Reference Manual
00809-0100-4895, Rev AA
July 2018
Rosemount
TM
SPS 4001B
Single Probe Autocalibration Sequencer
Reference Manual
00809-0100-4895, Rev AA
July 2018
SPS 4001B
Table of Contents
Essential Instructions ................................................................................ i
Preface ..................................................................................................... ii
Definitions ................................................................................................ ii
Symbols ................................................................................................... ii
SECTION 1
Description and
Specifications
Component Checklist ............................................................................ 1-1
Overview ............................................................................................... 1-2
Specifications ........................................................................................ 1-3
Physical Description .............................................................................. 1-4
Theory of Operation ............................................................................ 1-6
SECTION 2
Installation
Overview ............................................................................................... 2-1
Mechanical Installation .......................................................................... 2-1
Gas Connections .................................................................................. 2-2
Electrical Connections .......................................................................... 2-4
SECTION 3
Operation
Overview ............................................................................................... 3-1
Calibration Requirements .................................................................... 3-1
Reference Air Flow Setup .................................................................. 3-3
Calibration Gas Flow Setup ............................................................... 3-3
Automatic Calibration ........................................................................... 3-3
Semi-automatic Calibration ................................................................... 3-4
SECTION 4
Maintenance and Service
Overview ............................................................................................... 4-1
Fuse Replacement ............................................................................... 4-2
Remove/Install Chassis ........................................................................ 4-4
Circuit Board Replacement ................................................................... 4-6
Solenoid Replacement .......................................................................... 4-6
Pressure Switch Replacement ............................................................ 4-7
Check Valve Replacement .................................................................. 4-7
Pressure Regulator Maintenance ....................................................... 4-7
Flow Meter Adjustments ..................................................................... 4-7
Cleaning ................................................................................................ 4-7
SECTION 5
Troubleshooting
Overview ............................................................................................... 5-1
SPS 4001B Troubleshooting............................................................... 5-1
SECTION 6
Replacement Parts
SPS 4001B............................................................................................ 6-2
Calibration Components ....................................................................... 6-3
APPENDIX A
Safety Data
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
APPENDIX B
Return of Materials
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
TOC-1
Reference Manual
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July 2018
SPS 4001B
Reference Manual
00809-0100-4895, Rev AA
July 2018
SPS 4001B
TOC-2
ESSENTIAL
INSTRUCTIONS
SPS 4001B Single Probe
Autocalibration Sequencer
READ THIS PAGE BEFORE PROCEEDING!
Emerson designs, manufactures and tests its products to meet many national
and international standards. Because these instruments are sophisticated
technical products, you MUST properly install, use, and maintain them to
ensure they continue to operate within their normal specifications. The
following instructions MUST be adhered to and integrated into your safety
program when installing, using, and maintaining Emerson’s Rosemount
products. Failure to follow the proper instructions may cause any one of the
following situations to occur: Loss of life; personal injury; property damage;
damage to this instrument; and warranty invalidation.
•
Read all instructions prior to installing, operating, and servicing the
product.
•
If you do not understand any of the instructions, contact your
Emerson representative for clarification.
•
Follow all warnings, cautions, and instructions marked on and
supplied with the product.
•
Inform and educate your personnel in the proper installation,
operation, and maintenance of the product.
•
Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes. Connect all products to the proper electrical and
pressure sources.
•
To ensure proper performance, use qualified personnel to install,
operate, update, program, and maintain the product.
•
When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson. Unauthorized parts and
procedures can affect the product's performance, place the safe
operation of your process at risk, and VOID YOUR WARRANTY.
Look-alike substitutions may result in fire, electrical hazards, or
improper operation.
•
Ensure that all equipment doors are closed and protective covers
are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.
The information contained in this document is subject to change without
notice.
Reference Manual
00809-0100-4895, Rev AA
July 2018
SPS 4001B
PREFACE The purpose of this manual is to provide information concerning the
components, functions, installation and maintenance of the SPS 4001B
Single Probe Autocalibration Sequencer.
Some sections may describe equipment not used in your configuration. The
user should become thoroughly familiar with the operation of this module
before operating it. Read this instruction manual completely.
DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES
found throughout this publication.
NOTE
Highlights an essential operating procedure, condition, or statement.
SYMBOLS
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a
manual illustration number. It is not a part number, and is not related to the
illustration in any technical manner.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
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July 2018
SPS 4001B
ii
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-3
Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-4
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-6
COMPONENT
CHECKLIST
A typical SPS 4001B Single Probe Autocalibration Sequencer should contain
the items shown in Figure 1-1. Record the part number, serial number, and
order number for the SPS 4001B on the back cover of this manual.
