Rosemount Oxymitter 5000 O2 Transmitter with FOUNDATION Fieldbus Communications-Rev 1.0 Manuals & Guides

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OXYMITTER 5000 OXYGEN TRANSMITTER WITH FOUNDATION FIELDBUS COMMUNICATIONS

Instruction Bulletin IB-106-350 Revision 1.0

Oxymitter 5000

Part no. _______________ Serial no. _______________ Order no. _______________

Cal Recommended

Autocal

F fieldbus

OUNDATION

STAY OFF THE STACK!

28550032

HIGHLIGHTS OF CHANGES

Effective March, 1999 Rev. 1.0

PAGE SUMMARY

3-1 Added note referencing appendices for fieldbus information. A-5 Added Table A-4. A-6 Added Table A-5.

IB-106-350

OXYMITTER 5000 OXYGEN TRANSMITTER WITH FOUNDATION FIELDBUS COMMUNICATIONS

NOTICE

Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product.

The products described in this document are NOT designed for nuclear-qualified applications.

Using non-nuclear-qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings.

For information on Fisher-Rosemount nuclear-qualified products, contact your local FisherRosemount Sales Representative.

Rosemount is a registered trademark of Rosemount Inc. Delta V, the Delta V logotype, PlantWeb, and the PlantWeb logotype are trademarks of Fisher-Rosemount.

OUNDATION

is a trademark of the Fieldbus Foundation.

Rosemount satisfies all obligations coming from legislation to harmonize the product requirements in the European Union.

ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a peri od of on e year after the date of s h ipment, Rosemou n t shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).

The remedy(ies) provided above s h all be pu rch as er's sole remedy(ies ) f or an y failure of Rosemount to comply with the warranty provisions, whether claims by the purchaser are based in contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deteriora tion due to environment. Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the warranty period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be subject to the same warran t y as is extended to Rosemoun t by the original manu f actu rer.

At the time of installation it is important that the required services are supplied to the system and that the electronic controller is set up at least to the point where it is controlling the sensor heater. This will ensure, that should there be a delay between installation and full commissioning that the sensor being supplied with ac power and reference air will not be subjected to component deterioration.

IB-106-350

PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the Oxymitter 5000

components, functions, installation, and maintenance.

This manual is designed to provide information about the Oxymitter 5000. We recommend that you

thoroughly familiarize yourself with the Description and Installation sections before installing your transmitter.

The description presents the basic principles of the transmitter along with its performance characteristics and components. The remaining sections contain detailed procedures and information necessary to install and service the transmitter.

Before contacting Rosemount concerning any questions, first consult this manual. It describes most situations encountered in your equipment’s operation and details necessary action.

DEFINITIONS

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 essential operating procedure, condition, or statemen t.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

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

NOTE

The number in the low er rig h t corn er of each illu stration in th is pu blication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

IB-106-35

IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING AND

INSTALLATION OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections shou ld be made to all earthing points, in tern al an d ex tern al, where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all tim es.

3. Mains supply cords s h ou ld comply w it h t h e requ irements of IEC227 or IEC 245.

4. All wiring shall be su itable f or us e in an ambient temperature of greater than 75°C .

5. All cable glands used shou ld be of s u ch in tern al dimensions as to provide adequ ate cable an ch orag e.

6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local s tan dards.

7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then only by trained service personnel.

8. Where equipment or covers are mark ed with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch .

9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions .

10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

IB-106-350

iii

BELANGRIJK

Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.

De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften.

1. Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten, intern en extern.

2. Na installatie of controle moeten alle veiligheidsdeksels en -aardingen terug geplaatst worden. Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven.

3. Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.

4. Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen, hoger dan 75°C.

5. Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd is.

6. Om de veilige werking van dit toestel te verzekeren, moet de voeding door een stroomonderbreker gevoerd worden (min 10A) welke alle draden van de voeding moet onderbreken. De stroomonderbreker mag een mechanische schakelaar bevatten. Zoniet moet een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten onderworpen zijn aan een erkende standaard zoals IEC947.

7. Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning aanwezig. Deze deksels mogen enkel verwijderd worden nadat de voedingsspanning werd afgelegd en enkel door getraind onderhoudspersoneel.

8. Waar toestellen of deksels aangegeven staan met het symbool is er gevaar voor hete oppervlakken. Deze deksels mogen enkel verwijderd worden door getraind onderhoudspersoneel nadat de voedingsspanning verwijderd werd. Sommige oppper-vlakken kunnen 45 minuten later nog steeds heet aanvoelen.

9. Waar toestellen of deksels aangegeven staan met het symbool gelieve het handboek te raadplegen.

10. Alle grafische symbolen gebruikt in dit produkt, zijn afkomstig uit een of meer van devolgende standaards: EN61010-1, IEC417 en ISO3864.

IB-106-350

VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.

Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bør også følges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse forefindes.

2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og jordforbindelser reetableres.

3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.

4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur højere end 75° C.

5. Alle benyttede kabelforskruninger skal have en intern dimension, så passende kabelaflastning kan etableres.

6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse mod indirekte berøring gennem afbryder (min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsitua-tion. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og mærkes som sådan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947.

7. Hvor udstyr eller dæksler er mærket med dette symbol, er farlige spændinger normalt forekom-mende bagved. Disse dæksler bør kun afmonteres, når forsyningsspændingen er frakoblet - og da kun af instrueret servicepersonale.

8. Hvor udstyr eller dæksler er mærket med dette symbol, forefindes meget varme overflader bagved. Disse dæksler bør kun afmonteres af instrueret servicepersonale, når forsyningsspænding er frakoblet. Visse overflader vil stadig være for varme at berøre i op til 45 minutter efter frakobling.

9. Hvor udstyr eller dæksler er mærket med dette symbol, se da i betjeningsmanual for instruktion.

10. Alle benyttede grafiske symboler i dette udstyr findes i én eller flere af følgende standarder:- EN61010-1, IEC417 & ISO3864.

IB-106-350

BELANGRIJK

Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.

Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving anders voorschrijft.

1. Alle voorziene interne- en externe aardaansluitingen dienen op adequate wijze aangesloten te worden.

2. Na installatie,onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels /kappen en aardingen om reden van veiligheid weer aangebracht te worden.

3. Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of IEC 245.

4. Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven 75°C.

5. Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankering van de kabel wordt verkregen.

6. Om een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats te vinden via een meerpolige automatische zekering (min.10A) die foutconditie optreedt. Deze automatische zekering mag ook voorzien zijn van een mechanisch bediende schakelaar. Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars dienen te voldoen aan een erkende standaard zoals IEC 947.

alle

spanningvoerende geleiders verbreekt indien een

7. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder spanning voerende delen bevinden die gevaar op kunnen leveren. Deze beschermdeksels/kappen mogen uitsluitend verwijderd worden door getraind personeel als de spanning is afgeschakeld.

8. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder hete oppervlakken of onderdelen bevinden. Bepaalde delen kunnen mogelijk na 45 min. nog te heet zijn om aan te raken.

9. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, dient men de bedieningshandleiding te raadplegen.

10. Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende standaarden: EN 61010-1, IEC 417 & ISO 3864.

IB-106-350

TÄRKEÄÄ

Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa.

Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive) yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta, elleivät kansalliset standardit estä sitä.

1. Riittävät maadoituskytkennät on tehtävä kaikkiin maadoituspisteisiin, sisäisiin ja ulkoisiin.

2. Asennuksen ja vianetsinnän jälkeen on kaikki suojat ja suojamaat asennettava takaisin pai-koilleen. Maadoitusliittimen kunnollinen toiminta täytyy aina ylläpitää.

3. Jännitesyöttöjohtimien täytyy täyttää IEC227 ja IEC245 vaatimukset.

4. Kaikkien johdotuksien tulee toimia >75°C lämpötiloissa.

5. Kaikkien läpivientiholkkien sisähalkaisijan täytyy olla sellainen että kaapeli lukkiutuu kun-nolla kiinni.

6. Turvallisen toiminnan varmistamiseksi täytyy jännitesyöttö varustaa turvakytkimellä (min 10A), joka kytkee irti kaikki jännitesyöttöjohtimet vikatilanteessa. Suojaan täytyy myös sisältyä mekaaninen erotuskytkin. Jos ei, niin jännitesyöttö on pystyttävä katkaisemaan muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi. Turvakytkimien tai kat-kaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä.

7. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla hengenvaarallisen suuruinen jännite. Suojaa ei saa poistaa jänniteen ollessa kytkettynä laitteeseen ja poistamisen saa suorittaa vain alan asian-tuntija.

8. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla kuuma pinta. Suojan saa poistaa vain alan asiantuntija kun jännite-syöttö on katkaistu. Tällainen pinta voi säilyä kosketuskuumana jopa 45 mi-nuuttia.

9. Mikäli laite tai kosketussuoja on merkitty tällä merkillä katso lisäohjeita käyttöohjekirjasta

10. Kaikki tässä tuotteessa käytetyt graafiset symbolit ovat yhdestä tai useammasta seuraavis-ta standardeista: EN61010-1, IEC417 & ISO3864.

IB-106-350

vii

IMPORTANT

Consignes de sécurité concernant le raccordement et l’installation de cet appareil.

Les consignes de sécurité ci-dessous s’adressent particulièrement à tous les états membres de la communauté européenne. Elles doivent être strictement appliquées afin de satisfaire aux directives concernant la basse tension. Les états non membres de la communauté européenne doivent également appliquer ces consignes sauf si elles sont en contradiction avec les standards locaux ou nationaux.

1. Un raccordement adéquat à la terre doit être effectuée à chaque borne de mise à la terre, interne et externe.

2. Après installation ou dépannage, tous les capots de protection et toutes les prises de terre doivent être remis en place, toutes les prises de terre doivent être respectées en permanence.

3. Les câbles d’alimentation électrique doivent être conformes aux normes IEC227 ou IEC245

4. Tous les raccordements doivent pouvoir supporter une température ambiante supérieure à 75°C.

5. Tous les presse-étoupes utilisés doivent avoir un diamètre interne en rapport avec les câbles afin d’assurer un serrage correct sur ces derniers.

6. Afin de garantir la sécurité du fonctionnement de cet appareil, le raccordement à l’alimentation électrique doit être réalisé exclusivement au travers d’un disjoncteur (minimum 10A.) isolant tous les conducteurs en cas d’anomalie. Ce disjoncteur doit également pouvoir être actionné manuellement, de façon mécanique. Dans le cas contraire, un autre système doit être mis en place afin de pouvoir isoler l’appareil et doit être signalisé comme tel. Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telle IEC947.

7. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des tensions dangereuses sont présentes. Ces capots ne doivent être démontés que lorsque l’alimentation est coupée, et uniquement par un personnel compétent.

8. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des surfaces dangereusement chaudes sont présentes. Ces capots ne doivent être démontés que lorsque l’alimentation est coupée, et uniquement par un personnel compétent. Certaines surfaces peuvent rester chaudes jusqu’à 45 mn.

9. Lorsque les équipements ou les capots affichent le symbole suivant, se reporter au manuel d’instructions.

10. Tous les symboles graphiques utilisés dans ce produit sont conformes à un ou plusieurs des standards suivants: EN61010-1, IEC417 & ISO3864.

IB-106-350

viii

Wichtig

Sicherheitshinweise für den Anschluß und die Installation dieser Geräte.

Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der Niederspannungsrichtlinie zu genügen. Nichtmitgliedsstaaten der europäischen Gemeinschaft sollten die national gültigen Normen und Richtlinien einhalten.

1. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden.

2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerät müssen alle Sicherheitsabdeckungen und Erdungen wieder installiert werden. Die Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gestört sein.

3. Die Netzspannungsversorgung muß den Anforderungen der IEC227 oder IEC245 genügen.

4. Alle Verdrahtungen sollten mindestens bis 75 °C ihre Funktion dauerhaft erfüllen.

5. Alle Kabeldurchführungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so gewählt werden, daß diese eine sichere Verkabelung des Gerätes ermöglichen.

6. Um eine sichere Funktion des Gerätes zu gewährleisten, muß die Spannungsversorgung über mindestens 10 A abgesichert sein. Im Fehlerfall muß dadurch gewährleistet sein, daß die Spannungsversorgung zum Gerät bzw. zu den Geräten unterbrochen wird. Ein mechanischer Schutzschalter kann in dieses System integriert werden. Falls eine derartige Vorrichtung nicht vorhanden ist, muß eine andere Möglichkeit zur Unterbrechung der Spannungszufuhr gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden. Ein solcher Mechanismus zur Spannungsunterbrechung muß mit den Normen und Richtlinien für die allgemeine Installation von Elektrogeräten, wie zum Beispiel der IEC947, übereinstimmen.

7. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, die eine gefährliche (Netzspannung) Spannung führen. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen.

8. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, in bzw. unter denen heiße Teile vorhanden sind. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen. Bis 45 Minuten nach dem Unterbrechen der Netzzufuhr können derartig Teile noch über eine erhöhte Temperatur verfügen.

9. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, bei denen vor dem Eingriff die entsprechenden Kapitel im Handbuch sorgfältig durchgelesen werden müssen.

10. Alle in diesem Gerät verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgend aufgeführten Standards: EN61010-1, IEC417 & ISO3864.

IB-106-350

IMPORTANTE

Norme di sicurezza per il cablaggio e l’installazione dello strumento.

Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all’Unione Europea, salvo quanto disposto dalle vigenti normative l ocali o nazionali

1. Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra interni ed esterni, dove

2. Dopo l’installazione o la localizzazione dei guasti, assicurarsi che tutti i coperchi di protezione siano stati

3. I cavi di alimentazione della rete devono essere secondo disposizioni IEC227 o IEC245.

4. L’intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore a 75°C.

5. Le dimensioni di tutti i connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggio

previsti.

collocati e le messa a terra siano collegate. L’integrità di ciscun morsetto di terra deve essere costantemente garantita.

al cavo.

6. Per garantire un sicuro funzionamento dello strumento il collegamento alla rete di alimentazione principale dovrà essere eseguita tramite interruttore automatico (min.10A), in grado di disattivare tutti i conduttori di circuito in caso di guasto. Tale interruttore dovrà inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione dell’alimentazione, chiaramente identificabile. Gli interruttori dovranno essere conformi agli standard riconosciuti, quali IEC947.

7. Il simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza di elevati voltaggi. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento.

8. Il simbolo riportato sullo strumento o sui coperchi di protezione indica rischio di contatto con superfici ad alta temperatura. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento. Alcune superfici possono mantenere temperature elevate per oltre 45 minuti.

9. Se lo strumento o il coperchio di protezione riportano il simbolo, fare riferimento alle istruzioni del manuale Operatore.

10. Tutti i simboli grafici utilizzati in questo prodotto sono previsti da uno o più dei seguenti standard: EN61010-1, IEC417 e ISO3864.

IB-106-350

VIKTIG

Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret.

Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder.

1. Passende jordforbindelser må tilkobles alle jordingspunkter, interne og eksterne hvor disse forefinnes.

2. Etter installasjon eller feilsøking skal alle sikkerhetsdeksler og jordforbindelser reetableres. Jordingsforbindelsene må alltid holdes i god stand.

3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.

4. Alle ledningsforbindelser skal være konstruert for en omgivelsestemperatur høyere en 750C.

5. Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnåes.

6. For å oppnå sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom en strømbryter (minimum 10A) som vil bryte spenningsforsyningen til alle elektriske kretser ved en feilsituasjon. Strømbryteren kan også inneholde en mekanisk operert bryter for å isolere instrumentet fra spenningsforsyningen. Dersom det ikke er en mekanisk operert bryter installert, må det være en annen måte å isolere utstyret fra spenningsforsyningen, og denne måten må være tydelig merket. Kretsbrytere eller kontakter skal oppfylle kravene i en annerkjent standard av typen IEC947 eller tilsvarende.

7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell.

8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. Noen overflater kan være for varme til å berøres i opp til 45 minutter etter spenningsforsyning frakoblet.

9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til instruksjonsmanualen for instrukser.

10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av følgende standarder: EN61010-1, IEC417 & ISO3864.

IB-106-350

IMPORTANTE

Instruções de segurança para ligação e instalação deste aparelho.

As seguintes instruções de segurança aplicam-se especificamente a todos os estados membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tensão. Relativamente aos estados que não pertençam à UE, deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação local a tiver substituído.

1. Devem ser feitas ligações de terra apropriadas a todos os pontos de terra, internos ou externos.

2. Após a instalação ou eventual reparação, devem ser recolocadas todas as tampas de seg urança e terras de protecção. Deve manter-se sempre a integridade de todos os terminais de terra.

3. Os cabos de alimentação eléctrica devem obedecer às exigências das normas IEC227 ou IEC245.

4. Os cabos e fios utilizados nas ligações eléctricas devem ser adequados para utilização a uma temperatura ambiente até 75º C.

5. As dimensões internas dos bucins dos cabos devem ser adequadas a uma boa fixação dos cabos.

6. Para assegurar um funcionamento seguro deste equipamento, a ligação ao cabo de alimentação eléctrica deve ser feita através de um disjuntor (min. 10A) que desligará todos os condutores de circuitos durante uma avaria. O disjuntor poderá também conter um interruptor de isolamento accionado manualmente. Caso contrário, deverá ser instalado qualquer outro meio para desligar o equipamento da energia eléctrica, devendo ser assinalado convenientemente. Os disjuntores ou interruptores devem obedecer a uma norma reconhecida, tipo IEC947.

7. Sempre que o equipamento ou as tampas contiverem o símbolo, é provável a existência de tensões perigosas. Estas tampas só devem ser retiradas quando a energia eléctrica tiver sido desligada e por Pessoal da Assistência devidamente treinado.

8. Sempre que o equipamento ou as tampas contiverem o símbolo, há perigo de existência de superfícies quentes. Estas tampas só devem ser retiradas por Pessoal da Assistência devidamente treinado e depois de a energia eléctrica ter sido desligada. Algumas superfícies permanecem quentes até 45 minutos depois.

9. Sempre que o equipamento ou as tampas contiverem o símbolo, o Manual de Funcionamento deve ser consultado para obtenção das necessárias instruções.

10. Todos os símbolos gráficos utilizados neste produto baseiam-se em uma ou mais das seguintes normas: EN61010-1, IEC417 e ISO3864.

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IMPORTANTE

Instrucciones de seguridad para el montaje y cableado de este aparato.

Las siguientes instrucciones de seguridad , son de aplicacion especifica a todos los miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension.

1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en aquellos terminales previstos al efecto.

2. Una vez finalizada las operaciones de mantenimiento del equipo, se deben volver a colocar las cubiertas de seguridad aasi como los terminales de tierra. Se debe comprobar la integridad de cada terminal.

3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245.

4. Todo el cableado sera adecuado para una temperatura ambiental de 75ºC.

5. Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables.

6. Para un manejo seguro del equipo, la alimentacion electrica se realizara a traves de un interruptor magnetotermico ( min 10 A ), el cual desconectara la alimentacion electrica al equipo en todas sus fases durante un fallo. Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio.

7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa, dicho alojamiento solamente se abrira una vez que se haya interrumpido la alimentacion electrica al equipo asimismo la intervencion sera llevada a cabo por personal entrenado para estas labores.

8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con alta temperatura, por tanto se abrira una vez que se haya interrumpido la alimentacion electrica al equipo por personal entrenado para estas labores, y al menos se esperara unos 45 minutos para enfriar las superficies calientes.

9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el manual de instrucciones.

10. Todos los simbolos graficos usados en esta hoja, estan de acuerdo a las siguientes normas EN61010-1, IEC417 & ISO 3864.

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VIKTIGT

Säkerhetsföreskrifter för kablage och installation av denna apparat.

Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varje avseende för att överensstämma med Lågspännings direktivet. Icke EU medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala eller nationella föreskrifter.

1. Tillämplig jordkontakt skall utföras till alla jordade punkter, såväl internt som externt där så erfordras.

2. Efter installation eller felsökning skall samtliga säkerhetshöljen och säkerhetsjord återplaceras. Samtliga jordterminaler måste hållas obrutna hela tiden.

3. Matningsspänningens kabel måste överensstämma med föreskrifterna i IEC227 eller IEC245.

4. Allt kablage skall vara lämpligt för användning i en omgivningstemperatur högre än 75ºC.

5. Alla kabelförskruvningar som används skall ha inre dimensioner som motsvarar adekvat kabelförankring.

6. För att säkerställa säker drift av denna utrustning skall anslutning till huvudströmmen endast göras genom en säkring (min 10A) som skall frånkoppla alla strömförande kretsar när något fel uppstår. Säkringen kan även ha en mekanisk frånskiljare. Om så inte är fallet, måste ett annat förfarande för att frånskilja utrustningen från strömförsörjning tillhandahållas och klart framgå genom markering. Säkring eller omkopplare måste överensstämma med en gällande standard såsom t ex IEC947.

7. Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för livsfarlig spänning i närheten. Dessa höljen får endast avlägsnas när strömmen ej är ansluten till utrustningen - och då endast av utbildad servicepersonal.

8. När utrustning eller hölje är markerad med vidstående symbol föreligger risk för brännskada vid kontakt med uppvärmd yta. Dessa höljen får endast avlägsnas av utbildad servicepersonal, när strömmen kopplats från utrustningen. Vissa ytor kan vara mycket varma att vidröra även upp till 45 minuter efter avstängning av strömmen.

9. När utrustning eller hölje markerats med vidstående symbol bör instruktionsmanualen studeras för information.

10.

Samtliga grafiska symboler som förekommer i denna produkt finns angivna i en eller flera av följande föreskrifter:- EN61010-1, IEC417 & ISO3864.

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IB-106-350

CERAMIC FIBER PRODUCTS

MATERIAL SAFETY DATA SHEET

JULY 1, 1996

SECTION I. IDENTIFICATION

PRODUCT NAME

Ceramic Fiber Heaters, Molded Insulation Modules and Ceramic Fiber Radiant Heater Panels.

CHEMICAL FAMILY

Vitreous Aluminosilicate Fibers with Silicon Dioxide.

CHEMICAL NAME

N.A.

CHEMICAL FORMULA

N.A.

MANUFACTURER’S NAME AND ADDRESS

Watlow Columbia 573-474-9402 2101 Pennsylvania Drive 573-814-1300, ext. 5170 Columbia, MO 65202

HEALTH HAZARD SUMMARY

WARNING

• Possible cancer hazard based on tests with laboratory animals.

• May be irritating to skin, eyes and respiratory tract.

• May be harmful if inhaled.

• Cristobalite (crystalline silica) formed at high temperatures (above 1800ºF) can cause severe respiratory disease.

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SECTION II. PHYSICAL DATA

APPEARANCE AND ODOR

Cream to white colored fiber shapes. With or without optional white to gray granular surface coating and/or optional black surface coating.

SPECIFIC WEIGHT: 12-25 lb./cubic foot BOILING POINT: N.A.

VOLATILES (% BY WT.): N.A. WATER SOLUBILITY: N.A.

SECTION III. HAZARDOUS INGREDIENTS

MATERIAL, QUANTITY, AND THRESHOLD/EXPOSURE LIMIT VALUES

Aluminosilicate (vitreous) 99+ % 1 fiber/cc TWA CAS. No. 142844-00-06 10 fibers/cc CL Zirconium Silicate 0-10% 5 mg/cubic meter (TLV) Black Surface Coating** 0 - 1% 5 mg/cubic meter (TLV) Armorphous Silica/Silicon Dioxide 0-10% 20 mppcf (6 mg/cubic meter)

**Composition is a trade secret.

PEL (OSHA 1978) 3 gm cubic meter (Respirable dust): 10 mg/cubic meter, Intended TLV (ACGIH 1984-85)

SECTION IV. FIRE AND EXPLOSION DATA

FLASH POINT: None FLAMMABILITY LIMITS: N.A.

EXTINGUISHING MEDIA

Use extinguishing agent suitable for type of surrounding fire.

UNUSUAL FIRE AND EXPLOSION HAZARDS/SPECIAL FIRE FIGHTING PROCEDURES

N.A.

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SECTION V. HEALTH HAZARD DATA

THRESHOLD LIMIT VALUE

(See Section III)

EFFECTS OF OVER EXPOSURE

EYE

Avoid contact with eyes. Slightly to moderately irritating. Abrasive action may cause damage to outer surface of eye.

INHALATION

May cause respiratory tract irritation. Repeated or prolonged breathing of particles of respirable size may cause inflammation of the lung leading to chest pain, difficult breathing, coughing and possible fibrotic change in the lung (Pneumoconiosis). Pre-existing medical conditions may be aggravated by exposure: specifically, bronchial hyperreactivity and chronic bronc hia l or lung disease.

INGESTION

May cause gastrointestinal disturbances. Symptoms may include irritation and nausea, vomiting and diarrhea.

SKIN

Slightly to moderate irritating. May cause irritation and inflammation due to mechanical reaction to sharp, broken ends of fibers.

EXPOSURE TO USED CERAMIC FIBER PRODUCT

Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) may undergo partial conversion to cristobalite, a form of crystalline silica which can cause severe respiratory disease (Pneumoconiosis). The amount of cristobalite present will depend on the temperature and length of time in service. (See Section IX for permissible exposure levels).

SPECIAL TOXIC EFFECTS

The existing toxicology and epidemiology data bases for RCF’s are still preliminary. Information will be updated as studies are completed and reviewed. The following is a review of the results to date:

EPIDEMIOLOGY

At this time there are no known published reports demonstrating negative health outcomes of workers exposed to refractory ceramic fiber (RCF). Epidemiologic investigations of RCF production workers are ongoing.

1) There is no evidence of any fibrotic lung disease (interstitial fibrosis) whatsoever on x-ray.

2) There is no evide nce of any lung disease among those employees exposed to RCF that had never smoked.

3) A statistical “trend” was observed in the exposed population between the duration of exposure to RCF and a

decrease in some measures of pulmonary function. These observations are clinically insignificant. In other words, if these observations were made on an individual employee, the results would be interpreted as being within the normal range.

4) Pleural plaques (thickening along the chest wall) have been observed in a small number of employees who had a

long duration of employment. There are several occupational and non-occupational causes for pleural plaque. It should be noted that plaques are not “pre-cancer” nor are they associated with any measurable effect on lung function.

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TOXICOLOGY

A number of studies on the health effects of inhalation exposure of rats and hamsters are available. Rats were exposed to RCF in a series of life-time nose-only inhalation studies. The animals were exposed to 30, 16, 9, and 3 mg/m corresponds with approximately 200, 150, 75, and 25 fibers/cc.

Animals exposed to 30 and 16 mg/m posed to 9 mg/m

had developed a mild parenchymal fibrosis; animals exposed to the lowest dose were found to have

were observed to have developed a pleural and parenchymal fibroses; animals ex-

the response typically observed any time a material is inhaled into the deep lung. While a statistica lly significant increase in lung tumors was observed following exposure to the highest dose, there was no excess lung cancers at the other doses. Two rats exposed to 30 mg/m

The International Agency for Research on Cancer (IARC) reviewed the carcinogenicity data on man-made vitreous fi-

and one rat exposed to 9 mg/m3 developed masotheliomas.

bers (including ceramic fiber, glasswool, rockwool, and slagwool) in 1987. IARC classified ceramic fiber, fibrous glasswool and mineral wool (rockwool and slagwool) as possible human carcinogens (Group 2B).

EMERGENCY FIRST AID PROCEDURES

EYE CONTACT

Flush eyes immediately with large amounts of water for approximately 15 minutes. Eye lids should be held away from the eyeball to insure thorough r insing. Do not rub eyes. Get medical attention if irritation persists.

INHALATION

Remove person from source of exposure and move to fresh air. Some people may be sensitive to fiber induced irritation of the respiratory tract. If symptoms such as shortness of breath, coughing, wheezing or chest pain develop, seek medical attention. If person experiences continued breathing difficulties, administer oxygen until medical assistance can be rendered.

, which

INGESTION

Do not induce vomiting. Get medical attention if irritation persists.

SKIN CONTACT

Do not rub or scra tch exposed skin. Wash area of contact thoroughly with soap and water. Using a skin cream or lotion after washing may be helpful. Get medical attention if irritation persists.

SECTION VI. REACTIVITY DATA

STABILITY/CONDITIONS TO AVOID

Stable under normal conditions of use.

HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID

N.A.

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INCOMPATIBILITY/MATERIALS TO AVOID

Incompatible with hydrofluoric acid and concentrated alkali.

HAZARDOUS DECOMPOSITION PRODUCTS

N.A.

SECTION VII. SPILL OR LEAK PROCEDURES

STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED

Where possible, use vacuum suction with HEPA filters to clean up spilled material. Use dust suppressant where sweeping if necessary. Avoid clean up procedure which may result in water pollution. (Observe Special Protection Information Section VIII.)

WASTE DISPOSAL METHODS

The transportation, treatment, and disposal of this waste material must be conducted in compliance with all applicable Federal, State, and Local regulations.

SECTION VIII. SPECIAL PROTECTION INFORMATION

RESPIRATORY PROTECTION

Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. NIOSH/MSHA approved breathing equipment may be required for non-routine and emergency use. (See Section IX for suitable equipment).

Pending the results of long term health effects studies, engineering control of airborne fibers to the lowest levels attainable is advised.

VENTILATION

Ventilation should be used whenever possible to control or reduce airborne concentrations of fiber and dust. Carbon monoxide, carbon dioxide, oxides of nitrogen, reactive hydrocarbons and a small amount of formaldehyde may accompany binder burn-off during first heat. Use adequate ventilation or other precautions to eliminate vapors resulting from binder burn-off. Exposure to burn-off fumes may cause respiratory tract irritation, bronchial hyper-reactivity and asthmatic response.

SKIN PROTECTION

Wear gloves, hats and full body clothing to prevent skin contact. Use separate lockers for work clothes to prevent fiber transfer to street cl othes. Wash work clothes separ ately from other clothing and rinse washing machine thoro ughly after use.

EYE PROTECTION

Wear safety glasses or chemical worker’s goggles to prevent eye contact. Do not wear contact lenses when working with this substance. Have eye baths readily available where eye contact can occur.

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SECTION IX. SPECIAL PRECAUTIONS

PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING

General cleanliness should be followed. The Toxicology data indicate that ceramic fiber should be handled with caution. T he handling practices described in this

MSDS must be strictly followed. In particular, when handling refractory ceramic fiber in any application, special caution should be taken to avoid unnecessary cutting and tearing of the material to minimize generation of airborne dust.

It is recommended that full body clothing be worn to reduce the potential for skin irritation. Washable or disposable clothing may be used. Do not ta ke unwashed work clothing home. Work clothes should be washed separately from other clothing. Rinse washing machine thor oughly after use. If clothing is to be launde red by someone else, inform launderer of proper procedure. Work clothes and street clothes should be kept separate to prevent contamination.

Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) may undergo partial conversion to cristobalite, a form of crystalline silica. This reaction occurs at the furnace lining hot face. As a consequence, this material becomes more friable; special caution must be taken to minimize generation of airborne dust. The amount of cristobalite present will depend on the temperature and length in service.

IARC has recently reviewed the animal, human, and other relevant experimental data on silica in order to critically evaluate and classify the cancer causing potential. Based on its review, IARC classified crystalline silica as a group 2A carcinogen ( probable human carcinogen).

The OSHA permissible exposure limit (PEL for cristobalite is 0.05 mg/m value (TLV) for cristobalite is 0.05 mg/m

(respirable dust) (ACGIH 1991-92). Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. The minimum respiratory protection recommended for given airborne fiber or cristobalite concentrations are:

(respirable dust). The ACGIH threshold limit

CONCENTRATION

0-1 fiber/cc or 0-0.05 mg/m (the OSHA PEL) 9970 or equivalent).

Up to 5 fibers/cc or up to 10 times the Half face, air-purifying respirator equipped OSHA PEL for cristobalite with high efficiency particulate air (HEPA)

Up to 25 fibers/cc or 50 times the OSHA Full face, air-purifying respirator with high PEL for cristobalite (2.5 mg/m

Greater than 25 fibers/cc or 50 times the Full face, positive pressure supplied air respiraOSHA PEL for cristobalite (2.5 mg/m

cristobalite Optional disposable dust respirator (e.g. 3M

filter cartridges (e.g. 3M 6000 series with 2040 filter or equivalent).

) efficiency particulate air (HEPA) filter cart-

ridges (e.g. 3M 7800S with 7255 filters or equivalent) or powered air-purifying respirator (PARR) equipped with HEPA filter cartridges (e.g. 3M W3265S with W3267 filters or equivalent).

) tor (e.g. 3M 7800S with W9435 hose & W3196

low pressure regulator kit connected to clean air supply or equivalent).

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If airborne fiber or cristobalite concentrations are not known, as minimum protection, use NIOSH/MSHA approved half face, air-purifying respirator with HEPA filter cartridges.

Insulation surface should be lightly sprayed with water before removal to suppress airborne dust. As water evaporates during removal, additional water should be sprayed on surfaces as needed. Only enough water should be sprayed to suppress dust so that water does not run onto the floor of the work area. To aid the wetting process, a surfactant can be used.

After RCF removal is completed, dust-suppressing cleaning methods, such as wet sweeping or vacuuming, should be used to clean the work area. If dry vacuuming is used, the vacuum must be equipped with HEPA filter. Air blowing or dry sweeping should not be used. Dust-suppressing components can be used to clean up light dust.

Product packaging may contain product residue. Do not reuse except to reship or return Ceramic Fiber products to the factory.

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Section Page

Rosemount Warranty.....................................................................................................................................i

I. INTRODUCTION.......................................................................................................................1-1

1-1. Component Checklist of Typical System (Package Contents)........................................ 1-1

1-2. System Overview............................................................................................................ 1-1

1-3. IMPS 4000 (Optional) .................................................................................................... 1-4

1-4. SPS 4000 (Optional)....................................................................................................... 1-6

1-5. Specifications.................................................................................................................. 1-8

II. INSTALLATION........................................................................................................................ 2-1

2-1. Mechanical Installation................................................................................................... 2-1

2-2. Electrical Installation (For Oxymitter 5000 without SPS 4000) .....................................2-9

2-3. Electrical Installation (For Oxymitter 5000 with SPS 4000) ........................................ 2-10

2-4. Pneumatic Installation (For Oxymitter 5000 without SPS 4000).................................. 2-12

2-5. Pneumatic Installation (For Oxymitter 5000 with SPS 4000)....................................... 2-13

III. STARTUP.................................................................................................................................... 3-1

3-1. General............................................................................................................................ 3-1

3-2. LOGIC I/O...................................................................................................................... 3-4

3-3. Recommended Configuration..........................................................................................3-5

3-4. Power Up........................................................................................................................3-6

3-5. Start Up Oxymitter 5000 Calibration.............................................................................. 3-7

3-6. IMPS 4000 Connections................................................................................................. 3-7

IV. OPERATION FROM LOCAL KEYPAD................................................................................. 4-1

4-1. General............................................................................................................................ 4-1

V. TROUBLESHOOTING.............................................................................................................. 5-1

5-1. General............................................................................................................................ 5-1

5-2. Alarm Indications............................................................................................................ 5-1

5-3. Alarm Contacts...............................................................................................................5-1

5-4. Identifying and Correcting Alarm Indications................................................................. 5-2

5-5. SPS 4000 Troubleshooting...........................................................................................5-17

VI. MAINTENANCE AND SERVICE..........................................................................................6-1

6-1. Overview......................................................................................................................... 6-1

6-2. Calibration ...................................................................................................................... 6-1

6-3. LED Status Indicators..................................................................................................... 6-5

6-4. Oxymitter 5000 Removal/Replacement.......................................................................... 6-6

6-5. Electronics Replacement................................................................................................. 6-8

6-6. Entire Probe Replacement (Excluding Electronics)...................................................... 6-11

6-7. Heater Strut Replacement.............................................................................................6-11

6-8. Cell Replacement.......................................................................................................... 6-13

6-9. Ceramic Diffusion Element Replacement..................................................................... 6-15

6-10. SPS 4000 Maintenance and Component Replacement..................................................6-16

VII. REPLACEMENT PARTS......................................................................................................... 7-1

VIII. RETURNING EQUIPMENT TO THE FACTORY ............................................................8-1

8-1. Equipment Return Procedure.......................................................................................... 8-1

IX. OPTIONAL ACCESSORIES.................................................................................................... 9-1

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TABLE OF CONTENTS (Continued)

Section Page

APPENDIX A. FIELDBUS PARAMETER DESCRIPTION........................................................A-1

APPENDIX B. ANALOG INPUT (AI) FUNCTION BLOCK.................................................... B-1

APPENDIX C. PID FUNCTION BLOCK......................................................................................C-1

INDEX ........................................................................................................................................................I-1

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LIST OF ILLUSTRATIONS

Figure Page

1-1 Typical System Package......................................................................................................... 1-0

1-2 Oxymitter 5000 Autocalibration System Options .................................................................. 1-2

1-3 Oxymitter 5000 F

OUNDATION

1-4 Typical System Installation.................................................................................................... 1-5

1-5 SPS 4000................................................................................................................................ 1-6

2-1 Oxymitter 5000 Installation.................................................................................................... 2-2

2-2 Oxymitter 5000 Installation (with SPS 4000)........................................................................2-3

2-3 Oxymitter 5000 with Abrasive Shield.................................................................................... 2-4

2-4 Oxymitter 5000 Adaptor Plate Installation............................................................................. 2-5

2-5 Oxymitter 5000 Mounting Flange Installation....................................................................... 2-6

2-6 Oxymitter 5000 Bracing Installation...................................................................................... 2-7

2-7 Orienting the Optional Vee Deflector.................................................................................... 2-7

2-8 Installation with Drip Loop and Insulation Removal.............................................................2-8

2-9 Terminal Block ...................................................................................................................... 2-9

2-10 SPS 4000 Electrical Connections......................................................................................... 2-11

2-11 Air Set, Plant Air Connection...............................................................................................2-12

2-12 Oxymitter 5000 Gas Connections ........................................................................................ 2-13

3-1 Integral Electronics................................................................................................................ 3-1

3-2 Oxymitter 5000 Defaults........................................................................................................ 3-3

3-3 Startup and Normal Operation............................................................................................... 3-6

3-4 Calibration Keys.....................................................................................................................3-7

4-1 Normal Operation .................................................................................................................. 4-1

5-1 Fault 1, Open Thermocouple.................................................................................................. 5-3

5-2 Fault 2, Shorted Thermocouple.............................................................................................. 5-4

5-3 Fault 3, Reversed Thermocouple...........................................................................................5-5

5-4 Fault 4, Open Heater.............................................................................................................. 5-6

5-5 Fault 5, High High Heater Temp............................................................................................ 5-7

5-6 Fault 6, High Case Temp........................................................................................................5-8

5-7 Fault 7, Low Heater Temp.....................................................................................................5-9

5-8 Fault 8, High Heater Temp................................................................................................... 5-10

5-9 Fault 9, High Cell mV.......................................................................................................... 5-11

5-10 Fault 10, Bad Cell................................................................................................................5-12

