Original Issue
February 2005
SBX 1000
QUICK START GUIDE
Use the following Quick Start Guide only if you are familiar with the installation
requirements for the SBX 1000 In-Situ Oxygen Transmitter.
If you cannot use the Quick Start Guide, turn to Section 2, Installation, in
this Instruction Manual.
The following drawing shows a simplified installation diagram for the
SBX 1000.
SBX 1000
Line Voltage
4-20 mA Analog
Cal. Gas
Instr. Air (Ref. Air)
37640001
1. Install the SBX 1000 in an appropriate location on the stack or duct.
Refer to Selecting Location in Section 2, Installation, for information on
selecting a location for the SBX 1000.
2. Connect reference air to the SBX 1000 as shown in the figure above.
3. Connect the line voltage and 4-20 mA analog output as shown in the
figure below.
AC Terminal
Line Voltage
(90 to 250 VAC)
Logic I/O Signal
4-20 mA
Analog Signal
Terminal
Block
Cover
AC L1
AC N
+
-
+
-
Left Side of
SBX 1000
AC Line
Voltage Port
Ground
Lugs
Signal
Port
4. Verify the SBX 1000 switch configuration is as desired. Refer to
Configuration in Section 3, Configuration and Startup.
5. Apply power to the SBX 1000; the cell heater will turn on. Allow
approximately one half hour for the cell to heat to operating
temperature. Once the ramp cycle has completed and the SBX 1000 is
at normal operation, proceed with step 6.
6. Perform a manual calibration per the following procedure. Refer to
Section 4, Calibration for more information regarding calibration.
37640002
iii
SBX 1000
Instruction Manual
IM-106-360, Original Issue
February 2005
Manual Calibration Quick Reference Guide
Technical Support Hotline
Perform a Manual Calibration as follows:
1. Place the control loop in manual.
2. Press the CAL key. The Cal LED will remain lit.
3. Apply the first calibration gas.
4. Press the CAL key. When the unit has taken the readings using the first
calibration gas, the Cal LED will flash continuously.
5. Remove the first calibration gas and apply the second calibration gas.
6. Push the CAL key. The Cal LED will remain lit. When the unit has taken
the readings using the second calibration gas, the Cal LED will flash a
two-pattern flash or a three-pattern flash. A two-pattern flash equals a
valid calibration, three-pattern flash equals an invalid calibration.
7. Remove the second calibration gas and cap off the calibration gas port.
8. Press the CAL key. The Cal LED will remain lit as the unit purges.
When the purge is complete, the Cal LED will turn off.
9. If the calibration was valid, the DIAGNOSTIC ALARMS LEDs indicate
normal operation. If the new calibration values are not within the
parameters, the DIAGNOSTIC ALARMS LEDs will indicate an alarm.
10. Place the control loop in automatic.
For assistance with technical problems, please call the Customer Support
Center (CSC). The CSC is staffed 24 hours a day, 7 days a week.
Phone: 1-800-433-6076
In addition to the CSC, you may also contact Field Watch. Field Watch
coordinates Rosemount Analytical field service throughout the U.S. and
abroad.
Phone: 1-800-654-RSMT (1-800-654-7768)
Rosemount Analytical may also be reached via the Internet through e-mail
and the World Wide Web:
e-mail: GAS.CSC@emersonprocess.com
World Wide Web: www.raihome.com
iv
Instruction Manual
IM-106-360, Original Issue
February 2005
SBX 1000
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-5
COMPONENT CHECKLIST
Figure 1-1. Typical System Package
A typical Rosemount Analytical SBX 1000 In-Situ Oxygen Transmitter should
contain the items in Figure 1-1. The Reference Air Set (item 1) and Mounting
Plate with Hardware (item 2) are optional items. Record the part number,
serial number, and order number for each component of your system.