NOTE
The SPS 4001B operates exactly the same with either the Oxymitter 4000
Oxygen Transmitter or the Oxymitter 5000 Oxygen Transmitter with
FOUNDATION fieldbus communications. Any references to the Oxymitter
4000 throughout this instruction manual also apply to the Oxymitter 5000.
Figure 1-1. SPS 4001B Package
2
1.
SPS 4001B
2.
Instruction Manual
1
37470004
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SPS 4001B
1-2
OVERVIEW The SPS 4001B provides the capability of performing automatic, timed or on
demand, calibrations of a single Oxymitter 4000 without sending a technician
to the probe site.
The SPS 4001B replaces the SPS 4000, a similar unit with exposed analog
devices mounted to a stainless steel support bracket. The operating
parameters of the SPS 4000 and SPS 4001B are identical. All SPS units
require additional calibration system components. These components,
available from Emerson, are listed in Table 1-1.
The SPS 4001B is fully enclosed in a NEMA cabinet suited for wall-mounting.
The enclosure provides added protection against corrosive atmospheres and
incidental impact damage.
Emerson has offered multiprobe autocalibration sequencer systems for many
years. These autocalibration systems are most cost effective for boilers and
other combustion processes that utilize many probes. Users with only one
probe per combustion process can take advantage of Emerson's
autocalibration capability with the SPS 4001B.
1-3
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SPS 4001B
SPECIFICATIONS
Specifications
SPS 4001B Assembly
Part Number
6A00175G01
Mounting Wall mount
Materials of Construction:
Enclosure Fiberglass
Manifold Aluminum with 1/4 in. NPT ports
Pneumatic tubing - Low
Pressure
Pneumatic tubing - High
Pressure
Buna N with overbraid
Impolene
Assembly hardware Galvanized and stainless steel
Humidity range 5 - 95% relative humidity, non condensing
Ambient temperature range -40° to 149°F (-40° to 60°C) with optional heater
-25° to 149°F (-5° to 60°C)
Enclosure protection NEMA 4 (IP66)
Hazardous area option
(1)
Z-purge (by owner)
Electrical entries 1/2 in. NPT (0.875 in. with gland)
Input power 90 to 250 VAC ±10%, 50/60 Hz
Power consumption 15VA maximum
External electrical noise EN 61326-1 class A
Handshake signal to/from
Oxymitter 4000
(self-powered)
Cal initiate input from control
room:
5V (5mA maximum)
Internally 5V powered
In-Cal Relay Contact
(4)(5)
5 to 30 VDC, 100 mA, Form A (SPST)
Cal Failed Relay Contact
(4)(5)
5 to 30 VDC, 100 mA, Form A (SPST)
Cabling distance between SPS
4001B and Oxymitter 4000
Piping distance between
SPS 4001B and
Oxymitter 4000
(2) (3)
Maximum 1000 ft (303 m)
Maximum 300 ft (91 m)
Instrument Air Maximum 100 psi (689 kPa)
Calibration Gases 25 psi (172 kPa)
Approximate shipping weight 10 lbs (4.5 kg)
Pollution degree 2
Overvoltage Category II
Certification General Purpose
NOTES
(1)
Hazardous area option requires the addition of a Z-purging system by the owner.
(2)
Reference air is recommended with 9 ft (2.74 m) and 12 ft (3.66 m) long probes. Reference air is also
recommended when ambient air may not contain the normal 20.95% O2, such as when the probe is
mounted into a positive pressure duct with leaks or where there is a process unit nearby with leaks.
(3)
Customer to provide piping from remote SPS 4001B to probe.
(4)
External current limiting device must be provided by customer.
(5)
If contacts are used to drive relay coils, a reverse blocking (flyback) diode must be installed on the input
to the relay coil. Relay and diode to be provided by customer.
1-4
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July 2018
SPS 4001B
Table 1-1. Calibration
Components
NOTES
1A99119G01
Two disposable calibration gas bottles - 0.4% and 8% O2, balance
nitrogen - 550 liters each
(1) (2)
1A99119G02 Two flow regulators for calibration gas bottles
1A99119G03 Bottle rack
PHYSICAL
DESCRIPTION
(1)
Calibration gas bottles cannot be shipped via airfreight.
(2)
When the bottles are used with "CALIBRATION RECOMMENDED" features, the bottles should provide
2 to 3 years of calibrations in normal service.
The main components of the SPS 4001B are illustrated in Figure 1-2.
Manifold
The manifold provides porting to and from the calibration solenoids. The
manifold ports are accessible from outside the enclosure for making piping
connections. The Oxymitter 4000 calibration gases are piped into and
sequenced through the calibration gas solenoids mounted on the manifold.