5-11 Fault 11, EEPROM Corrupt................................................................................................. 5-13

5-12 Fault 12, Invalid Slope......................................................................................................... 5-14

5-13 Fault 13, Invalid Constant.................................................................................................... 5-15

5-14 Fault 14, Last Calibration Failed.......................................................................................... 5-16

5-15 SPS 4000 Troubleshooting Flowchart.................................................................................. 5-19

6-1 Oxymitter 5000 Exploded View............................................................................................. 6-2

6-2 Membrane Keypad................................................................................................................. 6-3

6-3 Inside Right Cover................................................................................................................. 6-4

6-4 Terminal Block ...................................................................................................................... 6-7

6-5 Electronic Assembly.............................................................................................................. 6-8

6-6 J8 Connector ..........................................................................................................................6-9

6-7 Fuse Location....................................................................................................................... 6-10

6-8 Heater Strut Assembly.......................................................................................................... 6-12

6-9 Cell Replacement Kit........................................................................................................... 6-13

6-10 Ceramic Diffusion Element Replacement............................................................................6-14

6-11 SPS 4000 Manifold Assembly .............................................................................................6-17

6-12 Power Supply Board and Interface Board Connections....................................................... 6-18

6-13 Calibration Gas and Reference Air Components..................................................................6-21

7-1 Cell Replacement................................................................................................................... 7-3

7-2 Probe Disassembly Kit........................................................................................................... 7-4

Fieldbus Connections............................................................. 1-4

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LIST OF TABLES

Table Page

1-1 Specifications......................................................................................................................... 1-8

1-2 Product Matrix.....................................................................................................................1-10

1-3 Calibration Gas Bottles........................................................................................................ 1-11

1-4 Intelligent Multiprobe Test Gas Sequencer Versions........................................................... 1-12

1-5 Z-Purge Option for Use with IMPS 4000............................................................................. 1-12

1-6 Single Probe Autocalibration Sequencer Coding................................................................. 1-12

3-1 Logic I/O Configuration......................................................................................................... 3-4

3-2 Logic I/O Parameters............................................................................................................. 3-5

5-1 Diagnostic/Unit Alarm Fault Definitions ...............................................................................5-2

5-2 SPS 4000 Fault Finding.......................................................................................................5-18

6-1 Diagnostic/Unit Alarms.......................................................................................................... 6-6

7-1 Replacement Parts for Probe..................................................................................................7-1

7-2 Replacement Parts for Electronics.........................................................................................7-5

7-3 Replacement Parts for SPS 4000............................................................................................ 7-7

7-4 Replacement Parts for Calibration Gas Bottles...................................................................... 7-7

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1 1

1. Instruction Bulletin

2. IMPS 4000 Intelligent MultiprobeTest Gas Sequencer (Optional)

3. Oxymitter 5000 with Integral Electronics

4. SPS 4000 Single Probe Autocalibration Sequencer (Optional) - (Shown with reference air option)

5. Adaptor Plate with Mounting Hardware and Gasket

6. Reference Air Set (used if SPS 4000 without reference air option or IMPS 4000 not supplied)

Figure 1-1. Typical System Package

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1-0

28550004

SECTION I. INTRODUCTION

1-1. COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS) . A typical

Rosemount Oxymitter 5000 Oxygen Transmitter should contain the items shown in Figure 1-1. Record the part number, serial number, and order number for each component of your system in the table located on the first page of this manual.

Use the product matrix in Table 1-1 at the end of this section to compare your order number against your unit. The first part of the matrix defines the model. The last part defines the various options and features of the Oxymitter 5000. Ensure the features and options specified by your order number are on or included with the unit.

1-2. SYSTEM OVERVIEW.

a. Scope. This Instruction Bulletin is designed to

supply details needed to install, start up, o perate, and maintain the Oxymitter 5000. Integral signal conditioning electronics outputs a digital

OUNDATION

fieldbus signal representing an O value and provides a membrane keypad for setup, calibration, and diagnostics. This same information, plus additional details, can be accessed via fieldbus digital communications.

OUNDATION

b. F

OUNDATION

fieldbus Technology.

fieldbus is an all digital, serial, two-way communication system that interconnects field equipment such as sensors, actuators, and controllers. Fieldbus is a Local Area Network (LAN) for instruments used in both process and manufacturing automation with built-in capacity to distribute the control application across the network. The fieldbus environment is the base level group of digital networks in the hierarchy of planet networks.

The fieldbus retains the desirable features of the 4-20 mA analog system, including a standardized physical interface to the wire, bus powered devices on a single wire, and intrinsic safety options, and enables additional capabilities, such as:

• Increased capabilities due to full digital com-

munications

• Reduced wiring and wire terminations due to

multiple devices on one set of wires

• Increased selection of suppliers due to

interoperability

• Reduced loading on control room equipment

with the distribution of some control and input/ output functions to field de vices

• Speed options for process control and manu-

facturing applications

c. System Description. The Oxymitter 5000 is de-

signed 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

10(P1/P2

) + C

Where:

1. P

is the partial pressure of the oxygen in the

measured gas on one side of the cell.

2. P

is the partial pressure of the oxygen in the

reference air on the opposite side of the cell.

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

NOTE

For best results, use clean, dry, instrument air (20.95% oxygen) as the reference air.

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 Oxymitter 5000 to provide exceptional sensitivity at low oxygen concentrations.

IB-106-350

1-1

The Oxymitter 5000 measures net oxygen concentration in the presence of all the products of combustion, including water vapor . Therefore, it may be considered an analysis on a “wet” basis. In comparison with older methods, such as the portable apparatus, which provides an analysis on a “dry” gas basis, the “wet” analysis will, in general, indicate a lower percentage of oxygen. The difference will be proportional to the water content of the sampled gas stream.

d. System Configuration. Oxymitter 5000 units are

available in five length op tions, giving the use r the flexibility to use an in situ penetration appropriate to the size of the stack or duct. The options on length are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), 9 ft (2.7 m ), or 12 f t (3.66 m).

e. System Features.

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.

Membrane keypad and F

bus communication are standard.

Field replaceable cell, heater, thermocou-

ple, and diffusion element.

OUNDATION

field-

The integral electronics control probe temperature and provide an output that represents the measured oxygen concentration. The power supply can accept voltages of 90-250 VAC and 50/60 Hz; therefore, no 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 integral electronics. The integral electronics accepts millivolt signals generated by the sensing cell and produces the outputs to be used by remotely connected devices. The output is a F

OUNDATION

fieldbus digital communication signal. Two calibration gas sequencers are available to

the Oxymitter 5000: the IMPS 4000 and the SPS 4000 (Figure 1-2).

Systems with multiprobe applications may employ an optional IMPS 4000 Intelligent Multiprobe Test Gas Sequencer. The IMPS 4000 provides automatic calibration gas sequencing for up to four Oxymitter 5000 units and accommodates autocalibrations based on the CALIBRATION RECOMMENDED signal from the Oxymitter 5000, a timed interval set up via fieldbus or the IMPS 4000, or when a calibration requ es t is i n it ia ted.

The Oxymitter 5000 is constructed of rug-

ged 316 L stainless steel for all wetted parts.

For systems with one or two Oxymitter 5000 units per combustion process, an optional SPS 4000 Single Probe Autocalibration Sequencer can be used with each Oxymitter 5000 to provide automatic calibration gas sequencing. The SPS 4000 can be mounted directly to the Oxymitter 5000 or in a remote location if space is limited. The sequencer performs autocalibrations based on the CALIBRATION RECOMMENDED signal from the Oxymitter 5000, a timed interval set up in fieldbus, or whenever a calibration request is initiated.

IB-106-350

Figure 1-2. Oxymitter 5000 Autocalibration

System Options

1-2

Integral electronics eliminates traditional

wiring between probe and electronics.

The integral electronics are adaptable for

line voltages from 90-250 VAC; therefore, no configuration is nece ssary.

The Oxymitter 5000 membrane keypad is

available in five languages:

English French German Italian Spanish

An operator can calibrate and diagnostically

troubleshoot the Oxymitter 5000 in one of three ways:

mable Logic Controller (PLC) in the IMPS 4000 provides fault indications using flashing LEDs and LCD display messages. Refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for more information.

f. Handling the Oxymitter 5000.

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.

(a) Membrane Keypad. The membrane

keypad, housed within the right side of the electronics housing, provides fault indication by way of flashing LEDs. Calibration can be performed from the membrane keypad.

OUNDATION

(b) F

fieldbus Interface. The Oxymitter 5000’s output carries a signal containing the oxygen level encoded in digital format. This digital output can also be used to communicate with the Oxymitter and access all of the Oxymitter’s status information.

The Oxymitter 5000 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.

g. System Considerations. Prior to installing your

Oxymitter 5000, make sure you have all the components necessary to make the system installation. Ensure all the components are prop e rly integrated to make the system functional.

IB-106-350

1-3

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. Figure 1-3 shows a typical system wiring. A typical system installation is illustrated in Figure 1-4.

A source of instrument air is optional at the Oxymitter 5000 for reference air use. Since the unit is equipped with an in-place calibration feature, provisions can be made to permanently connect calibration gas tanks to the Oxymitter

5000.

If the calibration gas bottles 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 co ndensation and corrosion. The check valve is in addition to the stop valve in the calibration gas kit or the solenoid valves in the IMPS 4000 or SPS 4000.

NOTE

The integral electronics is rated NEMA 4X (IP66) and is capable of operation at temperatures up to 149°F (65°C).

Retain the packaging in which the Oxymitter 5000 arrived from the factory in case any components are to be shipped to another site. This packaging has been designed to protect the product.

1-3. IMPS 4000 (OPTIONAL). Information on the

IMPS 4000 is available in the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin.

OXYMITTER 5000

WITH INTEGRAL ELECTRONICS

2 CALIBRATION GAS LINES

BY CUSTOMER

[300 FT (90 M) MAX]

Figure 1-3. Oxymitter 5000 F

LINE VOLTAGE

OUNDATION

FIELDBUS DIGITAL

SIGNAL

Fieldbus Connections

FIELDBUS COMPUTER

TERMINAL

28550005

IB-106-350

1-4

GASES

STACK

STANDARD

DUCT

OXYMITTER

5000

LINE

VOLTAGE

LOGIC I/O

FIELDBUS

DIGITAL

SIGNAL

FLOWMETER

CALIBRATION GAS

ADAPTOR PLATE

PRESSURE

REGULATOR

VOLTAGE

INSTRUMENT

AIR SUPPLY

(REFERENCE AIR)

STACK

ADAPTOR

PLATE

OXYMITTER

5000

LINE

GASES

IMPS 4000 OPTION

DUCT

CALIBRATION GAS

CALIBRATION GAS 2

CALIBRATION GAS 1

INST. AIR

SUPPLY

(WITH REFERENCE AIR OPTION)

SPS 4000 OPTION

GASES

DUCT

STACK

OXYMITTER

5000

INSTRUMENT

AIR SUPPLY

CALIBRATION

(LOW GAS)

LINE

VOLTAGE

FIELDBUS DIGITAL SIGNAL, RELAY OUTPUTS, AND REMOTE CONTACT INPUT

Figure 1-4. Typical System Installation

FIELDBUS

DIGITAL

SIGNAL

ADAPTOR PLATE

CALIBRATION GAS 1 (HIGH GAS)CALIBRATION

GAS 2

LOGIC I/O

REFERENCE

AIR

IMPS 4000

28550006

IB-106-350

1-5

CALIBRATION GAS

FLOWMETER

FRONT VIEW

REFERENCE GAS

FLOWMETER

REAR VIEW (OF MANIFOLD ONLY)

CALIBRATION GAS 1

INTERFACE

BOARD

(HIGH CALIBRATION GAS)

SOLENOID

REFERENCE AIR PRESSURE REGULATOR (OPTIONAL)

NOTE:

MANIFOLD COVER IS REMOVED TO SHOW INTERNAL COMPONENTS.

ALSO, BOARD COMPONENTS ARE NOT SHOWN FOR CLARITY.

TERMINAL

COVER

POWER

SUPPLY BOARD

CALIBRATION GAS 2

(LOW CALIBRATION GAS)

Figure 1-5. SPS 4000

1-4. SPS 4000 (OPTIONAL). The SPS 4000 Single

Probe Autocalibration Sequencer provides the capability of performing automatic, timed or on demand, calibrations of a single Oxymitter 5000 without sending a technician to the installation site.

a. Mounting. The SPS 4000 can be mounted ei-

ther directly to an Oxymitter 5000 or at a remote location if space is limited. In addition, the integrally mounted SPS 4000 can be configured for a horizontally or vertically mounted Oxymitter 5000 (Figure 2-2). The information in this instruction bulletin will cover the integrally mounted units only. For information on remote mounted units, refer to the SPS 4000 Single

SOLENOID

PRESSURE SWITCH

MANIFOLD

26170001

Probe Autocalibration Sequencer Instruction Bulletin.

b. Components (Figure 1-5). The SPS 4000

consists of a manifold and a calibration gas flowmeter. The manifold provides electrical feedthroughs and calibration gas ports to route power and signal connections and calibration gases to and from the sequencer. In addition, the manifold houses two calibration gas solenoids that sequence the gases to the Oxymitter 5000, a pressure switch that detects low calibration gas pressure, and two PC boards. A terminal strip housed within the terminal cover provides convenient access for all user connections.

IB-106-350

1-6

Components optional to the SPS 4000 include a reference air flowmeter and pressure regulator. The reference air flowmeter indicates the flow rate of reference air continuously flowing to the Oxymitter 5000. The reference air pressure regulator ensures the instrument air (reference air) flowing to the Oxymitter 5000 is at a constant pressure [20 psi (138 kPa)]. The regulator also has a filter to remove particulates in the reference air and a drain valve to bleed the moisture that collects in the filter bowl.

Brass fittings and Teflon tubing are standard. Stainless steel fittings and tubing are optional. Also, disposable calibration gas bottles are avail-

able as an option or ca n be purchased through a local supplier.

c. Operation. The SPS 4000 works in conjunction

with the Oxymitter 5000’s CALIBRATION RECOMMENDED feature to perform an autocalibration. This feature automatically performs a gasless calibration check every hour on the Oxymitter 5000. If a calibration is recommended and its contact output signal is set for “handshaking” with the sequencer, the Oxymitter 5000 sends a signal to the sequencer. The sequencer automatically performs a calibration upon receiving the signal. Thus, no human interface is required for the automatic calibration to take place.

IB-106-350

1-7

1-5. SPECIFICATIONS.

Table 1-1. Specifications

Oxymitter 5000 O2 Range:

Standard .................................................................... 0 to 10% O

0 to 25% O 0 to 40% O2 (via F

Accuracy ........................................................................... ±0.75% of reading or 0.1% O

2 2

OUNDATION

fieldbus)

, whichever is greater

System Response to Calibration Gas .............................. Initial response in less than 3 seconds T90 in less than

8 seconds

Temperature Limits:

Process ....................................................................... 32° to 1300°F (0° to 704°C) up to 2400°F (1300°C) with

optional accessories

Electronics ................................................................. -40° to 149°F (-40° to 65°C) Ambient

Probe Lengths ................................................................... 18 in. (457 mm)

3 ft (0.91 m) 6 ft (1.83 m) 9 ft (2.74 m) 12 ft (3.66 m)

Mounting and M ounting Position ................................... Vertical or horizontal

Materials:

Probe .......................................................................... Wetted or welded parts - 316L stainless steel

Non-wetted parts - 304 stainless steel, low-copper aluminum

Electronics Enclosure ............................................... Low-copper aluminum

Calibration ........................................................................ Manual, semi-automatic, or automatic

Calibration Gas Mixtures Recommended ...................... 0.4% O

8% O2, Balance N

, Balance N

Calibration Gas Flow ....................................................... 5 scfh (2.5 l/m)

Reference Air .................................................................... 2 scfh (1 l/m), clean, dry, instrument-quality air

(20.95% O

), regulated to 5 psi (34 kPa)

Electronics ........................................................................ NEMA 4X, IP66 with fitting and pipe on reference exhaust

port to clear dry atmosphere

Electronic Noise ................................................................ Meets EN 50082-2 Generic Immunity Std. Part II.

Includes EN 61000-4-2 for Electrostatic Discharge 4 KV contact, 8 KV in air Includes IEC 801-4 for fast transients; 2 KV on power supply and control lines

Line Voltage ...................................................................... 90-250 VAC, 50/60 Hz. No configuration necessary

3/4 in. - 14 NPT conduit port

Signals:

Digital Output ........................................................... F

OUNDATION

fieldbus compatible

Logic I/O .................................................................... Two-terminal logic contact configurable as either an alarm

output or as a bi-directional calibration handshake signal to

IMPS 4000 or SPS 4000

.............................................................................. Self-powered (+5 V), in series with 340 ohms

.............................................................................. Conduit ports — 3/4 in.-14 NPT (one threaded hole for both

analog output and logic I/O)

IB-106-350

1-8

Table 1-1. Specifications (Continued)

Power Requirements:

Probe Heater ............................................................. 175 W nominal

Electronics ................................................................. 10 W nominal

Maximum ................................................................... 500 W

SPS 4000

Mounting .......................................................................... Integral to Oxymitter 5000

Remote from Oxymitter 5000

Materials of Construction:

Manifold/Electronics Enclosure .............................. Aluminum

Mounting Brackets ................................................... 316 stainless steel (SS)

Pneumatic Fittings .................................................... 1/8 in. brass NPT (SS optional)

Pneumatic Tubing ..................................................... 1/4 in. Teflon (SS optional)

Assembly Hardware ................................................. Galvanized and stainless steel

Humidity Range ............................................................... 100% relative humidity

Ambient Temperature Range ......................................... -40° to 149°F (-40° to 65°C)

Electrical Classification ................................................... NEMA 4X (IP56)

Explosion-Proof Option (bot h pending) ......................... CENELEC EExd IIB + H2

(Class 1, Div. 1, Group B,C,D)

Electrical Feedthroughs .................................................. 1/2 in. NPT

Input Power ...................................................................... 90 to 250 VAC, 50/60 Hz

Power Consumption ........................................................ 5 VA maximum

External Electrical Noise ................................................. EN 50 082-2, includes 4 KV electrostatic discharge

Handshake Signal

to/from Oxymitter 5000 (self-powered) .................. 5 V (5 mA maximum)

Cal Initiate Contact Input from Control Room ............ 5 VDC (self-powered)

Relay Outputs to Control Room ..................................... 5 to 30 VDC, Form A (SPST)

(one “In-Cal”, one “Cal Failed”)

Cabling Distance between

SPS 4000 and Oxymitter 5000 ................................. Maximum 1000 ft (303 m)

Piping Distance between SPS 4000

and Oxymitter 5000 .................................................. Maximum 300 ft (91 m)

Approximate Shipping Weight ....................................... 10 lbs (4.5 kg)

Fisher-Rosemount has satisfied all obligations coming from the European legislation to harmonize the product requirements in Europe.