1
2
3
4
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37640005
1. SBX 1000
2. Instruction Manual
3. Reference Air Set (not included, see Section 10, Optional Accessories)
4. Mounting Plate with Mounting Hardware and Gasket (not included,
see Section 10, Optional Accessories)
SBX 1000
SYSTEM OVERVIEW
Instruction Manual
IM-106-360, Original Issue
February 2005
Scope
System Description
This Instruction Manual is designed to supply details needed to install, start
up, operate, and maintain the SBX 1000. Signal conditioning electronics
outputs a 4-20 mA signal representing an oxygen value. The electronics
package includes a membrane keypad for setup, calibration, and diagnostics.
The SBX 1000 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 probe is permanently positioned within an exhaust duct or stack
and performs its task without the use of a sampling system.
The equipment measures oxygen percentage by reading the voltage
developed across a heated electrochemical cell, which consists of a small
yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous
metal electrodes. When operated at the proper temperature, the millivolt
output voltage of the cell is given by the following Nernst equation:
EMF = KT log
Where:
•P
side of the cell.
•P
opposite side of the cell.
• T is the absolute temperature.
• C is the cell constant.
• K is an arithmetic constant.
10(P1/P2
is the partial pressure of the oxygen in the measured gas on one
2
is the partial pressure of the oxygen in the reference air on the
1
) + C
NOTE
For best results, use clean, dry, instrument air (20.95% oxygen) as the
reference air.
When the cell is at operating temperature 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 SBX 1000 to provide
exceptional sensitivity at low oxygen concentrations.
The SBX 1000 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.
1-2
Instruction Manual
3
3
IM-106-360, Original Issue
February 2005
SBX 1000
System Configuration
System Features
The SBX 1000 is equipped with a 12 inch probe. The electronics control
instrument temperatures, provide an isolated 4-20 mA output proportional to
the measured oxygen concentration, and control the Logic I/O output contact.
The power supply can accept voltages of 90-250 VAC and 48/62 Hz; no
power supply setup procedures are required. The oxygen sensing cell is
maintained at a constant temperature by modulating the duty cycle of the
probe heater portion of the electronics. The electronics accepts millivolt
signals generated by the oxygen sensing cell and produces the outputs for
controlling remote user devices.
• The CALIBRATION RECOMMENDED feature detects when the
sensing cell is likely out of limits. This may eliminate the need to
calibrate on a "time since last cal" basis.
• The cell output voltage and sensitivity increase as the oxygen
concentration decreases.
• The oxygen cell, heater, thermocouple and diffusion element are field
replaceable.
• The SBX 1000 is constructed of rugged 316 L stainless steel for all
wetted parts.
• The SBX 1000 automatically adapts to line voltages from 90-250 VAC;
no input power configuration or setup is necessary.
• An operator can calibrate and diagnostically troubleshoot the SBX 1000
using the integral membrane keypad shown in Figure 1-2.
Figure 1-2. Membrane Keypad
HEATERT/C
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
TEST
POINTS
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
HEATER
02 CELL
CALIBRATION
02 CELL mV +
02 CELL mv HEATERT/C +
HEATERT/C -
CAL
TEST GAS +
PROCESS -
% 02
764000
• The membrane keypad, housed within the electronics housing,
provides fault indication by way of flashing LEDs. Calibration can be
performed from the membrane keypad.
1-3
SBX 1000
)
Handling the SBX 1000
Instruction Manual
IM-106-360, Original Issue
February 2005
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 SBX 1000 is designed for industrial applications. Treat each component of the system
with care to avoid physical damage. Some probe components are made from ceramics,
which are susceptible to shock when mishandled
System Considerations
Figure 1-3. Typical SBX
1000 Installation
Prior to installing your SBX 1000, make sure you have all the components
necessary for 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 temperatures,
environmental considerations, convenience, and serviceability. A typical
installation for an SBX 1000 is shown in Figure 1-3.