Figure 1-2. SPS 4001B Components
CALIBRATION GAS
FLOW METER
REFERENCE AIR
FLOW METER
CIRCUIT
BOARD
REFERENCE
AIR PRESSURE
REGULATOR
MANIFOLD
PRESSURE
SWITCH
CALIBRATION GAS 1
(LOW CAL GAS)
SOLENOID
CALIBRATION GAS 2
(HIGH CAL GAS)
SOLENOID
PART NUMBER DESCRIPTION
37740002
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SPS 4001B
Calibration Gas Solenoids
The solenoids sequence the calibration gases. One solenoid controls
calibration gas 1 (high calibration gas), and the other controls calibration gas
2 (low calibration gas). The solenoids activate and deactivate to allow the
calibration gases to flow between the sequencer and Oxymitter 4000.
Pressure Switch
The pressure switch detects if the pressure of a calibration gas is low, which
can be caused by an empty gas bottle, a disconnected gas line, etc.
Calibration is prohibited when calibration gas pressure is low.
Circuit Board
The circuit board converts the incoming line voltage from AC to DC for use by
the solenoids, terminations, and the programmable logic device. The power
circuit is protected by a 1.6 A, 250 V, fast acting fuse.
The board contains a programmable logic device (PLD) that has the
electronics to energize and deenergize the solenoids based on a signal from
the Oxymitter 4000.
A terminal strip provides convenient access for all signal and power user
connections.
Calibration Gas Flow Meter
The calibration gas flow meter indicates the flow rate of calibration gas flowing
to the Oxymitter 4000.
Reference Air Flow Meter
The reference air flow meter indicates the amount of reference air
continuously flowing to the Oxymitter 4000.
Pressure Regulator
The pressure regulator ensures the instrument air (reference air) flowing to
the Oxymitter 4000 is at a constant pressure [25 psi (172 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.
1-6
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SPS 4001B
THEORY OF
OPERATION
The Oxymitter 4000 is one of the few instruments found in industry that permit
the permanent piping of a calibration standard into the probe. Most
instruments measuring pressure, flow, or temperature, require that a
calibration standard be brought to the instrument or that the instrument be
taken to the calibration source in the instrument shop.
The permanent calibration gas connections allow for autocalibrations to occur
without operator intervention. The following paragraphs describe how an
Oxymitter 4000 is autocalibrated when used with the SPS 4001B.
In addition to the calibration methods available via the Oxymitter 4000
keypad, HART communicator, AMS software, or a remote contact, the SPS
4001B works in conjunction with the Oxymitter 4000's CAL RECOMMENDED
feature to perform an autocalibration.
This feature automatically performs an impedance check every hour on the
Oxymitter 4000. If a calibration is recommended and its contact output signal
is set for "handshaking" with the SPS 4001B sequencer, the Oxymitter 4000
sends a signal to the sequencer. The sequencer automatically performs a
calibration upon receiving the signal. Therefore, no human interface is
required for the automatic calibration to take place.
See Figure 1-3. When a calibration is required, the Oxymitter 4000 sends a
signal to the programmable logic device (PLD) on the interface board of the
sequencer. The PLD energizes the calibration gas 1 (high O2) solenoid.
Calibration gas 1 then flows through the sequencer to the Oxymitter 4000.
The Oxymitter 4000 measures the oxygen content of calibration gas 1 and
sends a signal to the sequencer indicating that it received the gas. When the
sequencer receives the signal, the PLD deenergizes the calibration gas 1
solenoid.
Next, the PLD energizes the calibration gas 2 (low O2) solenoid, and
calibration gas 2 then flows through the sequencer to the Oxymitter 4000. The
Oxymitter 4000 measures the oxygen content of calibration gas 2 and sends
a signal to the sequencer indicating that it received the gas. After measuring
the two calibration gases, the Oxymitter 4000 automatically makes an internal
calibration adjustment and sends the signal to the sequencer. When the
sequencer receives the signal, the PLD deenergizes the calibration gas 2
solenoid.
1-7
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SPS 4001B
SPS
4001B
REFERENCE AIR (SEE
NOTE
2)
Figure 1-3. SPS 4001B Calibration Setup
OXYMITTER 4000
(BOTTOM VIEW)
NOTES:
OXYMITTER 4000
LOGIC I/O
CHECK VALVE
(SEE NOTE 1)
1.
A CHECK VALVE IS REQUIRED AT THE
OXYMITTER 4000 (BETWEEN THE
CALIBRATION GAS FITTING AND THE
GAS LINE) TO PREVENT THE MIGRATION
OF PROCESS GASES DOWN THE
CALIBRATION GAS LINE.
2.
CLEAN, DRY INSTRUMENT AIR IS
RECOMMENDED FOR REFERENCE AIR.