IB-106-350

1-9

OXT5A Oxymitter 5000 In Situ Oxygen Transmitter

Oxygen Transmitter - Instruction Book

Code Sensing Probe Type

1 ANSI (N. American Std.) Probe with Ceramic Diffuser 2 ANSI Probe with Flame Arrestor and Ceramic Dif fuser 3 ANSI Probe with Snubber Diffuser 4 DIN (European Std.) Probe with Ceramic Diffuser 5 DIN Probe with Flame Arrestor and Snubber Diffuser 6 DIN Probe with Snubber Diffuser 7 JIS (Japanese Std.) Probe with Ceramic Diffuser 8 JIS Probe with Flame Arrestor and Ceramic Diffuser 9 JIS Probe with Snubber Diffuser

Code Probe Assembly

0 18 in. (457 mm) Probe 1 18 in. (457 mm) Probe with Abrasive Shield 2 3 ft (0.91 m) Probe 3 3 ft (0.91 m) Probe with Abrasive Shield 4 6 ft (1.83 m) Probe 5 6 ft (1.83 m) Probe with Abrasive Shield 6 9 ft (2.74 m) Probe 7 9 ft (2.74 m) Probe with Abrasive Shield 8 12 ft (3.66 m) Probe

(1)

9 12 ft (3.66 m) Probe with Abrasive Shield

Table 1-2. Product Ma t rix

(1)

Code Mounting Hardware - Stack Side

0 No Mounting Hardware (“0” must be chosen under “Mounting Hardware - Probe Side” below) 1 New Installation - Square weld plate with studs 2 Mounting to Model 218 Mounting Plate (with M odel 218 Shield Removed) 3 Mounting to Existing Model 218 Support Shield 4 Mounting to Other Mounting

(2)

5 Mounting to Model 132 Adaptor Plate

Code Mounting Hardware - Probe Side

0 No Mounting Hardware 1 Probe Only (ANSI) (N. American Std.) 2 New Bypass or Abrasive Shield (ANSI) 4 Probe Only (DIN) (European Std.) 5 New Bypass or Abrasive Shield (DIN) 7 Probe Only (JIS) (Japanese Std.) 8 New Bypass or Abrasive Shield (JIS)

Code Electronics Housing & Filtered Customer Termination - NEMA 4X, IP66

11 Standard Filtered Termination 12 Transient Protected Filtered Termination

Code Communications

FOUNDATION

fieldbus with Membrane Keypad

OXT5A3211111 (Cont’d) Example

IB-106-350

1-10

Table 1-2. Product Matrix (Continued)

Cont'd Code Language

1 English 2German 3 French 4 Spanish 5 Italian

Code Filtered Customer Termination

00 Specified as Part of E l ec tronics Housing

Code Calibration Accessories

00 No Hardware 01 Calibration Gas Flowmeter and Reference Air Set 02 Intelligent Multiprobe S equencer (Refer to Table 1-4)

XX Single Probe Sequencer – mounted to Oxy m i tter 5000 (Refer to Table 1-6)

Cont’d 1 00 XX Example

NOTES:

(1)

Recommended usages: High velocity particulates in flue s tream, installation within 11.5 f t (3.5 m) of soot blowers or heavy salt cake buildup. Applications: Pulverized coal, recovery boil ers, lime kiln. Regardless of appli cation, abrasive shields with support brackets are recommended for 9 ft (2.74 m) and 12 ft (3.66 m) probe installations, particularly horizontal installati ons.

(2)

Where possible, specify SPS number; otherwise, prov ide details of the existing mounting plate as follows: Plate with studs Bolt circle diameter, num ber, and arrangement of studs, stud thread, s tud height above mounting plate. Plate without studs Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessori es.

Table 1-3. Calibration Gas Bottles

PART

NUMBER DESCRIPTION

1A99119G01 Two disposable calibration gas bottles — 0.4% and 8% O2,

balance nitrogen — 550 liters each, includes bottle rack *

1A99119G02 Two flow regulators f or calibration g as bottles *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.

IB-106-350

1-11

Table 1-4. Intelligent Multiprobe Test Gas Sequencer Versions

NUMBER

PART

NUMBER DESCRIPTION

OF OXYMITTER

5000 UNITS

3D39695G01 IMPS 1 3D39695G02 IMPS 2 3D39695G03 IMPS 3 3D39695G04 IMPS 4 3D39695G05 IMPS w/115 V Heater 1 3D39695G06 IMPS w/115 V Heater 2 3D39695G07 IMPS w/115 V Heater 3 3D39695G08 IMPS w/115 V Heater 4 3D39695G09 IMPS w/220 V Heater 1 3D39695G10 IMPS w/220 V Heater 2 3D39695G11 IMPS w/220 V Heater 3 3D39695G12 IMPS w/220 V Heater 4

Table 1-5. Z-Purge Option for Use with IMPS 4000

PART

NUMBER DESCRIPTION

4513C24G03 Z-Purge System for IMPS used with Oxymitter 5000 4513C24G03 Z-Purge System for IMPS used with Oxymitter 5000,

includes loss of purge switch (WPS)

Table 1-6. Single Probe Autocalibration Sequencer Coding

OXYMITTER

REF AIR

SET

FITTINGS/

TUBING

5000

MOUNTING

BRASS/

CODE NO YES

TEFLONSTSTEEL HOR VERT

03 X X X 04 X X X 05 X X X 06 X X X 07 X X X 08 X X X 09 X X X 10 X X X

IB-106-350

1-12

SECTION II. INSTALLATION

Before installing this equipment, read the “Safety instructions for the wiring and installation of this apparatus” at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury or death.

2-1. MECHANICAL INSTALLATION.

a. Selecting Location.

The location of the Oxymitter 5000 in the

stack or flue is most important for maximum accuracy in the oxygen analyzing process. The Oxymitter 5000 must be positioned so the gas it measures is representative of the process. Best results are normally obtained if the Oxymitter 5000 is positioned near the center of the duct (40 to 60% insertion). Longer ducts may require several Oxymitter 5000 units since the O can vary due to stratification. A point too near the wall of the duct, or the inside radius of a bend, may not provide a representative sample because of the very low flow conditions. The sensing point should be selected so the process gas temperature falls within a range of 32° to 1300°F (0° to 704°C). Figure 2-1 through Figure 2-6 provide mechanical installation references. The ambient temperature of the integral electronics housing must not exceed 149°F (65°C).

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 Oxymitter 5000 upstream of any leakage.

2 2

Ensure the area is clear of internal and ex-

ternal obstructions that will interfere with installation and maintenance access to the membrane keypad. Allow adequate clearance for removal of the Oxymitter 5000 (Figure 2-1 or Figure 2-2).

Do not allow the temperature of the Oxymitter 5000 integral electronics to exceed 149°F (65°C) or damage to the unit may result.

b. Installation.

Ensure all components are available to in-

stall the Oxymitter 5000. If equipped with the optional ceramic diffusor element, ensure it is not damaged.

The Oxymitter 5000 may be installed intact

as it is received.

NOTE

An abrasive shield is recommended for high velocity particulates in the flue stream (such as those in coal-fired boilers, kilns, and recovery boilers). Vertical and horizontal brace clamps are provided for 9 ft and 12 ft (2.75 m and 3.66 m) probes to provide mechanical support for the Oxymitter 5000. Refer to Figure 2-6.

Weld or bolt adaptor plate (Figure 2-5) onto

the duct.

IB-106-350

2-1

SMART FAMILY

Rosemount Analytical Inc.

ALL DIMENSIONS ARE IN

INCHES WITH MILLIMETERS

IN PARENTHESES.

INSULATE IF EXPOSEDTO

NOTE:

AMBIENT WEATHER CONDITIONS

HART

800-433-6076

Orrville,OH 44667-0901

OXYMITTER 4000

85.8

49.8

31.8

(808)

(406)

18 IN.

3 FT

(1265)

(864)

6 FT

DIM "B"

REF.

GAS

DIM "A"

500VA

5 Amps

3/4 NPT

ELEC CONN

REF AIR

PROBE

TABLE 2 INSTALLATION/REMOVAL

121.8

(2179)

106

(1778)

(3094)

(2692)

9 FT

157.8

(4008)

142

(3607)

12 FT

6 mm TUBEJIS

4-20 mA

85-264VAC 48-62 Hz

SERIAL NO.

TAG NO.

VOLTS: WATTS:

OUTPUT: LINE FUSE:

CAL GAS

ANSI 1/4 (6.35) TUBE

DIN 6 mm TUBE

(305)

6.52

(39)

1.55

(166)

2.89

(73)

COVER REMOVAL & ACCESS

(305)

.062 THK GASKET

PROCESS FLOW MUST BE IN

THIS DIRECTION WITH RESPECT

TO DEFLECTOR 3534B48G01

3535B18H02

3535B46H01

3535B45H01

DIN

JIS

ANSI

2.27 (58)

DIA MAX

CAL.

GAS

3.80(96) ADD TO DIM “A”

FOR PROBE

DIM "B"

12.50 (318)

6.02 (153)

4.77 (121)

WITH

DIM "A"

STANDARD

DIFFUSER

5.14(131)

WITH CERAMIC

ADD TO DIM “A”

FOR PROBE WITH

REMOVAL ENVELOPE

JIS

SNUBBER

DIFFUSER

4512C18H01

DIN

4512C19H01

ARRESTOR

AND FLAME

CERAMIC DIFFUSER

ANSI

TABLE 1 MOUNTING FLANGE

4512C17H01

0.59

6.10

(155)

0.71

7.28

(185)

0.75

6.00

(153)

HOLE

FLANGE

DIA

(15)

5.12

5.71

(18)

(20)

4.75

(4) HOLES

DIA

(130)

(145)

(121)

EQ SP

ON BC

BOTTOMVIEW

26170013

Figure 2-1. Oxymitter 5000 Installation

IB-106-350

2-2

1/4 IN. TUBE

FITTING FOR

HIGH CAL

GAS IN

HORIZONTAL MOUNTED SPS 4000 A

1/4 IN. TUBE FITTING FOR

INSTRUMENT AIR IN (OPTIONAL)

11.00

(279.40)

NOMINAL

0.94

(23.88)

TERMINAL COVER

1/4 IN. TUBE

FITTING

TO CAL GAS

FLOWMETER

1/4 IN. TUBE

FITTING FOR

LOW CAL

GAS IN

0.94

(23.88)

2.00 (50.80)

1/2 NPT SIGNAL CONDUIT PORT

(CUSTOMER TO

SUPPLY FITTING)

14.00 (355.60) NOMINAL

12.00 (304.80) NOMINAL

VERTICAL MOUNTED SPS 4000 A

13.00

(330.20)

NOMINAL

1/2 IN. CONDUIT FITTING FOR LINE VOLTAGE

10 (254)

NOMINAL

2.00 (50.80) NOMINAL

CLEARANCE TO

REMOVE COVER

NOTE:

DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.

12.00 (304.80) NOMINAL

TO VIEW AND

OPERATE

OXYMITTER 5000

KEYPAD

2.00 (50.80) NOMINAL CLEARANCE TO REMOVE COVER

FLOWMETER (OPTIONAL)

CALIBRATION GAS

FLOWMETER

(CALIBRATION GAS OUT

TO OXYMITTER 5000)

REFERENCE AIR

(REFERENCE AIR OUT

TO OXYMITTER 5000)

10 (254)

NOMINAL

Figure 2-2. Oxymitter 5000 Installation (with SPS 4000)

IB-106-350

2-3

12.00 (304.80) NOMINAL

TO VIEW AND

OPERATE

OXYMITTER 5000

KEYPAD

26170003

ALL DIMENSIONS ARE IN

INCHES WITH MILLIMETERS

IN PARENTHESES.

3/4 NPT ELECTRICAL CONNECTION

NOTE:

(318)

12.50

DIM "B"

REMOVAL ENVELOPE

7.00

(178)

CAL.

GAS

4.77

6.02

(121)

(153)

1/4 IN.TUBE

6 mm TUBE

*ADD CHECK VALVE IN CAL GAS LINE

ANSI

CAL GAS*

REF AIR

(24)

9.25

0.94

7.48

(235)

(190)

-3D39003

(19)

9.25

0.75

7.48

(235)

9.00

(229)

TABLE 4 ABRASIVE SHIELD

FLANGE ANSI JIS DIN

FLANGE

DIA

(19)

0.75

HOLE

7.50

DIA

(8) HOLES

(190)

EQ SP

ON BC

NOTES:

1.THESE FLAT FACED FLANGES ARE MANUFACTUREDTO ANSI, DIN, & JISBOLT PATTERNS;

3.6 (91) DIA NOMINAL

DIFFUSER/DUST SEAL ASSY

86.5

INSTALLATION/REMOVALTABLE

50.5

DIM "B"

DIM "A"

3 FT

PROBE

(1283)

(787)

(2197)

(1702)

6 FT

122.5

158.5

(3112)

139

103

(2616)

9 FT

26170014

(4026)

(3531)

12 FT

DIM "A"

3.9

(99)

ASSEMBLY

(5)

0.2

AND ARE NOT PRESSURE RATED.

SNUBBER/DUST SEAL

DEFLECTOR ASSY

Figure 2-3. Oxymitter 5000 with Abrasive Shield

IB-106-350

2-4

JIS

9.25

(P/N 3535B58G04)

(235)

4.92

(125)

(M-20 x 2.5)

(200)

7.894

8 THREADED HOLES

EQUALLY SPACED ON

D DIA B.C.

ABRASIVE SHIELD

FLANGE O.D.

WITH ABRASIVE SHIELD

TABLE VI. ADAPTOR PLATE* DIMENSIONS FOR OXYMITTER 5000

DIN

(P/N 3535B58G06)

ANSI

(P/N 3535B58G02)

IN.

(mm)

"A"

DIMENSIONS

JIS

6.50

(P/N 4512C35G01)

9.25

9.00

(235)

(229)

(165)

3.94

(100)

4.75

(121)

"B"

DIA

(M-12 x 1.75)

(M-16 x 2)

0.625-11

"C"

THREAD

(130)

5.118

7.48

7.50

"D"

(190)

(191)

DIA

ATTACHING HARDWARE.

*PART NUMBERS FOR ADAPTOR PLATES INCLUDE

22.5

CROSSHATCHED AREA IN 4

CORNERS MAY BE USED TO

PROVIDE ADDITIONAL HOLES FOR

FIELD BOLTING OF PLATE TO

OUTSIDE WALL SURFACE.

AND 12 FT ABRASIVE SHIELD

ADAPTOR PLATE FOR 3, 6, 9,

INSTALLATIONS. SEE SHEET 2.

TABLE V. ADAPTOR PLATE* DIMENSIONS FOR OXYMITTER 5000

DIN

7.5

(P/N 4512C36G01)

ANSI

6.00

(P/N 4512C34G01)

IN.

(mm)

"A"

DIMENSIONS

(191)

(M-16 x 2)

(145)

5.708

(153)

0.625-11

"B"

THREAD

4.75

"C"

(121)

DIA

ATTACHING HARDWARE.

*PART NUMBERS FOR ADAPTOR PLATES INCLUDE

IN INCHES WITH

MILLIMETERS IN

PARENTHESES.

2.500 DIA

(63.5)

NOTE:DIMENSIONS ARE

Figure 2-4. Oxymitter 5000 Adaptor Plate Installation

IB-106-350

2-5

4 STUDS,

LOCKWASHERS AND

NUTS EQUALLY

SPACED ON

C DIA B.C.

ADAPTOR PLATE

FOR OXYMITTER 5000

INSTALLATION. SEE

SHEET 1.

26170033

INSTALLATION FOR METAL

WALL STACK OR DUCT

CONSTRUCTION

INSTALLATION FOR MASONRY

WALL STACK CONSTRUCTION

MTG HOLES SHOWN ROTATED

45 OUT OF TRUE POSITION

WELD OR BOLT ADAPTOR PLATE TO METAL WALL OF STACK OR DUCT. JOINT MUST BE AIRTIGHT.

0.50 [13]

3.75 [95]

MIN DIA HOLE IN WALL

STACK OR DUCT METAL WALL

0.50 [13]

BOLT ADAPTOR

PLATE TO OUTSIDE

WALL SURFACE

FIELD WELD

PIPE TO

ADAPTOR PLATE

MTG HOLES

SHOWN ROTATED

45 OUT OF

TRUE POSITION

JOINT MUST

BE AIRTIGHT

OUTSIDE WALL

SURFACE

NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPT

ADAPTOR PLATE NOT FURNISHED BY ROSEMOUNT.

4.50 [114] O.D. REF

PIPE 4.00 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH BY CUSTOMER

MASONRY STACK WALL

2.50 [63.5]

WELD OR BOLT ADAPTOR PLATE TO METAL WALL OF STACK OR DUCT. JOINT MUST BE AIRTIGHT.

BOLT ADAPTOR

PLATE TO OUTSIDE

WALL SURFACE

MIN DIA HOLE IN WALL

STACK OR DUCT METAL WALL

NOTE: DIMENSIONS IN INCHES WITH

MILLIMETERS IN PARENTHESES.

JOINT MUST

BE AIRTIGHT

OUTSIDE WALL

SURFACE

Figure 2-5. Oxymitter 5000 Mounting Flange Installation

IB-106-350

2-6

FIELD WELD PIPE TO ADAPTOR PLATE

3.50 [89] O.D. REF

PIPE 3.00 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH BY CUSTOMER

MASONRY STACK WALL

60 MAX

30 MIN

4.12

(105)

BRACE BARS (NOT BY ROSEMOUNT)

2.00 (51)

1.00 (25)

2 HOLES - 0.625 (16) DIA FOR

0.50 (12) DIA BOLT

NOTE: DIMENSIONS IN INCHES WITH

MILLIMETERS IN PARETHESES.

VERTICAL BRACE CLAMP ASSY. HORIZONTAL BRACE CLAMP ASSY.

(BOTH BRACE CLAMP ASSEMBLIES ARE THE SAME. INSTALLATION AND LOCATION OF CLAMP ASSEMBLIES AND BRACE BARS TO BE DONE IN FIELD.)

5.62

(143)

ABRASIVE SHIELD

BY ROSEMOUNT

}

4.12

(105)

NOTE: BRACING IS FOR VERTICAL AND HORIZONTAL OXYMITTER 4000

INSTALLATION. EXTERNAL BRACING REQUIRED FOR 9 FT AND 12 FT (2.75 M AND 3.66 M) PROBES AS SHOWN ABOVE.

0.375

1.00 (25) MAX

Figure 2-6. Oxymitter 5000 Bracing Installation

If using the optional ceramic diffusor ele-

ment, the vee deflector must be correctly oriented. Before inserting the Oxymitter 5000, check the direction of flow of the gas in the duct. Orient the vee deflector so the apex points upstream toward the flow (Figure 2-7). This may be done by loosening the setscrews and rotating the vee deflector to the desired position. Retighten the setscrews.

In vertical installations, ensure the system

cable drops vertically from the Oxymitter 5000 and the conduit is routed below the level of the electronics housing. This drip loop minimizes the possibility that moisture will damage the electronics (Figure 2-8).

(10)

36.00 (914)

5.62

(143)

GAS FLOW DIRECTION

VEE

DEFLECTOR

APEX

DIFFUSION

FILTER

ELEMENT

Figure 2-7. Orienting the Optional Vee Deflector

26170034

SETSCREW

DEFLECTOR

VEE

22220020

IB-106-350

2-7

REPLACE INSULATION

AFTER INSTALLING

OXYMITTER 5000

INSULATION

LINE

VOLT AGE

FIELDBUS DIGIT AL SIGNAL

DRIP LOOP

CAL.

GAS

ADAPTOR

PLATE

Figure 2-8. Installation with Drip Loop and Insulation Removal

If the system has an abrasive shield, check

the dust seal gaskets. The joints in the two gaskets must be staggered 180°. Also, make sure the gaskets are in the hub grooves as the Oxymitter 5000 slides into the 15° forcing cone in the abrasive shield.

NOTE

If process temperatures will exceed 392°F (200°C), use anti-seize compound on stud threads to ease future removal of Oxymitter

5000.

Insert probe through the opening in the

mounting flange and bolt the unit to the flange. When probe lengths selected are 9

STACK OR DUCT METALWALL

28550007

or 12 ft (2.74 or 3.66 m), special brackets are supplied to provide additional support for the probe inside the flue or stack (Figure 2-6).