Gases
Duct
Stack
SBX 1000
Line Voltage
Logic I/O Signal
4-20 mA
Analog Signal
Adapter
Plate
Flowmeter
Calibration Gas
Instrument
Air Supply
(Reference Air
Pressure
Regulator
37640004
1-4
A source of instrument air is optional at the SBX 1000 for reference air use.
Since the unit is equipped with an in-place calibration feature, provisions can
be made to permanently connect calibration gas bottles to the SBX 1000. If
the calibration gas bottles, Table 1-2, will 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 the calibration gas line and subsequent
flue gas condensation and corrosion.
NOTE
The electronics is rated NEMA 4X (IP66) and is capable of operation at
temperatures up to 158°F (70°C).
Retain the packaging in which the SBX 1000 arrived from the factory in case
any components are to be shipped to another site. This packaging has been
designed to protect the product.
Instruction Manual
IM-106-360, Original Issue
February 2005
SPECIFICATIONS
SBX 1000
SBX 1000 Specifications
O
Range
2
Standard 0 to 10% O2, 0 to 25% O
Accuracy Typically ±1.5% of reading or 0.1% O2, whichever is
greater
Lowest detectable limit 0.1% O
System Response to
Calibration Gas
Temperature Limits
Process 32° to 1300°F (0° to 704°C)
Electronics Housing -40° to 158°F (-40° to 70°C) ambient
Probe Lengths 12 in. (305 mm)
Mounting and Mounting Position Vertical or horizontal
Materials
Probe Wetted or welded parts - 316L stainless steel (SS)
Electronics Enclosure Low-copper aluminum
Calibration Manual
Calibration Gas Mixtures
Recommended
Calibration Gas Flow 5 scfh (2.5 l/m)
Reference Air (optional) 2 scfh (1 l/m), clean, dry, instrument-quality air
Electronics NEMA 4X, IP66 with fitting and pipe on reference
Electrical Noise Meets EN 55022 Generic Emissions Std.
Line Voltage 90-250 VAC, 48/62 Hz. No configuration necessary.
Signals
Analog Output 4-20 mA isolated from power supply, 950 ohms max.
Logic I/O Two-terminal logic contact for alarm output
Conduit Ports 3/4 in.-14 NPT (one threaded hole for both analog
Power Requirements
Probe Heater 175 W nominal
Electronics 10 W nominal
Certifications General Purpose
2
Initial – less than 3 seconds, T90 – less than
8 seconds
Non-wetted parts - 304 SS, low-copper aluminum
0.4% O
8% O2, Balance N
(20.95% O
exhaust port to clear dry atmosphere
Includes EN 61000-4-2 for Electrostatic Discharge
Includes EN 61000-4-3 for RFI
Includes EN 61000-4-4 for Fast Transient Immunity
Includes EN 61000-4-6 for RFI
3/4 in. - 14 NPT conduit port
load
output and logic I/O)
, Balance N
2
), regulated to 5 psi (34 kPa)
2
2
2
2
APPROVED
C
US
1-5
SBX 1000
Table 1-1. Product Matrix
SBX1000
Code Sensing Probe Type
0 Snubber Diffusion Element
Code Probe Assembly
0 12 in. (305 mm) Probe Length
Instruction Manual
IM-106-360, Original Issue
February 2005
In-Situ Oxygen Transmitter (SBX 1000)
Code Mounting Hardware - Stack Side
0 Ordered Separately PN 4512C34G01 (ANSI)
Code Mounting Hardware - Probe Side
0 Universal Flange (ANSI/DIN)
Code Electronics Housing
0 Housing and Filtered Customer Termination - NEMA 4X, IP66
Code Electronics Mounting
0 Integral to Probe with Transient Protected Filtered Termination
Code Signal Output
0 One 4-20mA
Code Alarm Output
0 One Self Powered (+5V) 340 ohm resistance
SBX100000000000 Example
Table 1-2. Calibration
Gas Bottles
Part Number Description
1A99119G01 Two disposable calibration gas bottles - 0.4% and 8% O
1A99119G02 Two pressure regulators for calibration gas bottles
1A99119G03 Gas bottle rack
Notes:
*Calibration gas bottles cannot be shipped via airfreight.