Uninsulated stacks or ducts may cause ambient temperatures around the electronics to exceed 149°F (65°C), which may cause overheating damage to the electronics.

If insulation is being removed to access the

duct work for Oxymitter 5000 mounting, make sure the insulation is replaced afterward (Figure 2-8).

IB-106-350

2-8

2-2. ELECTRICAL INSTALLATION (FOR OXY-

MITTER 5000 WITHOUT SPS 4000). All wir-

ing 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 currentcarrying 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.

NOTE

To maintain CE compliance, ensure a good connection exists between the mounting flange bolts and earth.

Remove screw (36, Figure 6-1), gasket (37), and cover lock (38). Remove terminal block cover (31).

b. Connect Line Voltage. Connect the line, or L1,

wire to the L1 terminal and the neutral, or L2 wire, to the N terminal (Figure 2-9). The Oxymitter 5000 automatically will configure itself for 90-250 VAC line voltage and 50/60 Hz. The power supply requires no setup.

c. Connect fieldbus Digital Signal and Logic I/O/

Calibration Handshake Leads (Figure 2-9).

Fieldbus Digital Signal. The fieldbus digital

signal carries the O

value. This digital sig-

nal can also be used to communicate with the Oxymitter.

Logic I/O/Calibration Handshake. The out-

put can either be an alarm or provide the handshaking to interface with an IMPS

4000. For more information, refer to paragraph 5-3 and the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin.

If autocalibration is not utilized, a common

bi-directional logic contact is provided for any of the diagnostic alarms listed in Table 5-1. The assignment of alarms which

Figure 2-9. Terminal Block

IB-106-350

2-9

can actuate this contact can be modified to one of seven additional groupings listed in Table 3-1.

The logic contact is 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 an equal interposing relay will be mounted where the contact wires terminate in the control/relay room.

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.

Disconnect and lock out power before connecting the unit to the power supply.

d. Install terminal block cover (31, Figure 6-1) and

secure with cover lock (38), gasket (37), and screw (36).

2-3. ELECTRICAL INSTALLATION (FOR OXY-

MITTER 5000 WITH SPS 4000). All wiring

must conform to local and national codes.

a. Autocalibration Connections.

Autocalibration systems will inject gases into the probe and make electronic adjustments with no operator attention required. The SPS 4000 provides solenoid valves and circuitry for calibrating a single Oxymitter 5000 unit.

The SPS 4000 autocalibration system utilizes the Oxymitter 5000’s bidirectional logic contact as a “handshake” signal; therefore, this signal is not available for alarming purposes.

The following contacts ar e provided through the autocalibration system:

One contact closure per probe from the

control room to the SPS 4000 for “calibration initiate”.

One contact output per probe from SPS

4000 to the control room for “in calibration” notification.

One contact per probe from SPS 4000 to

the control room for “calibration failed” notification, which includes output from pressure switch indicating “cal gas bottles empty”.

IB-106-350

2-10

NOTE

The fieldbus digital signal can be configured to respond normally during a ny calibration, or can be configured to hold the last O

value upon the intitiation of

calibration. Factory default is for the fieldbus signal to operate normally throughout calibration. Holding the last O value may be useful if several probes are being averaged for the purpose of automatic control. Unless several probes are being averaged, always place any control loops using the O

signal into

manual prior to calibrating.

b. Other Electrical Connections.

Remove screws (26, Figure 6-11) securing

terminal cover (27). Remove the cover to expose terminal strip (25).

Connect Line Voltage. Ro ute the line volt-

age leads into the manifold through the 1/2 in. line voltage conduit fitting (Figure 2-2) and out through the bottom of the manifold. Connect the LINE IN and NEUTRAL leads to terminals L and N, respectively, as shown in Figure 2-10. Also, be

sure to connect the ground wire to the ground lug. The unit automatically will configure itself for 90 to 250 VAC line voltage and 50/60 Hz. The power supply requires no setup.

Connect Remote Contact Inp ut Wiring. To

set up the SPS 4000 to initiate a calibration from a remote location, route the 5 VDC calibration initiate contact input leads through the 1/2 in. NP T signal conduit port (Figure 2-2) and out thr ough the bottom of the manifold. Connect the (+) and (-) CAL INITIATE leads to terminals 1 and 2, respectively, as shown in Figure 2-10.

Figure 2-10. SPS 4000 Electrical Connections

IB-106-350

2-11

Figure 2-11. Air Set, Plant Air Connection

Connect Relay Output Wiring. Relay con-

nections are available to signal when the Oxymitter 5000 is in calibration or when calibration failed. Relay outputs can be connected to either indicator lights or a computer interface. The relay contacts are capable of handling a 5 to 30 VDC maximum power source. The cabling requirement is 1000 ft (303 m) maximum. Route the relay output leads through the 1/2 in. NPT signal conduit port (Figure 2-2) and out through the bottom of the manifold. Connect the (+) and (-) CAL FAIL leads and the (+) and (-) IN CAL leads to terminals 7, 8, 9, and 10, respectively, as shown in Figure 2-10.

Connect fieldbus Digital Signal Wiring.

Route the signal wiring into the manifold through the 1/2 in. NP T signal conduit port (Figure 2-2) and out thr ough the bottom of the manifold. Connect the (+) and (-) signal leads to terminals 3 and 4, respectively, as shown in Figure 2-10.

Once all connections are made, install ter-

minal cover (27, Figure 6-11) and secure with screws (26).

2-4. PNEUMATIC INSTALLATION (FOR OXY-

MITTER 5000 WITHOUT SPS 4000).

a. Reference Air Package. After the Oxymitter

5000 is installed, connect the reference air set to the Oxymitter 5000. The reference air set should be installed in accordance with Figure 2-11.

Instrument Air (Reference Air): 10 psig (68.95 kPag) minimum, 225 psig (1551.38 kPag) maximum at 2 scfh (56.6 L/hr) maximum; less than 40 parts-per-million total hydrocarbons. Regulator outlet pressure should be set at 5 psi (35 kPa). Reference air can be supplied by the reference air set of the IMPS 4000.

If using an IMPS 4000, refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for the proper reference air connections.

IB-106-350

2-12

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% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

b. Calibration Gas. Two calibration gas concen-

trations are used with the Oxymitter 5000, Low Gas - 0.4% O

and High Gas - 8% O2. See Figure

2-12 for the Oxymitter 5000 connections.

2-5. PNEUMATIC INSTALLATION (FOR OXY-

MITTER 5000 WITH SPS 4000).

a. Calibration Gas Connections. Locate the

1/4 in. calibration gas fittings on the SPS 4000

manifold (Figure 2-2). Connect O

calibration

gas 1 (high calibration gas) to the HIGH CALGAS IN fitting and O

calibration gas 2 (low

calibration gas) to the LOW CAL GAS IN fitting. Ensure the calibration gas pressure is set at 20 psi (138 kPa).

b. Reference Air Connection (Optional). If the

reference air option (which includes the reference air flowmeter, pressure regulator, and necessary tubing and fittings) is used, connect the instrument air to the 1/4 in. fitting on the reference air pressure regulator (Figure 2-2). The pressure regulator is factory set at 20 psi (138 kPa). Readjust by turning the knob on the top of the regulator to obtain the desired pressure.

If the SPS 4000 does not have the reference air option, connect the reference air to the Oxymitter 5000 as instructed in paragraph 2-4.

Rosemount Analytical Inc.

SMART FAMILY

Orrville,OH 44667-0901

HART

800-433-6076

OXYMITTER 4000 SERIAL NO.

CALIBRATION GAS

TAG NO. VOLTS: WATTS:

85-264VAC 48-62 Hz

4-20 mA

OUTPUT: LINE FUSE:

500VA

5 Amps

REFERENCE AIR

Figure 2-12. Oxymitter 5000 Gas Connections

26170025

NOTE

Upon completing installation, make sure that the Oxymitter 5000 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold Oxymitter 5000 exposed to the process gases.

During outages, and if possible, leave all Oxymitter 5000 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 Oxymitter 5000 units and remove them from the wash area.

IB-106-350

2-13/2-14

Install all protective equipment covers and safety ground leads before equipment startup. Failure to install covers and ground leads could result in serious injury or death.

NOTE

Refer to Appendices A, B, and C for fieldbus information concerning the Oxymitter

5000.

3-1. GENERAL.

a. Verify Mechanical Installation.

Oxymitter 5000 is installed correctly (Section II, INSTALLAT ION) .

b. Verify Terminal Block Wiring.

Remove screw (36, Figure 6-1), gasket (37), and cover lock (38) that secure the

3 3

SECTION III. STARTUP

Ensure the

terminal block cover. Remove the cover to expose the terminal block (Figure 3-1).

Check the terminal block wiring. Be sure the power, fieldbus signal, and logic outputs are properly connected and secure.

Install the housing cover on the terminal block and secure with cover lock (38, Figure 6-1), gasket (37), and screw (36).

For an Oxymitter 5000 with an integrally mounted SPS 4000, remove screws (26, Figure 6-11) and terminal cover (27). Check that the power and signal terminations are properly connected to terminal strip (25) and secure according to instructions in Section II, INSTALLATION.

Install terminal cover (27) and secure with screws (26).

Figure 3-1. Integral Electronics

IB-106-350

3-1

c. Verify Oxymitter 5000 Configuration (Figure

3-2). Located on the microprocessor board, the

top board, is a switch that controls the simulate enable status of the Oxymitter 5000. To allow the Oxymitter to be placed in simulation mode, place position two of SW2 in the ON position. Once the Oxymitter has been set to the simulate mode, switch position two of SW2 to the OFF position to remove the Oxymitter from simulate mode. Note that SW2 does not actually place the Oxymitter in simulate mode, it only allows the Oxymitter to be placed into simulate mode through the fieldbus interface.

Positions 1, 3, and 4 o f SW 2 are not used, and should remain in the OFF position.

Refer to Appendix A for more information on using the AI block.

e. Once the cell is up to operating temperature, the

percentage can be read:

Access TP5 and TP6 next to the membrane

keypad. Attach a multimeter across TP5 and TP6. The calibration and process gases can now be monitored. Pressing the 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 % O

seen

by the cell. Oxygen levels, as seen on the multimeter, are:

Typically, the probe’s sensing cell, which is in direct contact with the process gases, is heated to approximately 1357°F (736°C), and the external temperature of the probe body may exceed 842°F (450°C). If operating conditions also contain high oxygen levels and combustible gases, the Oxymitter 5000 may self-ignite.

d. O2 Range. The O2 range of the Oxymitter is set

through the fieldbus interface using the AI block.

8.0% O2 = 8.0 VDC

0.4% O2 = 0.4 VDC

NOTE

The maximum reading available at TP5 and TP6 is 30 VDC. While the Oxymitter will measure oxygen concentrations up to 40%, the test point output will reach a maximum of 30 VDC at a 30% oxygen concentration.

OUNDATION

fieldbus.

IB-106-350

3-2

SIMULATE

ENABLE

HEATERT/C

DIAGNOSTIC

ALARMS

HEATER

O2 CELL

CALIBRATION

CALIBRATION RECOMMENDED

O2 CELL mV +

TEST

POINTS

O2 CELL mV -

HEATERT/C +

HEATERT/C -

INC INC

HIGH

GAS

LOW GAS

DEC DEC

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3 TP4

TP5 TP6

1 2 3 4

NOT USED

OFF NOT USED NOT USED

SW2

RED

DEFAULT

POSITION

(EX-FACTORY)

YEL

GRN

ORG

NOT USED ON

NOT USED NOT USED

Figure 3-2. Oxymitter 5000 Defaults

IB-106-350

3-3

28550011

3-2. LOGIC I/O. T his two-terminal logic contact can

be configured either as a solid-state relay-activated alarm or as a bi-directional calibration handshake signal to an IMPS 4000 or SPS 4000. The configuration of this signal depends on the setting of the IO_PIN_MODE parameter via fieldbus. The different modes available are described in Table 3-1. The IO_PIN_MODE and IO_PIN_STATE parameters are described in Table 3-2.

a. Alarm. When configured as an alarm, this signal

alerts you to an out-of-spec condition. The output is 5 V in series with a 340 ohm resistor. For optimum performance, Rosemount recommends connecting the output to a Potter & Bromfield

3.2 mA DC relay (P/N R10S-E1Y1-J1.0K).

Of the ten modes in Table 3-1, modes 0 through 7 are the alarm modes. The factory default is

Table 3-1. Logic I/O Configuration

Mode Configuration

mode 5 for Oxymitter 5000 units without an IMPS 4000 or SPS 4000. In this mode, the output will signal when a unit alarm or a CALIBRATION RECOMMENDED indication occurs.

b. Calibration Handshake Signal. If using an op-

tional IMPS 4000 or SPS 4000, the logic I/O must be configured for calibration handshaking. Of the ten modes in Table 3-1, only modes 8 and 9 are configured fo r calibr ation handshaking. For an Oxymitter 5000 with an IMPS 4000 or an SPS 4000, the factory sets the default to mode 8. In this mode, the logic I/O will be used to communicate between the Oxymitter 5000 and sequencer and to signal the sequencer when a CALIBRATION RECOMMENDATION indication occurs.

0 The unit is not configured for any alarm condition. 1 The unit is configured for a Unit Alarm. 2 The unit is configured for Low O2. 3 The unit is configured for both a Unit Alarm and Lo w O2. 4 The unit is configured for a High AC Impeda nce/CALIBRATION RECOMMENDED. 5* The unit is configured for both a Unit Alarm and a High AC Impedance/CALIBRATION

RECOMMENDED. 6 The unit is configured for both a Low O2 and High AC Impedance/CALIBRATION RECOMMENDED. 7 The unit is configured for a Unit Alarm, a Low O2, and a High AC Impedance/CALIBRATION

RECOMMENDED. 8** The unit is configured for a calibration handshake with IMPS 4000 or SPS 4000. CALIBRATION

RECOMMENDED will initiate the calibration cycle. 9 The unit is configured for a calibration handshake. CALIBRATION RECOMMENDED will not initiate the

calibration cycle with the IMPS 4000 or SPS 4000.

* The default condition f or an Ox ymitter 5000 with ou t an IMPS 4000 or SPS 4000.

** The defau lt con dition for an Oxymitter 5000 with an IMPS 4000 or SPS 4000.

IB-106-350

3-4

Table 3-2. Logic I/O Parameters

Parameter Definition Range

Parameter

Number

IO_PIN_MODE This parameter represents the operating mode of the

discrete IO pin of the transmitter.

IO_PIN_STATE This parameter represents the current state of the

transmitter’s discrete IO pin. 0=FALSE, 1=TRUE.

3-3. RECOMMENDED CONFIGURATION.

a. Fieldbus Signal Upon Critical Alarm. When a

critical alarm occurs which causes the O2 reading to become unstable or unreliable, the Oxymitter will flag the O

reading. All further O2 readings

will be flagged as Out Of Service until the problem has been corrected.

If the O

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 action should be taken.

b. Calibration. Rosemount recommends utilizing

an autocalibration system, actuated by the “calibration recommended” diagnostic. New O may operate for more than a year, but older cells may require recalibration every few weeks as they near the end of their life. This strategy ensures that the O

reading is always accurate, and

eliminates many unnecessary calibrations based on calendar days or weeks since previous calibration. When utilizing the SPS 4000 or the IMPS 4000, consider wiring some or all associated alarm contacts.

cells

1-10 40

0-1 41

CALIBRATION INITIATE. Contact from

the control room to an SPS 4000 or IMPS 4000 (one per probe) provides the ability to manually initiate a calibration at any time from the control room. Note that calibrations can also be initiated via fieldbus or from the keypad on the Oxymitter 5000.

IN CALIBRATION. One contact per

probe provides notification to the control room that the “calibration recommended” diagnostic has initiated an automatic calibration through the SPS 4000 or IMPS

4000. If the O

signal is being utilized in an

automatic control loop, this contact should be utilized to place the control loop into manual during calibration.

CALIBRATION FAILED. One contact

per probe from and SPS 4000 or IMPS 4000 to the control room for notification that the calibration procedure failed. Grouped with this alarm is an output from a pressure switch that indicates when the calibration gas bottles are empty.

IB-106-350

3-5

3-4. POWER UP.

a. Startup Display. 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 tempe rature.

b. Operating Display. The ramp cycle turns into a

cycle where the diagnostic LEDs light in sequence from the top to the bottom, one at a time.

HEA TERT/C

DIAGNOSTIC

ALARMS

CALIBRATION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEA TER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3

TP4

TP5 TP6

SW2

After the bottom LED turns on, the sequence starts again at the top with the HEATER T/C LED (Figure 3-3).

Error. If there is an error condition at

startup, one of the diagnostics LEDs will be blinking. Refer to Section V, TROUBLESHOOTING, to determine the cause of the error. Clear the error, cycle power, and the operating display should return.

Keypad. The five membrane keys on the

membrane keypad are only used during calibration to adjust the high and low gas and to initiate the calibration sequence (Figure 3-4).

HEATER T/C

HEATER

O CELL

YEL

RED

GRN

ORG

CALIBRATION

HEATER T/C

HEATER

O CELL

CALIBRATION

2 3 4 1 2 3 4

LIGHTING SEQUENCE DURING NORMAL OPERATION

2 3 4 1 2 3 4

LIGHTING SEQUENCE DURING WARM-UP

Figure 3-3. Startup and Normal Operation

IB-106-350

3-6

28550012

HEATER T/C

DIAGNOSTIC

ALARMS

CALIBRATION

CALIBRATION REQUIRED

02 CELL mV +

TEST

POINTS

02 CELL mv HEATER T/C + HEATER T/C -

HEATER

02 CELL

3-5. START UP OXYMITTER 5000 CALIBRA-

TION. Refer to Section VI, MAINTENANCE AND

SERVICE, for calibration instructions.

3-6. IMPS 4000 CONNECTIONS. See the IMPS 4000

Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for wiring and pneumatic connections.

INC INC

HIGH

DEC DEC

GAS

LOW GAS

TEST GAS +

PROCESS -

Figure 3-4. Calibration Keys

CAL

%02

IB-106-350

3-7/3-8

4 4

SECTION IV. OPERATION FROM LOCAL KEYPAD

4-1. GENERAL.

a. Overview.

normal operation. The diagnostic LEDs will display the operating cycle. All other LEDs should be off (Figure 4-1).

DIAGNOSTIC ALARM LEDS. If there is an error in the system, one of these LEDs will flash various blink codes (Section V, TROUBLESHOOTING). In the case of multiple errors, only one will be displayed based on a priority system. Correct the problem and cycle power. The operating display will return or the next error will be displayed. The alarms are:

CALIBRATION Turns on when the system determines a calibration is recommended.

TEST POINTS. Test points 1 through 6 will allow you to monitor with a multimeter: the heater thermocouple, O and the process O

Ensure the Oxymitter 5000 is at

HEATER T/C HEATER O2 CELL CALIBRATION

RECOMMENDED

cell millivolt,

LED.

(a) TP1 and TP2 monitor the oxygen cell

millivolt output which equates to the percentage of oxygen present.

(b) TP3 and TP4 monitor the heater

thermocouple.

or the calibration gas parameter. The maximum reading available from these test points is 30 VDC. This corresponds to 30% oxygen concentrations.

CAL LED. The CAL LED is on steady or flashing during calibration. Further information is available in Section VI, MAINTENANCE AND SERVICE.

Keys.

(a) INC and DEC. The INC and DEC

keys are used to set the values of the calibration gases. Attach a multimeter across TP5 and TP6. The calibration and process gases can now be monitored. Pressing the INC or DEC once will cause the output to switch from the process gas to the calibration gas.