When the bottles are used with CALIBRATION RECOMMENDED features, the bottles should provide
2 to 3 years of calibrations in normal service.
nitrogen - 550 liters each, includes bottle rack*
, balance
2
1-6
Instruction Manual
IM-106-360, Original Issue
February 2005
Section 2 Installation
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-6
Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-8
Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-9
Before installing this equipment, read the "Safety instructions for the wiring and installation
of this apparatus" at the front of this Instruction Manual. Failure to follow safety instructions
could result in serious injury or death.
SBX 1000
The SBX 1000 and probe is heavy. Use proper lifting and carrying procedures to avoid
personal injury.
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.
http://www.raihome.com
SBX 1000
MECHANICAL INSTALLATION
Instruction Manual
IM-106-360, Original Issue
February 2005
Selecting Location
Probe Installation
1. The location of the SBX 1000 in the stack or flue is most important for
maximum accuracy in the oxygen analyzing process. The SBX 1000
must be positioned so the gas it measures is representative of the
process. 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 the process
gas temperature falls within a range of 32° to 1300°F (0° to 704°C).
Figure 2-1 through Figure 2-3 provide mechanical installation
references. The ambient temperature of the integral electronics housing
must not exceed 158°F (70°C).
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 SBX 1000
upstream of any leakage.
3. Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance access to the membrane
keypad. Allow adequate clearance for removal of the SBX 1000.
Do not allow the temperature of the SBX 1000 electronics to exceed 158°F (70°C) or
damage to the unit may result.
1. Ensure all components are available to install the SBX 1000. If
equipped with the optional ceramic diffusion element, ensure it is not
damaged.
2. The SBX 1000 may be installed intact as it is received.
3. Weld or bolt adapter plate, Figure 2-2, onto the duct.
2-2
Instruction Manual
IM-106-360, Original Issue
February 2005
Figure 2-1. SBX 1000 Probe
Installation
SBX 1000
18.5
(470)
Dim "B"
REF.
GAS
10.5
(267)
E
V
I
-
L
A
E
R
T
E
I
H
P
U
S
O
M
T
G
A
N
I
N
E
R
V
A
I
S
O
L
P
C
R
-
I
C
N
E
H
W
W
-
T
H
X
E
G
I
T
N
I
P
-
E
E
K
3/4 NPT
Elec Conn
Ref Air
800-433-6076
Orrville,OH 44667-0901
Rosemount Analytical Inc.
R
Analytical
Cal Gas
Dim "A"
Table 2. Installation/Removal
12 in.
Probe
DIN 6 mm Tube
ANSI 1/4 (6,35) Tube
12
(305)
(39)
1.55
6.52
(166)
(73)
2.89
Cover removal
and access
12
(305)
All dimensions are in inches
with millimeters in parentheses.
Note:
3535B18H02
3535B45H01
0.062 Thk Gasket
ANSI
DIN
Insulate if exposed to ambient
weather conditions
2.27 (58)
Dia Max
E
V
I
-
L
A
E
R
T
E
I
H
P
U
S
O
M
T
G
A
N
I
N
E
R
V
A
I
S
O
L
P
C
R
-
I
C
N
E
H
W
W
-
T
H
X
E
G
I
T
N
I
P
-
E
E
K
CAL.
GAS
12.3 (312)
Bottom View
Dim “B” Removal Envelope
5.8 (147)
4.5 (114)
Dim “A”
(20)
0.75
7.28
ANSI/DIN
6P00172H01
Table 1. Mounting Flange
(185)
Flange Dia
Hole Dia
4.75/5.71
(121/145)
(4) Holes
eq sp on BC
37640006
2-3
SBX 1000
Figure 2-2. Adapter Plate
Dimensions and Installation
Instruction Manual
IM-106-360, Original Issue
February 2005
2.500 (63,5)
Dia
ADAPTER PLATE OUTLINE
Table 3. Mounting Plate
Dimensions for SBX 1000
A
C
6.00
(153)
0.625-11
4.75
(121)
4 Studs, lockwashers,
and nuts equally
spaced on “C” dia B.C.