HEA TERT/C

DIAGNOSTIC

ALARMS

CALIBRATION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEA TER

O2 CELL

CALIBRA TION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

HEATER T/C

CALIBRATION

HEATER

O CELL

TP1 TP2 TP3 TP4

TP5 TP6

SW2

YEL

RED

GRN

ORG

CAL LED

Figure 4-1. Normal Operation

IB-106-350

4-1

2 3 4 1 2 3 4

LIGHTING SEQUENCE DURING NORMAL OPERATION

28550013

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 % O seen by the cell. Oxygen levels, as seen on the multimeter, are:

8.0% O

0.4% O

= 8.0 volts DC

= 0.4 volts DC

(b) CAL. The CAL key can:

1 Initiate a calibration.

2 Sequence through calibration.

3 Abort the calibration.

b. Model 751 Remote Powered Loop LCD Dis-

play (Optional). Refer to Remote Powered

Loop LCD manual for calibration and operation.

IB-106-350

4-2

SECTION V. TROUBLESHOOTING

Install all protective equipment covers and safety ground leads after troubleshooting. Failure to install covers and ground leads could result in serious injury or death.

5 5

will flash a code that will correspond to an error message. Only one LED will blink at a time. An alarm code guide is provided inside the screw cover for the electronics. All alarm indications will be available via fieldbus. When the error is corrected and/or power is cycled, the diagnostic alarms will clear or the next error on the priority list will appear.

5-1. GENERAL. The troubleshooting section describes

how to identify and isolate faults that may develop in the Oxymitter 5000. Also, additional troubleshooting information is provided in paragraph 5-5 for those units with the optional SPS 4000. When troubleshooting the Oxymitter 5000, reference the following information.

a. Grounding. It is essential that adequate

grounding precautions are taken when installing the system. Thoroughly check both the pr obe and electronics to ensure the grounding quality has not degraded during fault finding. The system provides facilities for 100% effective grounding and the total elimination of ground loops.

b. Electrical Noise. The Oxymitter 5000 has been

designed to operate in the type of environment normally found in a boiler room or control room. Noise suppression circuits are employed on all field terminations and main inputs. When fault finding, evaluate the electrical noise being generated in the immediate circuitry of a faulty system. Also, ensure all cable shields are connected to earth.

c. Loose Integrated Circuits. The Oxymitter

5000 uses a microprocessor and supporting integrated circuits (IC). If the electronics are handled roughly during installation or located where subjected to severe vibration, the ICs could work loose. Before troubleshooting the system, ensure all ICs are fully seated.

d. Electrostatic Discharge. Electrostatic discharge

can damage the ICs used in the electronics. Before removing or ha ndling the p roc essor boa rd or the ICs, ensure you are at ground potential.

5-2. ALARM INDICATIONS. The majority of the

fault conditions for the Oxymitter 5000 will be indicated by one of the four LEDs referred to as diagnostic, or unit, alarms on the operator’s keypad. An LED

5-3. ALARM CONTACTS.

If autocalibration is not utilized, a common bidirectional logic contact is provided for any of the diagnostic alarms listed in Table 5-1. The assignment of alarms which can actuate this contact can be modified to one of seven additional groupings listed in Table 7-1.

b. If autocalibration systems are utilized, the bidi-

rectional logic contact is utilized as a “handshake” signal between the autocalibration system (SPS 4000 or IMPS 4000) and is unavailable for alarming purposes. The following additional contacts are pro vided through the auto calibration systems:

SPS 4000 and IMPS 4000, 1-4 probes.

(a) One contact closure per probe from

the control room to the SPS 4000 or IMPS 4000 for “calibration initiate”.

(b) One contact output per probe from

SPS 4000 or IMPS 4000 to the control room for “in calibration” notification.

the SPS 4000 or IMPS 4000 to the control room for “calibration failed” notification. (Includes output from pressure switch indicating “cal gas bottles empty”.)

IB-106-350

5-1

Additional IMPS Alarm Contacts.

indicated using the four diagnostic, or unit, alarms. The pattern of repeating blinks will define the prob-

(a) One contact per IMPS 4000 for “low

calibration gas flowing”.

(b) One contact per IMPS 4000 for “high

calibration gas flowing”.

5-4. IDENTIFYING AND CORRECTING ALARM

INDICATIONS. Faults in the Oxymitter 5000 are

lem. A condensed table of the errors and the corresponding blink codes can be found on the inside right cover of the electronics housing. Table 5-1 also identifies the blink code and fault status of each LED as well as the output of the fieldbus digital signal line and a fault number that corresponds to the troubleshooting instructions provided in this sectio n.

Table 5-1. Diagnostic/Unit Alarm Fault Definitions

LED FLASHES STATUS PV STATUS FAULT SELF-CLEARING

HEATER T/C 1 OPEN BAD 1 NO

2 SHORTED BAD 2 NO 3 REVERSED BAD 3 NO

HEATER 1 OPEN BAD 4 NO

2 HIGH HIGH TEMP BAD 5 YES 3 HIGH CASE TEMP BAD 6 YES 4 LOW TEMP BAD 7 NO 5 HIGH TEMP BAD 8 YES

O2 CELL 1 HIGH mV BAD 9 YES

3 BAD UNCERTAIN 10 YES 4 EEPROM CORRUPT BAD 11 NO

CALIBRATION 1 INVALID SLOPE UNCERTAIN 12 YES

2 INVALID CONSTANT UNCERTAIN 13 YES 3 LAST CALIBRATION

UNCERTAIN 14 YES

FAILED

** CALIBRATION RECOM-

GOOD YES

MENDED

* Critical alarm conditions will render the O2 measurement as unusable, and any of these events will cause the PV values to

be tagged Out of Service. Alarms which are not “self-clearing” will require recycling of power to the electronics.

**The CALIBRATION RECOMMENDED alarm flashes the Calibration Recommended alarm LED on the operator’s

keypad.

IB-106-350

5-2

a. Fault 1, Open Thermocouple. The HEATER

T/C LED flashes once, pauses for three seconds, and repeats (Figure 5-1).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

SW2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-1. Fault 1, Open Thermocouple

YEL

RED

28550014

GRN

ORG

Check connector J1. Ensure the connector

is properly seated.

Using a multimeter, measure TP3+ to TP4-.

If the reading is 1.2 VDC ±0.1 VDC, the thermocouple is open.

Remove power. Disconnect J1. Measure

continuity across the red and yellow thermocouple leads.

The measurement should read approxi-

mately 1 ohm.

If the thermocouple is open, see para-

graph 6-7, Heater Strut Replacement.

IB-106-350

5-3

b. Fault 2, Shorted Thermocouple. The HEATER

T/C LED flashes twice, pauses for three seconds, and repeats (Figure 5-2).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

SW2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-2. Fault 2, Shorted Thermocouple

YEL

RED

GRN

28550015

ORG

Using a multimeter, measure across TP3+

and TP4-.

If the reading is 0 ±0.5 mV, then a shorted

thermocouple is likely.

Remove power and disconnect J1.

Measure from TP3+ to TP4-. The reading

should be approximately 20 Kohms.

If so, the short is not on the PC board. See

paragraph 6-7, Heater Strut Replacement.

IB-106-350

5-4

c. Fault 3, Reversed Thermocouple. The

HEATER T/C LED flashes three times, pauses for three seconds, and repeats (Figure 5-3).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv HEATERT/C + HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3

TP4

TP5 TP6

SW2

Figure 5-3. Fault 3, Reversed Thermocouple

YEL

RED

GRN

28550016

ORG

Using a multimeter, measure TP3+ to TP4-.

If the reading is negative, the thermocouple

wiring is reversed.

Check red and yellow wires in the J1 con-

nector for the proper placement.

If the wiring is correct, the fault is in the PC

board. See paragraph 6-5b, Electronic Assembly Replacement.

IB-106-350

5-5

d. Fault 4, Open Heater. The HEATER LED

flashes once, pauses for three seconds, and repeats (Figure 5-4).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3 TP4

TP5 TP6

SW2

RED

YEL

GRN

28550017

ORG

Remove power. Remove the electronic as-

sembly per paragraph 6-5b, Electronic Assembly Replacement.

Using a multimeter, measure across the

heater connector J8.

The measurement should be approximately

72 ohms. If the heater is open, see paragraph 6-7, Heater Strut Replacement.

Figure 5-4. Fault 4, Open Heater

IB-106-350

5-6

e. Fault 5, High High Heater Temp. The

HEATER LED flashes twice, pauses for three seconds, and repeats (Figure 5-5).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRA TION

O2 CELL mV +

O2 CELL mv HEATERT/C + HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3 TP4

TP5 TP6

SW2

Figure 5-5. Fault 5, High High Heater Temp

YEL

RED

GRN

28550018

ORG

The high high heater temp alarm will acti-

vate when the thermocouple produces a voltage of 37.1 mV (1652°F/900°C).

The triac and the temperature control may

be at fault.

Remove power. Allow Oxymitter 5000 to

cool for five minutes. Restore power.

If the condition repeats, replace the

electronic assembly per paragraph 6-5b, Electronic Assembly Replacement.

IB-106-350

5-7

f. Fault 6, High Case Temp. The HEATER LED

flashes three times, pauses for three seconds, and repeats (Figure 5-6).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRA TION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-6. Fault 6, High Case Temp

SW2

RED

28550019

If the case temperature exceeds 185°F

(85°C), the temperature control will shut off and a fieldbus alarm will be sent.

This signifies that the environment where

the Oxymitter 5000 is installed exceeds the ambient temperature requirements or that

YEL

GRN

ORG

heat due to convection is causing case temperature to rise above the limit.

Placing a spool piece between the stack

flange and the Oxymitter 5000 flange may eliminate this problem.

If a spool piece does not solve the problem,

relocation is the only solution.

IB-106-350

5-8

g. Fault 7, Low Heater Temp. The HEATER

LED flashes four times, pauses for three seconds, and repeats (Figure 5-7).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv HEATERT/C + HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

SW2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-7. Fault 7, Low Heater Temp

RED

28550020

The low heater temperature alarm is active

when the thermocouple reading has dropped below 28.6 mV.

If the thermocouple reading continues to

ramp downward for one minute and does not return to the temperature set point of

YEL

GRN

ORG

approximately 29.3 mV, then an Open Heater fault will be displayed.

Power down the electronics. Remove the

electronic assembly per paragraph 6-5b, Electronic Assembly Replacement. Using a multimeter, measure across the heater connector, J8.

If the heater is good, the reading will be

aproximately 70 ohms. If the heater is open, see paragraph 6-7, Heater Strut Replacement.

IB-106-350

5-9

h. Fault 8, High Heater Temp. The HEATER

LED flashes five times, pauses for three seconds, and repeats (Figure 5-8).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

SW2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-8. Fault 8, High Heater Temp

RED

YEL

GRN

28550021

ORG

If the thermocouple produces a voltage in

excess of approximately 30.7 mV, the high heater temp alarm activates.

An alarm is sent via fieldbus.

This alarm is self-clearing. When tempera-

ture control is restored and the thermocouple voltage returns to the normal range, the alarm clears.

If the temperature continues to rise, the next

alarm will be the high high heater temp alarm.

IB-106-350

5-10

i. Fault 9, High Cell mV. The O2 CELL flashes

once, pauses for three seconds, and repeats (Figure 5-9).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRA TION

O2 CELL mV +

O2 CELL mv HEATERT/C + HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-9. Fault 9, High Cell mV

SW2

RED

YEL

GRN

28550022

ORG

Using a multimeter, measure across TP1+

to TP2-.

If you measure 1.2 VDC, the cell wires, ei-

ther orange or green, have become detached from the input.

One possible cause is connector J1. The or-

ange or green wire has come loose from the crimped connection.

The platinum pad could also be at fault. The

pad could have broken free from the back of the cell.

Replace heater strut per paragraph 6-7,

Heater Strut Replacement. If necessary, replace the cell flange assembly per paragraph 6-8, Cell Replacement.

IB-106-350

5-11

j. Fault 10, Bad Cell. The O2 CELL flashes three

times, pauses for three seconds, and repeats (Figure 5-10).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRA TION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

Figure 5-10. Fault 10, Bad Cell

TP1 TP2 TP3 TP4

TP5 TP6

SW2

RED

28550023

YEL

GRN

ORG

The bad cell alarm activates when the cell

exceeds the maximum resistance value.

The cell should be replaced. See paragraph

6-8, Cell Replacement, for cell replacement instructions.

IB-106-350

5-12

k. Fault 11, EEPROM Corrupt. The O2 CELL

LED flashes four times, pauses for three seconds, and repeats (Figure 5-11).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv HEATERT/C + HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

SW2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-11. Fault 11, EEPROM Corrupt

RED

28550024

This alarm can occur if the EEPROM is

changed for a later version. At power up, the EEPROM is not updated.

To correct this problem, power down and

then restore power. The alarm should clear.

If the alarm occurs while the unit is running,

YEL

GRN

ORG

there is a hardware problem on the microprocessor board.

If cycling the power does not clear the

alarm, see paragraph 6-5b, Electronic Assembly Replacement.

IB-106-350

5-13

l. Fault 12, Invalid Slope. The CALIBRATION

LED flashes once, pauses for three seconds, and repeats (Figure 5-12).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRA TION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-12. Fault 12, Invalid Slope

SW2

RED

28550025

During a calibration, the electronics calcu-

lates a slope value. If the value of the slope is less than 35 mV/deg or more than 52

YEL

GRN

ORG

mV/deg, the slope alarm will be active until the end of the purge cycle.

See paragraph 6-2, Calibration. Verify the

calibration by carefully repeating it. Ensure the calibration gases match the calibration gas parameters. If you attach a multimeter to TP1+ and TP2-, sample gas measurements are:

8% O

≈ 23 mV

0.4% O

Power down the Oxymitter 5000 and re-

≈ 85 mV

move it from the stack.

Replace the cell per paragraph 6-8, Cell

Replacement.

IB-106-350

5-14

m. Fault 13, Invalid Constant. The CALIBRA-

TION LED flashes twice, pauses for three seconds, and repeats (Figure 5-13).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv HEATERT/C + HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

SW2

TP1 TP2 TP3 TP4

TP5 TP6

Figure 5-13. Fault 13, Invalid Constant

YEL

RED

GRN

28550026

ORG

After a calibration has been performed, the

electronics calculates a cell constant value.

If the cell constant value is outside of the

range, -4 mV to 10 mV, the alarm will activate. See paragraph 6-2, Calibration, and verify the last calibration was performed correctly.

Power down the Oxymitter 5000 and re-

move it from the stack.

Replace the cell per paragraph 6-8, Cell

Replacement.

IB-106-350

5-15

n. Fault 14, Last Calibration Failed. The CALI-

BRATION LED flashes three times, pauses for three seconds, and repeats (Figure 5-14).

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRA TION RECOMMENDED

TEST

POINTS

INC INC

HIGH

LOW

GAS

DEC DEC

HEATER

O2 CELL

CALIBRA TION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

CAL

TEST GAS +

PROCESS -

% O2

TP1 TP2 TP3 TP4

TP5 TP6

SW2

RED

28550027

Figure 5-14. Fault 14, Last Calibration Failed

The last calibration failed alarm activates

when the slope and constant values calculated are out of range and the unit reverts to

using the previous calibration values.

The cell should be replaced. See paragraph

6-8, Cell Replacement, for cell replacement

YEL

GRN

ORG

instructions.

IB-106-350

5-16

Install all protective equipment covers and safety ground leads after troubleshooting. Failure to replace covers and ground leads could result in serious injury or death.

5-5. SPS 4000 TROUBLESHOOTING. Use the CAL

FAIL and IN CAL relay outputs to identify possible SPS 4000 faults.

a. If a calibration was not successfully completed,

the SPS 4000 sends a CAL FAIL contact indication to the control room. To determine if the SPS 4000 caused the failed calibration, go to the Oxymitter 5000 site to view the keypad. Or, access the Oxymitter via fieldbus.

If no alarms are indicated on the keypad or

via fieldbus, the calibration did not fail because of an Oxymitter 5000 fault. Therefore, a calibration gas flow problem occurred. Refer to Table 5-2 or Figure 5-15 to troubleshoot the SPS 4000.

TENANCE AND SERVICE, Also, verify your calibration gas setup.

(b) Perform another calibration and

monitor the process. If the calibration fails before both calibration gases finish sequencing, a gas flow problem exists. Refer to Table 5-2 or Figure 5-15 to troubleshoot the SPS 4000.

If the calibration setup is correct and the Oxymitter 5000 indicates an invalid slope fault (fault 12) before the gases are purged and a last calibration failed fault (fault 14) after the gases are purged, replace the Oxymitter 5000 cell per paragraph 6-8 in Section VI, MAINTENANCE AND SERVICE.

b. If a semi-automatic or manual calibration is be-

ing performed but no 5-30 VDC relay output contact (IN CAL or CAL FAIL) is being received by the control room, the interface board relays are malfunctioning. Replace the interface board per paragraph 6-10b.

If the LAST CAL FAILED alarm is indi-

cated on the keypad or via fieldbus, the failure is due to either a bad Oxymitter 5000 cell or a calibration gas flow problem.

(a) Verify your calibration setup per

paragraph 6-2 in Section VI, MAIN-

NOTE

If the unit is performing frequent autocalibrations, investigate at the Oxymitter 5000 site or via fieldbus. This condition may indicate an aging cell in the Oxymitter 5000.

IB-106-350

5-17

Table 5-2. SPS 4000 Fault Finding

SYMPTOM CHECK FAULT REMEDY

No calibration gas flow

Wiring Improper wire connections,

loose connections, or damaged wiring

Logic I/O Oxymitter 5000 logic I/O

not set for calibration hand-

Properly connect wiring or secure loose wiring connections; replace damaged wiring if necessary.

Set logic I/O to mode 8 via fieldbus using the IO_PIN_MODE parameter.

shaking with SPS 4000

Calibration gas lines be-

Clogged calibration gas line Replace clogged calibration gas line. tween cylinders and manifold

Calibration gas flowmeter knob

Calibration gas line between

Flowmeter knob not turned

counterclockwise to allow

flow

Turn calibration gas flowmeter knob counterclockwise to allow calibration gas to flow.

Clogged calibration gas line Replace clogged calibration gas line. manifold and calibration gas flowmeter

Fuse on power supply board Blown fuse Replace fuse per paragraph 6-10a. Interface board operation Interface board not sending

signals

Replace interface board per paragraph 6-10b.

Check valve Clogged check valve Replace check valve per paragraph

6-10e.

Calibration gas line between

Clogged calibration gas line Replace calibration gas line. calibration gas flowmeter and check valve

Calibration gas flowmeter Clogged flowmeter Replace flowmeter per paragraph

6-10h.

Power supply output Power supply failure Replace power supply board per para-

graph 6-10b. Solenoid Solenoid failure Replace solenoid per paragraph 6-10c. Pressure switch Pressure switch failure Replace pressure switch per paragraph

6-10d.

IB-106-350

5-18

Figure 5-15. SPS 4000 Troubleshooting Flowchart (Sheet 1 of 2)

IB-106-350

5-19

SYMPTOM — NO TEST GAS FLOW (CONTINUED)

CONTINUED

FROM SHEET

1OF2

PLACE JUMPER BETWEEN CAL RET TERMINAL AND EITHER HI GAS OR LO GAS TERMINAL OF J3. SEE NOTE 1.

IS THERE

FLOW?

USE METER (SEE NOTE 2) TO CHECK FOR SHORT BETWEEN CAL RET AND NO GAS TERMINALS OF J3.

IS THERE A SHORT?

YES

INTERFACE BOARD IS NOT SENDING SIGNAL. REPLACE INTERFACE BOARD PER PARAGRAPH 6-10b.

DISCONNECT CAL GAS LINE AT CHECK VALVE.

NOTE 1:

NOTE 2:

NOTE 3:

NOTE 4:

SECURELY TIGHTEN ALL J3 SCREW TERMINALS ON POWER SUPPLY BOARD TO MAKE CONNECTIONS.

USE A SIMPSON MODEL 260 OR EQUIVALENT MULTIMETER.

IF REPLACING THE CHECK VALVE DOES NOT CORRECT THE PROBLEM, A CLOG COULD EXIST IN THE RED SILICON GAS TUBE WITHIN THE PROBE.

IF CHECKING CAL GAS 1 SOLENOID CONNECTOR J5, ENSURE CAL RET TERMINAL IS JUMPERED TO HI GAS TERMINAL OF J3. IF CHECKING CAL GAS 2 SOLENOID CONNECTOR J4, ENSURE CAL RET TERMINAL IS JUMPERED TO LO GAS TERMINAL OF J3.

IS THERE

FLOW?

YES

REPLACE CHECK VALVE PER PARAGRAPH 6-10e. SEE NOTE 3.

DISCONNECT SOLENOID FROM POWER SUPPLY BOARD AND USE METER TO MEASURE ACROSS TWO OUTER PINS OF BOARD CONNECTOR. SEE NOTE 4. CHECK BOTH SOLENOIDS.

IS THERE +30VDC?

YES

DISCONNECT CAL GAS LINE AT MANIFOLD OUTPUT PORT.

IS THERE

FLOW?

YES

REPLACE PRESSURE SWITCH PER PARAGRAPH 6-10d.

REPLACE POWER SUPPLY BOARD PER PARAGRAPH 6-10b.

REPLACE SOLENOID PER PARAGRAPH 6-10c.

DISCONNECT CAL GAS LINE AT TOP FITTING OF CAL GAS FLOWMETER.

IS THERE

FLOW?

REPLACE FAULTY CAL GAS FLOWMETER PER PARAGRAPH 6-10h.

YES

REPLACE CLOGGED CAL GAS LINE BETWEEN CAL GAS FLOWMETER AND CHECK VALVE.

Figure 5-15. SPS 4000 Troubleshooting Flowchart (Sheet 2 of 2)

IB-106-350

5-20

27610002

SECTION VI. MAINTENANCE AND SERVICE

6-1. OVERVIEW. This section identifies the calib ration

methods available and provides the procedures to maintain and service the Oxymitter 5000 and optional integrally mounted SPS 4000.

Install all protective equipment covers and safety ground leads after equipment repair or service. Failure to install covers and ground leads could result in serious injury or death.

6-2. CALIBRATION.

a. During a calibration, two calibration gases with

known O

concentrations are applied to the

Oxymitter 5000. Slope and constant values calculated from the two calibration gases determine if the Oxymitter 5000 is correctly measuring the net concentration of O

in the industrial process.

Before calibrating the Oxymitter 5000, verify that the calibration gas parameters are correct by setting the gas concentrations used when calibrating the unit (See paragraph 4-1a5) and by setting the calibration gas flowmeter.

The calibration gas flowmeter regulates the calibration gas flow and must be set to 5 scfh. However, only adjust the flowmeter to 5 scfh after placing a new diffusion element on the end of the Oxymitter 5000. Adjusting the flowmeter at any other time can pressurize the cell and bias the calibration.

In applications with a heavy dust loading, the O probe diffusion element may become plugged over time, causing a slower speed of response. The best way to detect a plugged diffusion element is to note the time it takes the Oxymitter 5000 to return to the normal process reading after the last calibration gas is removed and the calibration gas line is blocked off. A plugged element also can be indicated by a slightly lower reading on the flowmeter.

Change the diffusion element when the calibration gas flowmeter reads slightly lower during calibration or when the response time to the process flue gases becomes very slow. Each time the diffusion element is changed, reset the calibration gas flowmeter to 5 scfh and calibrate the Oxymitter 5000. To change the diffusion element, refer to paragraph 6-8.

Three types of calibration methods are available: automatic, semi-automatic, and manual.

NOTE

A calibration can be aborted any time during the process by pressing the CAL key (Figure 6-2) on the Oxymitter 5000 keypad three times in a three second interval or via

OUNDATION

fieldbus or an IMPS 4000. An aborted calibration will retain the values of the previous good calibration.

Automatic Calibration. Automatic calibra-

tions require no operator action. However, the calibration gases must be permanently piped to the Oxymitter 5000, an SPS 4000 or IMPS 4000 must be installed to sequence the gases, and the Oxymitter 5000’s logic I/O must be set to mode 8 via fieldbus using the IO_PIN_MODE parameter so the sequencer and Oxymitter 5000 can communicate.

Depending on your system setup, an automatic calibration can be initiated by the

following methods:

(a) The Oxymitter 5000’s CALIBRATION

RECOMMENDED alarm signals that a calibration is required.

(b) Enter a time to next calibration using

the TIME_TO_NEXT_CAL parameter via fieldbus. Calibrations will then occur regularly at this interval.

IB-106-350

6-1

Note: The Electronic Assembly, item 12,

consists of items 13 through 24.

DIAGNOSTIC

ALARMS

HEATERT/C

CALIBRATION RECOMMENDED

HEATER

CALIBRATION

TEST

POINTS

02 CELL mV +

02 CELL mv -

HEATERT/C +

INC

HEATERT/C -

INC

HIGH GAS

LOW GAS

DEC

TEST GAS + PROCESS -

02 CELL

CAL

% 02

Note: Not all parts shown.

1. Heater Strut Assembly

2. Diffusion Assembly (Snubber)

3. Retainer Screw

4. Cell and Flange Assembly

5. Corrugated Seal

6. Probe Tube Assembly

7. Screw

8. Tube Connector

9. Gas Port

10. O-ring

11. Right Housing Cover

12. Electronic Assembly

13. Screw

14. Membrane Keypad

15. Snap Connector

16. Captive Screw

17. Microprocessor Board

18. Screw

19. Washer

20. Fieldbus Output Board

21. Fieldbus Isolator Board

22. Fuse Cap

23. Fuse

24. Power Supply Board

25. Electronic Housing

26. Screw

Figure 6-1. Oxymitter 5000 Exploded View

IB-106-350

6-2

27. Lock Washer

28. Cable Clamp

29. Terminal Block

30. Captive Screw

31. Left Housing Cover

32. SiliconTube

33. Tube Clamp

34. Screw

35. Washer

36. Screw

37. Gasket

38. Cover Lock

28550001

HEATERT/C

DIAGNOSTIC

ALARMS

CALIBRATION RECOMMENDED

TEST

POINTS

HEATER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv -

HEATERT/C +

HEATERT/C -

to sequence the gases, and the Oxymitter 5000’s logic I/O must be set to mode 8 or 9 via fieldbus so the sequencer and Oxymitter 5000 can communicate.

Depending on your system setup, a semiautomatic calibration can be initiated by the following methods:

(a) Oxymitter 5000. Press the CAL key

on the Oxymitter 5000 keypad.

INC INC

HIGH

LOW

GAS

DEC DEC

CAL

TEST GAS +

PROCESS -

% O2

22220067

Figure 6-2. Membrane Keypad

interval via the IMPS 4000 keypad that will initiate an automatic calibration at a scheduled time interval (in hours). To set the CalIntvX parameter of the CHANGE PRESETS display mode, refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for more information.

Once an automatic calibration is initiated, by any of the methods previously described, the Oxymitter 5000’s CALIBRATION RECOMMENDED alarm signals an IMPS 4000 or SPS 4000 to initiate a calibration. The sequencer sends an “in cal” signal to the control room so that any automatic control loops can be placed in manual. Then, the sequencer begins to sequence the calibration gases.

Semi-Automatic Calibration. Semi-automatic

calibrations only require operator initiation. However, the calibration gases must be permanently piped to the Oxymitter 5000, an SPS 4000 or IMPS 4000 must be installed

(b) IMPS 4000. Use the IMPS 4000 key-

pad to change the InitCalX parameter of the CHANGE PRESETS display mode from 0000 to 0001. Refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for more information.

OUNDATION

to perform the O

fieldbus. Use fieldbus

CAL method.

(d) Remote Contact. Initiate a calibration

from a remote location via the remote contact input connection provided by an IMPS 4000 or SPS 4000. Refer to the documentation available for the control system in use for more information.

Once a semi-automatic calibration is initiated, by any of the methods previously described, the Oxymitter 5000’s CALIBRATION RECOMMENDED alarm signals an IMPS 4000 or SPS 4000 to initiate a calibration. The sequencer sends an “in cal” signal to the control room so that any automatic control loops can be placed in maual. Then, the sequencer begins to sequence the calibration gases.

Manual Calibration. Manual calibrations

must be performed at the Oxymitter 5000 site and require operator intervention throughout the proc ess.

Manual calibration instructions can also be found, in condensed form, on the inside of the right electronics housing cover (Figure 6-3).

IB-106-350

6-3

ALARMS

LED

HEATER T/C

HEATER

O2 CELL

CALIBRATION

MANUAL CALIBRATION

PLACE CONTROL LOOP

IN MANUAL IF CAL LED ON

FLASHES

1 3

STATUS

OPEN

SHORTED

REVERSED

OPEN

HIGH HIGH

TEMP

HIGH CASE

TEMP

LOW TEMP

HIGH TEMP

OPEN

BAD

EPROM

CORRUPT

INVALID SLOPE

INVALID

CONSTANT

LAST CAL

FAILED

GO TO STEP 2

PUSH CAL

CAL LED ON

PUSH CAL

CAL LED FLASH

APPLY TG1

PUSH CAL

CAL LED ON SOLID

WAIT FOR FLASH

REMOVE TG1 & APPLY TG2

PUSH CAL

CAL LED ON SOLID

WAIT FOR FLASH

2 FLASH VALID CAL

3 FLASH INVALID CAL

REMOVE TG2

PUSH CAL

CAL LED ON FOR

PURGE TIME CAL LED OFF

SW2 DIP SWITCH

NOT USED

OFF NOT USED NOT USED

NOT USED ON NOT USED NOT USED

Figure 6-3. Inside Right Cover

28550029

Use the following procedure to perform a manual calibration:

(a) Place control loop in manual.

(b) Verify the calibration gas parameters

are correct per paragraph 6-2.a.

CALIBRATION RECOMMENDED LED off and the CAL LED off, start at step 1.

(d) If performing a manual calibration with

CALIBRATION RECOMMENDED LED on and the CAL LED on, start at step 2.

1 Push the CAL key. The CALI-

BRATION RECOMMENDED LED will come on and the CAL LED will be on solid. If a multimeter is attached across TP5 and TP6, the reading will display the percentage of oxygen seen by the cell.

2 Push the CAL key. The CALI-

BRATION RECOMMENDED LED will turn off and the CAL LED will flash continuously. The flashing LED indicates that the Oxymitter 5000 is ready to accept the first calibration gas.

3 Apply the first calibration gas.

(Electronics will abort the calibration if step 4 is not done within 30 minutes).

4 Push the CAL key; the CAL LED

will be on solid. A timer is activated to allow the calibration gas adequate time to flow (default time of five minutes). When the timer times out, the Oxymitter 5000 has taken the readings using the first calibration gas and the CAL LED will flash continuously. The flashing indicates the Oxymitter 5000 is ready to take readings using the second calibration gas.

IB-106-350

6-4

5 Remove the first calibration gas

and apply the second calibration gas. (Electronics will abort the calibration if step 6 is not done within 30 minutes).

(e) Place control loop in automatic.

OUNDATION

c. F

fieldbus O2 CAL METHOD.

To perform a calibration using F fieldbus, use the following procedure.

OUNDATION

6 Push the CAL key; the CAL LED

will be on solid. The timer is activated for the second calibration gas flow. When the timer times out, the CAL LED will flash a 2 pattern flash or a 3 pattern flash (2 pattern flash equals a valid calibration, 3 pattern flash equals an invalid calibration).

If the slope or the constant is out of specification, a diagnostic alarm LED will be flashing. The diagnostic alarm will remain active until the purge cycle is over. If the three pattern flash occurs without a diagnostic alarm, the calibration gases could be the same or the calibration gas was not turned on.

The CAL LED flashing indicates the calibration is done. (See Section V, TROUBLESHOOTING, for an explanation of the 2 pattern and 3 pattern flashes).

7 Remove the second calibration

gas and cap off the calibration gas port.

From the computer running the fieldbus

control program, run the O

Cal Method.

Failure to remove the Oxymitter 5000 from automatic control loops prior to performing this procedure may result in a dangerous operating condition.

In the first O

CAL screen, a “Loop should

be removed from automatic control” warning appears. Remove the Oxymitter 5000 from any automatic control loops to avoid a potentially dangerous operating condition and press OK.

From this point, follow the on-screen

prompts to complete the calibration procedure. When a step is complete, select Proceed to Next Step and press the Next button.

During the wait periods, such as during a

purge, the Time Remaining display may be updated by selecting Update and pressing the Next button.

8 Push the CAL key; the CAL LED

will be on solid as the unit purges. (Default purge time is three minutes). When the purge is complete, the CAL LED will turn off.

If the calibration was valid, the DIAGNOSTIC ALARMS LEDs will indicate normal operation. If the new calibration values, slope or constant, is not within the parameters, the DIAGNOSTIC ALARMS LED will indicate an alarm. (See Section V, TROUBLESHOOTING, for alarm codes). If the calibration was invalid, the Oxymitter 5000 will return to normal operation, as it was before a calibration was initiated, and the parameters will not be updated.

IB-106-350

6-3. LED STATUS INDICATORS.

a. Diagnostic/Unit Alarms. Table 6-1 lists the

types and status of alarms that will be encountered. (See Section V, TROUBLESHOOTING, for a detailed description of each fault).

b. When the electronics determines a calibration is

recommended, the CALIBRATION RECOMMENDED LED is on solid.

c. The CAL LED turns on when a calibration is

recommended and is on during the calibration process. During calibration, the CAL LED can be flashing, which would indicate operator ac tion is requested, or on solid, which indicates calculations and measurements are in progress.

6-5

Table 6-1. Diagnostic/Unit Alarms

LED FLASHES STATUS FAULT

1OPEN

HEATER T/C 2 SHORTED

3 REVERSED 1OPEN 2 HIGH HIGH

TEMP

HEATER 3 HIGH CASE

TEMP

4LOW TEMP 5 HIGH TEMP 1 HIGH mV

O2 CELL 3 BAD

4 EEPROM

CORRUPT

CALIBRATION 1 INVALID

SLOPE

2 INVALID

CONSTANT

3LAST

CALIBRA-

TION

FAILED

It is recommended that the Oxymitter 5000 be removed from the stack for all service activities. The unit should be allowed to cool and be t aken to a clean work area. Failure to comply may cause severe burns.

10 11

(b) Shut off the calibration gases at the

cylinders and the instrument air.

1 2 3 4 5

strument air lines from the Oxymitter

5000.

(d) While facing the Oxymitter 5000 and

looking at the Rosemount label, r e m o ve screw (36, Figure 6-1), gasket (37) and cover lock (38) securing left housing cover (31) . Remove the c over to expose the terminal block Figure 6-4.

7 8

(e) Loosen the screw on the AC terminal

cover and slide the cover back to ac-

cess the neutral and line terminals. Loosen the AC line and neutral terminal screws and remove the leads. Loosen the ground lug scre ws and remove the leads. Slide the line power leads out of the AC line voltage port.

(f) Loosen the logic I/O and the fieldbus

signal terminal screws. Remove the leads from the terminals and slide the wires out of the signal port.

(g) Remove insulation to access the

mounting bolts. Unbolt the Oxymitter 5000 from the stack and take it to a clean work area.

(h) Allow the unit to cool to a comfort-

able working temperature.

Replace.

(a) Bolt the Oxymitter 5000 to the stack

and install insulation.

Disconnect and lock out power before working on any electrical components. There is voltage up to 115 VAC.

6-4. OXYMITTER 5000 REMOVAL/REPLACEMENT.

a. Oxymitter 5000 (without Integrally Mounted

SPS 4000).

Remove.

(a) Turn off power to the system.

IB-106-350

(b) Insert the logic I/O and fieldbus signal

leads in the signal port and connect to the logic I/O and fieldbus digital signal screw terminals (Figure 6-4).

voltage port and connect to the AC line screw terminals. Connect the line, or L1, wire to the L1 terminal, and the neutral, or L2, wire to the N terminal. Slide the AC terminal cover over the terminal connection and tighten the cover screw.

6-6

Figure 6-4. Terminal Block

(d) Install left housing cover (31, Figure

6-1) and ensure it is tight. Secure the cover using cover lock (38), gasket (37), and screw (36).

(e) Connect the calibration gas and in-

strument air lines to the Oxymitter

5000.

(f) Turn on the calibration gases at the

cylinders and turn on instrument air.

(g) Restore power to the system.

b. Oxymitter 5000 (with Integrally Mounted

SPS 4000).

Remove.

(a) Turn off power to the system. (b) Shut off the calibration gases at the

cylinders and the instrument air.

calibration gas lines from the SPS

4000. If the instrument air does not flow through the SPS 4000, disconnect the instrument air directly at the Oxymitter 5000.

fold. Remove the terminal cover to expose the terminal strip.

(e) Tag all customer-wired leads that are

connected to the terminal strip before removing.

(f) On the terminal strip, loosen the

screws securing the customer-wired LINE IN and NEUTRAL leads to terminals L and N (Figure 2-10). Also, remove the customer-wired ground lead from the ground lug. Remove the leads from the terminal strip and slide them from the manifold through the line voltage conduit port.

(g) Next, loosen the screws of remote

contact input terminals 1 and 2; fieldbus digital signal terminals 3 and 4; and relay output terminals 7, 8, 9, and 10. Remove the leads from the terminal strip and slide them from the manifold through the signal conduit port.

(h) Remove insulation to access the

mounting bolts. Unbolt the Oxymitter 5000/SPS 4000 assembly from the stack and take the entire assembly to a clean work area.

(d) Remove the screws securing the ter-

minal cover to the SPS 4000 mani-

IB-106-350

(i) Allow the unit to cool to a comfort-

able working temperature.

6-7

MOUNTING SCREW

Rosemount Analytical Inc. Orrville,OH 44667-0901

800-433-6076

OXYMITTER 4000 SERIAL NO. TAG NO. VOLTS: WATTS:

85-264VAC 48-62 Hz

4-20 mA

OUTPUT: LINE FUSE:

MOUNTING

SMART FAMILY

HART

500VA

5 Amps

Figure 6-5. Electronic Assembly

Replace.

(a) Bolt the Oxymitter 5000/SPS 4000

assembly to the stack and install insulation.

SCREW

HEA TERT/C

LOW GAS

HEA TER

O2 CELL

CALIBRATION

O2 CELL mV +

O2 CELL mv HEA TERT/C + HEA TERT/C -

CAL

TEST GAS +

PROCESS -

% O2

DIAGNOSTIC

ALARMS

CALIBRATION RECOMMENDED

TEST

POINTS

INC INC

HIGH

GAS

DEC DEC

TP1 TP2 TP3 TP4

TP5 TP6

SW2

YEL

RED

GRN

ORG

MOUNTING SCREW

Follow the instructions in paragraph 6-4.a.1

to remove the Oxymitter 5000 from the stack or duct. If removing an Oxymitter 5000/SPS 4000 assembly, follow the instructions in paragraph 6-4.b.1.

28550031

(b) Follow the instructions in paragraph

2-3 to connect the line voltage and signal leads to an Oxymitter 5000/ SPS 4000 assembly.