"A"
"B"
Stud Size
“C"
Dia B.C.
B
INSTALLATION FOR METAL WALL
STACK OR DUCT CONSTRUCTION
2.50 (63,5)
Minimum dia
hole in wall
Stack or duct
metal wall
Weld or bolt adapter plate to
metal wall of stack or duct.
Joint must be air tight.
Note: Dimensions are in inches with
millimeters in parentheses.
37640007
2-4
4. In vertical installations, ensure the system cable drops vertically from
the SBX 1000 and the conduit is routed below the level of the
electronics housing. This drip loop minimizes the possibility that
moisture will damage the electronics. See Figure 2-3.
5. Insert probe through the opening in the mounting plate and bolt the unit
to the plate. (Two mounting flange gaskets are provided. Use the ANSI
or DIN gasket applicable to your installation.)
NOTE
To maintain CE compliance, ensure a good connection exists between the
mounting plate studs or earthing screws on electronics housing and earth.
Instruction Manual
3
6
0008
IM-106-360, Original Issue
February 2005
Figure 2-3. Drip Loops and
Insulation Removal
Replace insulation
after installing
SBX 1000
SBX 1000
4-20 mA
Analog Signal
Logic I/O Signal
Line Voltage
E
V
I
-
L
A
E
R
T
E
I
H
P
S
O
M
T
G
A
N
I
N
E
R
V
A
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S
O
L
P
U
C
-
W
X
R
I
C
N
E
H
W
-
T
H
E
G
I
T
N
I
P
-
E
E
K
CAL.
GAS
and
Drip Loop
Insulation
Adapter Plate
Stack or Duct
Metal Wall
4
7
6. Ensure the SBX 1000 is properly grounded (earthed) by way of both
internal and external points.
Uninsulated stacks or ducts may cause ambient temperatures around the electronics to
exceed 158°F (70°C), which may cause overheating damage to the electronics.
7. If duct work insulation is removed for probe mounting, make sure the
insulation is replaced. See Figure 2-3.
8. Make sure the probe installation does not obscure the warnings on the
housing covers.
2-5
SBX 1000
Instruction Manual
IM-106-360, Original Issue
February 2005
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.
The probe is heavy. Use proper lifting and carrying procedures to avoid personnel injury.
NOTE
To maintain CE compliance, ensure a good connection exists between the
mounting flange bolts and earth.
2-6
Instruction Manual
l
IM-106-360, Original Issue
February 2005
SBX 1000
Connect Line Voltage
Figure 2-4. Remove/Install
Ter m ina l C ov e r
1. See Figure 2-4. Using both hands or strap wrench, turn cover
counterclockwise to loosen. Remove cover.
2. See Figure 2-5. Connect line (L1 wire) to L1 terminal.
3. Connect the neutral (L2 wire) to the N terminal. The SBX 1000
automatically will configure itself for 90-250 VAC line voltage and 50/60
Hz. To avoid a shock hazard, the power terminal cover must be
installed.
4. Connect ground wire (green wire) to one of two ground lugs.
Cover
Figure 2-5. Electrical
Installation
Analog Signal
90-250 VAC, 50-60 Hz
Line Voltage Input
4-20mA
Logic I/O
Signal
Ground
+
-
+
-
Line 1
Neutral
Ground
4-20 mA
Analog Signal
-
+
-
Ground
Lugs
37640033
Logic I/O Signa
Line Voltage
+
AC L1
AC N
Terminal
Block
37640009
2-7
SBX 1000
Instruction Manual
IM-106-360, Original Issue
February 2005
Connect O2 Signal and Logic I/O Signal
PNEUMATIC INSTALLATION
1. 4-20 mA O2 Signal. The 4-20 mA signal represents the O2 value.
Connect the signal wiring as shown in Figure 2-5.
2. Connect the Logic I/O signal wiring as shown in Figure 2-5. The Logic
I/O contact is a self-powered, +5 VDC, 340 Ohm series resistance. An
interposing relay will be required if this contact is to be utilized to
annunciate a higher voltage device, such as a light or horn, and may
also be required for certain DCS input cards. A Potter & Brumfield
R10S-E1Y1-J1.0K 3.2 mA DC or equivalent interposing relay will be
mounted where the contact wires terminate in the control/relay room.
3. See Figure 2-4. Install and hand-tighten cover.
Optional Reference Air Package
Connect the reference air set, Figure 2-6. The reference air should be clean,
dry, instrument-quality air (20.95% O
), with less than 40 ppm total
2
hydrocarbons.
In most applications, ambient air is an adequate reference air source. For
optimal performance a Rosemount Analytical reference air package is
recommended. Refer to Section 10, Optional Accessories.
Regulator Inlet
Air pressure on the supply side of the reference air set must be regulated
from 10 psig (68,95 kPa gage) to 225 psig (1551,38 kPa gage) maximum.
Regulator Outlet
Set the reference air flow to 2 scfh (1 l/hr) maximum, regulated at 5 psig
(34 kPa gage).
Figure 2-6. Reference Air Set,
Plant Air Connection
Note: Dimensions are in inches with millimeters
in parentheses. All piping specified in U.S.
standards.
0.125-27 NPT
Outlet
1
4.81 (122,17)
Flow Set
Point Knob
1 Flowmeter 0.2-2.0 scfh (0,006-0,057 scmh) 771B635H02
2 Pressure Gage 0-15 psig (0-103 kPa gage) 275431-006
3 Combination Filter-Reg. 0-30 psig (0-207 kPa gage) 4505C21G01
2
1.19 (30,22)
10.0 (254) Ref
3
Outlet
Drain
Valve
Replacement Parts
3.12 (79,25 Max)
2.250 (57,15)
0.25-18 NPT
Inlet
(215,0)
2.0
(50,80)
1.50
(38,10)
8.50
Max
Mounting holes
3.19 (81,03) lg
0.312 (7,92) dia
through bolts
for
SCHEMATIC HOOKUP FOR REFERENCE AIR
SUPPLY TO SBX 1000 PROBE HEAD
R
Rosemount Analytical Inc.
Orrville,OH 44667-0901
800-433-6076
Analytical
0.250 in. or 6 mm O.D. Tubing
(supplied by customer)
1
2
Ref Air Set
263C152G01
3
Instrument Air
10-225 psig
(69-1551 kPa gage)
max.
37640010
2-8
Instruction Manual
IM-106-360, Original Issue
February 2005
Calibration Gas
SBX 1000
Figure 2-7. Calibration Gas
Connections
2-Stage
Regulators
Do not use 100% nitrogen as a low gas (zero gas). It is suggested that gas for the low (zero)
be between 0.4% and 2.0% O
than 40 parts per million. Failure to use proper gases will result in erroneous readings.
. Do not use gases with hydrocarbon concentrations of more
2
Two calibration gas concentrations are used with the SBX 1000, Low Gas -
0.4% O
and High Gas - 8% O2. See Figure 2-7 for a diagram showing the
2
typical calibration gas connection to the SBX 1000.
Cal Gas Check Valve
Whenever the calibration gas lines are permanently connected to the SBX
1000, be sure to install a check valve at the cal gas inlet to the SBX 1000. The
check valve is to prevent the breathing of flue gasses, and subsequent
corrosion of the cal gas plumbing and regulator equipment.
R
Rosemount Analytical Inc.