2-5 to connect the calibration gases and instrument air to an Oxymitter 5000/SPS 4000 assembly. Turn on the calibration gases at the cylinders and turn on instrument air.

(d) Restore power to the system.

6-5. ELECTRONICS REPLACEMENT. Each of the

following procedures details how to remove and replace a specific electronic component of the Oxymitter 5000.

a. Entire Electronics Replacement (with

Housing).

NOTE

Only perform this procedure on Oxymitter 5000 units without integrally mounted SPS 4000 units. If it is necessary to replace the entire electronics on an Oxymitter 5000/ SPS 4000 assembly, contact Rosemount for further instructions.

Remove the right housing cover unco vering

the electronic assembly (Figure 6-5). Depress and remove the J1 (cell and T/C)

connector from the J1 socket. Loosen the three captive mounting screws on the microprocessor board (top board).

The J8 connector (heater leads) can be ac-

cessed by moving the J1 connector leads out of the slot on the microprocessor board and sliding the electronic assembly partially out of the housing (Figure 6-6).

Squeeze the J8 connector on the sides and

carefully remove. The electronic assembly can now be completely removed from the housing.

Remove the four screws (7, Figure 6-1)

from the probe finned housing. The probe and the electronic housing can now be separated.

When reinstalling or replacing the elec-

tronic housing, make sure that o-ring ( 10) is in good condition. Place the J1 and J8 connectors in the hole on the flat side of the electronic ho using.

IB-106-350

6-8

250VAC

TIME LAG

3D39619G

POWER SUPPLY

REV

BOARD

13. Follow the instructions in paragraph 6-4a2 to install the Oxymitter 5000 into the stack or duct. If installing an Oxymitter 5000/ SPS 4000 assembly, follow the instructions in paragraph 6-4b2.

b. Electronic Assembly Replacement.

(Figure 6-5).

Remove the right housing cover unco vering

the electronic assembly.

Depress and remove the J1 (cell and T/C)

connector from the J1 socket. Loosen the three captive mounting screws on the mi-

22220061

croprocessor board (top board).

Figure 6-6. J8 Connector

Hold the J1 and J8 connectors out and to

the probe side of the electronic housing. Make sure that the conduit port of the electronic housing is on the same side as the CAL and REF gas ports. Replace the four screws and tighten.

Reconnect the J8 connector to the power

supply board. Make sure the connector is secure.

10. Holding the J1 connector leads, slide the electronic assembly the rest of the way into the housing. Align the electronic assembly so that it fits flush on the pins. To ensure that it is flush, gently try to rotate the electronics. If the electronics rotates, repeat the alignment.

11. Reconnect the J1 connector to the microprocessor board. Ensure the connector is secure and tighten the three captive screws on the microprocessor board (top board).

The J8 connector (heater leads) can be ac-

cessed by moving the J1 connector leads out of the slot on the microprocessor board and sliding the electronic assembly partially out of the housing (Figure 6-6).

Squeeze the J8 connector on the sides and

carefully remove. The electronic assembly can now be completely removed from the housing.

Reconnect the J8 connector to the power

supply board. Make sure the connector is secure.

Holding the J1 connector leads, slide the

electronic assembly the rest of the way into the housing. Align the electronic assembly so that it fits flush on the pins. To ensure that it is flush, gently try to rotate the electronics. If the electronics rotates, repeat the alignment.

Reconnect the J1 connector to the micro-

processor board. Ensure the connector is secure and tighten the three captive screws on the microprocessor board (top board).

12. Replace the housing cover and ensure it is tight.

IB-106-350

6-9

Replace the housing cover and ensure it is

tight.

c. Terminal Block Replacement (Figure 6-4).

Loosen the mounting screws on the terminal

block and carefully lift the block out of the housing.

POWER

SUPPLY

BOARD

Carefully align the new terminal block on

the pins so that it sits flat in the housing. The round end of the terminal block should be on the opposite side of the housing conduit ports and should not be able to rotate.

Tighten the three mounting screws and en-

sure the terminal block is secure in the housing.

d. Fuse Replacement (Figure 6-5).

Remove the right housing cover unco vering

the electronic assembly.

Depress and remove the J1 (cell and T/C)

connector from the J1 socket. Loosen the three captive mounting screws on the microprocessor board (top board).

The J8 connector (heater leads) can be ac-

cessed by moving the J1 connector leads out of the slot on the microprocessor board and sliding the electronic assembly partially out of the housing (Figure 6-6).

Squeeze the J8 connector on the sides and

carefully remove. The electronic assembly can now be completely removed from the housing.

FUSE

250VAC

TIME LAG

3D39619G

REV

22220058

Figure 6-7. Fuse Location

Completely remove the three mounting

screws on the microprocessor board.

Turn the electronic assembly over so that

you are looking at the bottom of the power supply printed circuit board. Gently depress the two white posts one at a time. Carefully separate the power supply board from the microprocessor board.

Remove the fuse and replace it with a new

one (Figure 6-7).

IB-106-350

6-10

Align the white posts with the post holes on

the power supply board and the pin connector on the power supply board with the connector port on the back of the microprocessor board. Gently push the boards together until the white posts snap in place. Ensure the assembly is secure by gently trying to separate the boards.

Reconnect connector J8 to the power supply

board. Make sure the connector is secure.

6-7. HEATER STRUT REPLACEMENT. This

paragraph covers heater strut replacement. Do not attempt to replace the heater strut until all other possibilities for poor performance have been considered. If heater strut replacement is needed, order a replacement heater strut. (Table 7-1).

Use heat resistant gloves and clothing when removing probe. Do not attempt to work on the probe until it has cooled to room temperature. The probe can be as hot as 800°F (427°C). This can cause severe burns.

NOTE

11. Reconnect the J1 connector to the microprocessor board. Ensure the connector is secure and tighten the three captive screws on the microprocessor board (top board).

12. Replace the housing cover and ensure that it is tight.

6-6. ENTIRE PROBE REPLACEMENT (EX-

CLUDING ELECTRONICS). Do not attempt to

replace the probe until all other possibilities for poor performance have been considered. If probe replacement is needed, see Table 7-1 for part numbers.

a. Follow the instructions in paragraph 6-4.a.1to

remove the Oxymitter 5000 from the stack or duct. If removing an Oxymitter 5000 with an integrally mounted SPS 4000, follow the instructions in paragraph 6-4.b.1.

b. Separate the probe and the electronics housing

per paragraph 6-5.a, steps 2 through 6.

c. Reinstall electronics on the new probe per para-

graph 6-5.a, steps 7 through 13.

If the Oxymitter 5000 has an integrally mounted SPS 4000, it is not necessary to remove the sequencer when replacing the heater strut.

a. Follow the instructions in paragraph 6-4a1 to

remove the Oxymitter 5000 from the stack or duct. If removing an Oxymitter 5000/SPS 4000 assembly, follow the instructions in paragraph 6-4.b.1.

b. Remove entire electronics per paragraph 6-5.a,

steps 2 through 6.

NOTE

If the Oxymitter 5000 is equipped with an integrally mounted SPS 4000 and installed in corrosive conditions, stainless steel gas tubes are used instead of silicon or Teflon tubes.

c. Carefully remove the CAL and REF gas silicon

tubes by pulling them off the CAL and REF gas ports. Pull the silicon tubes off the CAL and REF gas lines.

IB-106-350

6-11

V-DEFLECTOR

CERAMIC

DIFFUSER

ASSEMBLY

WIRE

LOOP

CERAMIC SUPPORT ROD

CELL FLANGE

HEATER

22220050

Figure 6-8. Heater Strut Assembly

d. Loosen, but do not remove, the three screws (34,

Figure 6-1) on the strut in the finned housing. The spring tension should release and the strut moves up.

e. Grasp the wire loop and carefully slide the strut

out of the probe tube (Figure 6-8).

f. When replacing the strut, align the slot on the

heater plate with the calibration gas line in the probe tube. Slide the strut into the p robe tube. It will turn to align the hole on the back plate of the strut with the calibration gas line. When the hole and the calibration gas line are aligned correctly, the strut will slide in the rest of the way.

g. Push down on the back plate of the strut to make

sure you have spring tension and then tighten the three screws on the back plate.

h. Replace the CAL and REF gas silicon tubes.

i. Install the entire electronics per paragraph 6-5.a,

steps 7 through 13.

j. Follow the instructions in paragraph 6-4.a.2to in-

stall the Oxymitter 5000 into the stack or duct. If installing an Oxymitter 5000/SPS 4000 assembly, follow the instructions in paragraph 6-4.b.2.

IB-106-350

6-12

PROBETUBE

(NOT INCLUDED

IN KIT)

CORRUGATED

SEAL

CELL AND

FLANGE

ASSEMBLY

SOCKET HEAD

CAP SCREWS

CALIBRATION GAS

PASSAGE

22220028

Figure 6-9. Cell Replacement Kit

6-8. CELL REPLACEMENT. This par agraph covers

oxygen sensing cell replacement. Do not attempt to replace the cell until all other possibilities for poor performance have been considered. If cell replacement is needed, order the cell replacement kit (Table 7-1).

The cell replacement kit (Figure 6-9) contains a cell and flange assembly, corrugated seal, setscrews, socket head cap screws, and anti-seize compound. The items are carefully packaged to preserve precise surface finishes. Do not remove items from the packaging until they are ready to be used. Spanner wrenches and hex wrenches needed for this procedure are part of an available special tools kit (Table 7-1).

Use heat-resistant gloves and clothing when removing the probe. Do not attempt to work on these components until they have cooled to room temperature. Probe components can be as hot as 800°F (427°C). This can cause severe burns.

Disconnect and lock out power before working on any electrical components. There is voltage of up to 115 VAC.

Do not remove the cell unless certain it needs to be replaced. Removal may damage the cell and platinum pad. Go through the complete troubleshooting procedure to make sure the cell needs to be replaced before removing it.

a. Follow the instructions in paragraph 6-4.a.1 to

remove the Oxymitter 5000 from the stack or duct. If removing an Oxymitter 5000/SPS 4000 assembly, follow the instructions in paragraph 6-4.b.1.

b. If the probe uses the standard diffusion element,

use a spanner wrench to remove the diffusion element.

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NOTE

To determine if the diffusion element needs to be replaced, refer to paragraph 6-2.

If equipped with the optional ceramic diffusor assembly, remove and discard the setscrews and remove the vee deflector (Figure 6-10). Use spanner wrenches from the probe disassembly kit (Table 7-1), to turn the hub free from the retainer. Inspect the diffusion element. If damaged, replace the element.

d. Loosen the four socket head cap screws from the

cell and flange assembly and remove the assembly and the corrugated seal. The cell flange has a notch that may be used to gently pry the flange away from the probe. Note that the contact pad inside of the probe will sometimes fuse to the oxygen sensing cell. If the cell is fused to the contact pad, push the cell assembly back into the probe (against spring pressure) and quickly twist the cell assembly. The cell and contact pad should separate. If the contact pa d stays fused to the cell, a new contact/thermocouple assembly must be installed. Disconnect the cell and the thermocouple wires at the probe electronics and withdraw the cell with the wires still attached.

e. Remove entire electronics per paragraph 6-5.a,

steps 2 through 6.

j. Install the entire electronics per paragraph 6-5.a,

steps 7 through 13.

k. Apply anti-seize compound to the threads of the

cell assembly, hub, and setscrews. Reinstall the hub on the cell assembly. Using pin spanner wrenches, torque to 10 ft-lbs (14 N·m). If applicable, reinstall the vee deflector, orienting apex toward gas flow. Secure with the setscrews and anti-seize compound. Torque to 25 in-lbs (2.8 N·m).

l. On systems equipped with an abrasive shield, in-

stall the dust seal gaskets, with joints 180° apart.

Reinstall the probe and gasket on the stack

flange.

n. Follow the instructions in paragraph 6-4.a.2 to

install the Oxymitter 5000 into the stack or duct. If installing an Oxymitter 5000/SPS 4000 assembly, follow the instructions in paragraph 6-4.b.2. If there is an abrasive shield in the stack, make sure the dust seal gaskets are in place as they enter the 15° reducing cone.

o. Turn on power and monitor thermocouple output.

It should stabilize at 29.3+0.2 mV. Set reference air flow at 2 scfh (56.6 l/hr). After the Oxymitter 5000 stabilizes, calibrate the unit. If new components have been installed, repeat calibration after 24 hours of operation.

f. If the contact assembly is damaged, replace the

strut or the contact pad. Instructions for replacing the contact pad are in the cell replacement kit.

g. Remove and discard the corrugated seal. Clean

the mating faces of the probe tube and retainer. Remove burrs and raised surfaces with a block of wood and crocus cloth. Clean the threads on the retainer and hub.

h. Rub a small amount of anti-seize compound on

both sides of the new corrugated seal.

i. Assemble the cell and flange assembly, corru-

gated seal, and probe tube. Make sure the calibration tube lines up with the calibration gas pa ssage in each component. Apply a small amount of anti-seize compound to the screw threads and use the screws to secure assembly. Torque to 35 in-lbs (4 N·m).

WRENCH

OPTIONAL CERAMIC

DIFFUSION ELEMENT

FILLET

SETSCREW

VEE

DEFLECTOR

22220029

CEMENT

PORT

RETAINER

HUB

CEMENT

Figure 6-10. Ceramic Diffusion Element Replacement

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6-9. CERAMIC DIFFUSION ELEM ENT

REPLACEMENT.

NOTE

This refers to ceramic diffuser element only.

a. General. The diffusion element protects the cell

from particles in process gases. It does not normally need to be replaced because the vee deflector protects it from particulate erosion. In severe environments, the filter may be broken or subject to excessive erosion. Examine the ceramic diffusion element whenever removing the probe for any purpose. Replace if damaged.

Damage to the ceramic diffusion element may become apparent during calibration. Compare probe response with previous response. A broken diffusion element will cause a slower response to calibration gas.

Hex wrenches needed to remove setscrews and socket head screws in the following procedure are available as part of a Probe Disassembly Kit, Table 7-1.

b. Replacement Procedure.

Follow the instructions in paragraph 6-4.a

to remove the Hazardous Area Oxymitter 5000 from the stack or duct.

Loosen setscrews, Figure 6-10, using hex

wrench from Probe Disassembly Kit, Table 7-1, and remove vee deflector. Inspect setscrews. If damaged, replace with stainless setscrews coated with anti-seize compound.

On systems equipped with abrasive shield,

remove dual dust seal gaskets.

Use spanner wrenches from Probe

Disassembly Kit, Table 7-1, to turn hub free from retainer.

Replace ceramic diffusion element using the

ceramic diffusion element replacement kit in Table 7-1. This consists of a diffusion element, cement, setscrews, anti-seize compound, and instructions.

Test fit replacement ceramic diffusion ele-

ment to be sure seat is clean.

Do not get cement on ceramic diffusion element except where it touches the hub. Any cement on ceramic diffusion element blocks airflow through element. Wiping wet cement off of ceramic only forces cement into pores. Also, do not get any cement onto the flame arrester element.

Thoroughly mix cement and insert tip of

squeeze bottle into cement port. Tilt bo ttle and squeeze while simultaneously turning ceramic diffusion element into seat. Do not get any cement on upper part of ceramic diffusion element. Ensure complete penetration of cement around 3 grooves in hub. Cement should extrude from opposite hole. Wipe excess material back into holes and wipe top fillet of cement to form a uniform fillet. (A cotton swab is useful for this.) Clean any excess cement from hub with water.

10. Allow filter to dry at room temperature overnight or 1 to 2 hours at 200°F (93°C).

11. Wipe a heavy layer of anti-seize compound onto the threads and mating surfaces of the flame arrester, diffusion hub, and probe tube.

12. Assemble flame arrester and diffusion hub with two pin spanner wrenches. Torque to 10 ft-lbs (14 N·m). Secure with hub retaining setscrew.

Put hub in vise. Break out old ceramic dif-

fusion element with chisel along cement line. Use a 3/8 in. (9.5 mm) pin punch and clean fillet from the cement port.

Break out remaining ceramic diffusion ele-

ment by tapping lightly around hub with hammer. Clean grooves with pointed tool if necessary.

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13. On systems equipped with abrasive shield, install dust seal gaskets with joints 180( apart.

14. Reinstall vee deflector, orienting apex toward gas flow. Apply anti-seize compound to setscrews and tighten with hex wrench.

15. Reinstall probe on stack flange.

6-10. SPS 4000 MAINTENANCE AND COMPONENT

REPLACEMENT. These paragraphs describe SPS

4000 maintenance and component replacement procedures. Replacement parts referenced are available from Rosemount. Refer to Section VIII, REPLACEMENT PARTS, for part numbers and ordering information.

Install all protective equipment covers and safety ground leads af ter equipment repair or service. Failure to install covers and ground leads could result in serious injury or death.

a. Fuse Replacement. The SPS 4000 has a fuse

(17, Figure 6-11) on the power supply board (18). Refer to Table 7-3 for replacement fuse specifications. Perform the following procedure to check or replace the fuse.

Disconnect and lock out power before working on any electrical components.

Turn off power to the system.

Remove screw (7, Figure 6-11) securing

manifold cover lock (6) an d remove the lock.

Remove manifold cover ( 14).

Remove fuseholder (16) by pushing in the

top and turning 1/4 turn counterclockwise. Remove fuse (17).

Remove screw (7) securing manifold c over

lock (6) and remove the lock. Remove manifold cover ( 14).

Remove two screws (11) attaching spacers

(9) to manifold (5). Being careful not to disconnect the board

wiring, carefully lift power supply board (18) and interface board (19) from manifold (5) and set aside. Do not lose o-rings (8) from the bottom of spacers (9).

Tag all leads on the board to be replaced to

simplify installation. See Figure 6-12. If removing the power

supply board, remove the line voltage input leads from connector J7. Also, unplug calibration gas 1 solenoid leads from connector J5, calibration gas 2 solenoid leads from connector J4, and pressure switch leads from connector J2.

See Figure 6-12. If removing the interface board, remove the CAL INITIATE leads from connector J3, CAL FAIL and IN CAL leads from connector J4, and logic I/O handshake connection from connector J5.

Remove stop nuts (22, Figure 6-11), wash-

ers (21), and screws (10) securing power supply board (18) and interface board (19) to spacers (9).

Carefully separate boards (18 and 19).

10. Connect replacement board to board (18 or

19).

After checking or replacing fuse (17), in-

stall fuseholder (16) by pushing in the top and turning 1/4 turn clockwise.

Install manifold cover (14), and secure with

manifold cover lock (6) and screw (7).

b. Board Replacement. Perform the following

procedure to replace power supply board (18, Figure 6-11) or interface board (19).

Disconnect and lock out power before working on any electrical components.

Turn off power to the system.

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11. Install screws (10), washers (21), and stop nuts (22) to secure power supply board (18) and interface board (19) to spacers (9).

12. Install all applicable leads in the appropriate locations on the power supply board or interface board as shown in Figure 6-12.

13. Install power supply board (18, Figure 6-11) and interface board (19) into manifold (5). Align spacers (9) with the mounting holes on the manifold and secure with screws (11). Ensure o-rings (8) are installed between the spacers and the manifold surface.

14. Install manifold cover (14) and secure with manifold cover lock (6) and screw (7).

Rosemount Oxymitter 5000 O2 Transmitter with FOUNDATION Fieldbus Communications-Rev 1.0 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

ROSEMOUNT WARRANTY

PURPOSE

MATERIAL SAFETY DATA SHEET

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

SECTION I. INTRODUCTION

SECTION II. INSTALLATION

SECTION III. STARTUP

SECTION V. TROUBLESHOOTING

SECTION VI. MAINTENANCE AND SERVICE