Orrville,OH 44667-0901
800-433-6076
Analytical
INITIAL POWER UP
Instrument
2
LO O
2
Pressure Regulator/Filter
HI O
Upon completing installation, make sure that the SBX 1000 is turned on and operating prior
to firing up the combustion process. Damage can result from having a cold SBX 1000
exposed to the process gases.
During outages, and if possible, leave all SBX 1000 units running to prevent condensation
and premature aging from thermal cycling. If the ducts will be washed down during outage,
MAKE SURE to power down the SBX 1000 units and remove them from the wash area.
Air Supply
37640011
Do not power up the SBX 1000 at this time. The installation must be checked
carefully before power is applied. Refer to Section 3, Configuration and
Startup, for the installation check procedures and for initial power up
instructions.
2-9
SBX 1000
Instruction Manual
IM-106-360, Original Issue
February 2005
2-10
Instruction Manual
S
IM-106-360, Original Issue
February 2005
SBX 1000
Section 3 Configuration and Startup
Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-2
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-4
VERIFY INSTALLATION
Mechanical Installation
Reference Air
Terminal Block Wiring
Figure 3-1. Electronics Housing
Te rm i na l s
Prior to performing the configuration and startup procedures, you should
verify that the mechanical and electrical installations are complete and done
correctly.
Ensure the SBX 1000 is installed correctly. Check all mechanical fasteners.
pneumatic connections, and conduit connections. See Section 2, Installation.
If using a piped reference air source, make sure the reference air is set to 2
scfh (1 l/hr) maximum, 5 psig (34 kPa gage), at the reference air inlet.
1. Remove the cover from left side of the electronics housing.
2. Refer to Figure 3-1. Be sure the input line voltage wiring, the
oxygenoxygen signal wiring, and the Logic I/O signal wiring are properly
connected and secure.
3. Reinstall and secure the terminal block cover.
BX 1000
Electronics
Housing
R
Rosemount Analytical Inc.
Orrville,OH 44667-0901
800-433-6076
Analytical
http://www.raihome.com
4-20 mA
Analog Signal
Logic I/O
Signal
+
+
-
-
Ground Lugs
AC N
AC L1
Terminal
Block
37640012
SBX 1000
CONFIGURATION
Instruction Manual
IM-106-360, Original Issue
February 2005
Verify Configuration
Located in the electronics stack are two switches that configure outputs for
the SBX 1000 (Figure 3-2).
To verify the setting of these switches, unfasten and lift the electronics stack
part way out of the housing. Refer to Section 6, SBX 1000 Repair Procedures.
Remove power from the SBX 1000 before changing switch positions. If switch positions are
changed under power, damage to the electronics package may occur.
SW1 Setting
The two settings are for internally or externally powering the 4-20 mA signal.
The factory setting is for the 4-20 mA signal to be internally powered.
SW2 Setting
The factory sets this switch as follows:
1. Positions 1 and 4 are for factory use only. They must be in the position
shown in Figure 3-2.
2. Position 2 determines the oxygen range. This can be set to either 0 to
10% O
or 0 to 25% O2. The factory setting is 0 to 10% oxygen.
2
3. Position 3 determines the output at startup or when the device goes into
an alarm state. The settings are 3.5 mA or 21.6 mA. The factory setting
is 3.5 mA. If the oxygen measurement is being utilized as part of an
automatic control loop, the loop should be placed in manual upon this
failure event, or other appropriate actions should be taken.
3-2
Read O
Concentration
2
Once the cell is up to operating temperature, the oxygen percentage can be
read using one of the following methods:
1. Membrane Keypad - Access TP5 and TP6 on the microprocessor
board. Attach a multimeter across TP5 and TP6. The calibration and
process gases can now be monitored. Pressing INC or DEC once will
cause the output to switch from the process gas to the calibration gas.
Pressing INC or DEC a second time will increase or decrease the
calibration gas parameter. If the keys have been inactive for one minute,
the output reverts to the process gas. When a calibration has been
initiated, the value at TP5 and TP6 is the percent oxygen seen by the
cell. Oxygen levels, as seen on the multimeter, are:
8.0% O
0.4% O
= 8.0 VDC
2
= 0.4 VDC
2
2. 4-20mA output signal
Instruction Manual
IM-106-360, Original Issue
February 2005
Figure 3-2. Default
Configuration Settings
SBX 1000
power supply
SW1
DIAGNOSTIC
ALARMS
CALIBRATION
CALIBRATION RECOMMENDED
TEST
POINTS
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
EXERNAL:
4-20 mA
requires an
external
HEATERT/C
HEATER
O2 CELL
O2 CELL mV +
O2 CELL mV HEATERT/C +
HEATERT/C -
CAL
TEST GAS +
PROCESS -
% O2
TP1
TP2
TP3
TP4
TP5
TP6
SW2
1
2
3
4
INTERNAL:
4-20 mA is
internally
powered
(default)
ON
J1
YEL
RED
GRN
ORG
0to10%O /
0to25%O:
3.5 mA/21.6 mA:
OFF
Not Used
0 to 10% O
Not Used
2
3.5 mA
Default
Position
(Ex-Factory)
2
O Range
2
2
When alarm exists, or
on power up, output current
goes to this value
ON
0 to 25% O
21.6 mA
2
37640013
3-3
SBX 1000
STARTUP
Instruction Manual
IM-106-360, Original Issue
February 2005
Startup Display
Operating Display
Figure 3-3. Startup and
Normal Operation
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
TEST
POINTS
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
HEATER T/C
HEATER
O2 CELL
CALIBRATION
O2 CELL mV +
O2 CELL mv HEATERT/C +
HEATERT/C -
CAL
TEST GAS +
PROCESS -
% O2
When power is applied to the probe, the cell heater turns on. It takes
approximately one half hour for the cell to heat to operating temperature. This
condition is indicated by the top four LEDs (DIAGNOSTIC ALARMS) on the
membrane keypad (Figure 3-3). Starting with the CALIBRATION LED, the
LEDs light in ascending order until all four LEDs are on. At this point, all four
turn off and the cycle starts again. This ramp cycle continues until the cell is
up to operating temperature.
The ramp cycle turns into a cycle where the diagnostic LEDs light in sequence
from the top to the bottom, one at a time. After the bottom LED turns on, the
sequence starts again at the top with the HEATER T/C LED (Figure 3-3).
Heater T/C
Heater
O Cell
2
SW2
TP1
TP2
TP3
TP4
TP5
TP6
ON
1
2
3
4
J1
YEL
RED
GRN
ORG
Calibration
Heater T/C
Heater
O Cell
2
Calibration
1 2 3 4 1 2 3 4
Lighting Sequence During Warm-Up
(Startup Display)
3-4
1 2 3 4 1 2 3 4
Lighting Sequence During Normal Operation
(Operating Display)
KEYPAD
37640014
Instruction Manual
3
6
00
5
IM-106-360, Original Issue
February 2005
Figure 3-4. Membrane Keypad
SBX 1000
Error Display
If there is an error condition at startup, one of the diagnostic LEDs
(Figure 3-4) will be blinking. Refer to Section 7, Troubleshooting, to determine
the cause of the error. Clear the error, cycle power, and the operating display
should return.
Membrane Keypad
The five membrane keys on the membrane keypad (Figure 3-4) are only used
during calibration to adjust the high and low gas and to initiate the calibration
sequence.
Diagnostic
LEDs
Membrane
Keys
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
TEST
POINTS
HEATER T/C
HEATER
02 CELL
CALIBRATION
02 CELL mV +
02 CELL mv HEATERT/C +
HEATERT/C -
Membrane
Keys
INC INC
HIGH
LOW
GAS
GAS
DEC DEC
CAL
TEST GAS +
PROCESS -
% 02
Membrane
Key
1
4
7
3-5
SBX 1000
Instruction Manual
IM-106-360, Original Issue
February 2005
3-6
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