NO REFERENCE AIR IS REQUIRED IF
AMBIENT AIR CONDITIONS CONTAIN
20.95% OXYGEN.
INSTRUMENT
AIR IN
(SEE NOTE 2)
CALIBRATION
GAS 1
(HIGH O2)
CALIBRATION
GAS 2
(LOW O2)
CALIBR
A
TION GAS
37740005
1-8
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SPS 4001B
Reference Manual
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July 2018
SPS 4001B
Section 2 Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-4
OVERVIEW This section describes SPS 4001B installation.
MECHANICAL
INSTALLATION
The outline drawing in Figure 2-1 shows mounting centers and clearances of
the SPS 4001B. The unit is designed to mount on a wall, bulkhead, or pipe.
Ensure the unit is installed according to the following specifications.
1.
Install the unit no further than 300 ft (91 m) from the Oxymitter 4000 and
no further than 1000 ft (303 m) from the electronics package or any
customer-supplied remote input or relay output in the control room.
2.
Locate the unit where the ambient temperature is between -25° and
149°F (-5° and 60°C) or -40° and 149°F (-40° and 60°C) with optional
heater.
Before starting to install this equipment, read the "Safety instructions for the wiring and
installation of this apparatus" in Section A: Safety Data. Failure to follow the safety
instructions could result in serious injury or death.
Secure equipment cover and ground leads after installation. Failure to secure covers and
ground leads could result in serious injury or death.
The SPS 4001B is only intended for use in general purpose, ordinary locations
(non-hazardous). Do not install the SPS4001B in areas where flammable or ignitable
substabces are present.
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July 2018
SPS 4001B
2-2
GAS CONNECTIONS Use the following procedures to connect the reference air and the calibration
gases.
Reference Air (Figure 2-1)
The Oxymitter 4000 requires a source of reference air that is constantly
20.95% O2. Clean and dry instrument air provides the most stable source of
reference air. If instrument air is unavailable, the reference air port of the
probe can be left open, permitting ambient air to passively diffuse into the
probe.
1.
Connect the instrument air supply to the INST AIR IN port of the
manifold.
2.
The pressure regulator is factory set at 25 psi (172 kPa). If necessary,
readjust by turning the knob on the top of the regulator until the desired
pressure is obtained.
3.
Next, connect the reference air from the REF GAS OUT port of the
manifold to the REF GAS port on the Oxymitter 4000.
Calibration Gas (Figure 2-1)
1.
Connect O2 calibration gas 1 (high calibration gas) to the HI GAS IN
port on the manifold. Ensure the calibration gas pressure is set at 25 psi
(172 kPa).
2.
Connect O2 calibration gas 2 (low calibration gas) to the LOW GAS IN
port on the manifold. Ensure the calibration gas pressure is set at 25 psi
(172 kPa).
3.
Connect the calibration gas from the CAL GAS OUT manifold fitting to
the check valve connected to the CAL GAS port on the Oxymitter 4000.
Do not exceed maximum pressure for instrument air. Failure to limit pressure could result in
equipment failure, serious injury or death.
Instrument air is not recommended for the high calibration gas. Do not use 100% nitrogen
as a low gas (zero gas). It is suggested that the low (zero) gas 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.
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July 2018
SPS 4001B
2-3
Figure 2-1. Installation
5-15/16
(151)
REPLACEABLE
MOUNTING FOOT
(4 PLACES)
Analytical
CONDENSATE
DISCHARGE TUBE
(FROM AIR PRESSURE
REGULATOR/FILTER)
11
(279)
NOTE: DIMENSIONS ARE IN INCHES WITH
MILLIMETERS IN PARENTHESES.
TEST GAS REF GAS INST AIR
OUT OUT IN
SIGNAL
CABLE IN
MANIFOLD
3/8 IN. (9,5 MM)
CABLE GRIPS
6-1/2
(165)
POWER
CABLE IN
LOW GAS
HI GAS
IN IN
37470007
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SPS 4001B
2-4
ELECTRICAL
CONNECTIONS
All wiring must conform to local and national codes. Use the following
procedure to connect an SPS 4001B to an Oxymitter 4000.
NOTE
Ensure the Oxymitter 4000 is set up to handshake with the sequencer by
configuring the logic I/O to mode 8. Refer to the Oxymitter 4000 Oxygen
Transmitter Instruction Manual for more information.
NOTE
To maintain proper earth grounding, ensure a positive connection exists
between the ground lug and earth. Install this wire or ground lug first.
1.
Loosen the SPS 4001B cover screws and open the cover.
2.
Route the line voltage cable into the enclosure through the rear cable
grip. Ensure adequate wire length to connect the line voltage leads per
Figure 2-2, then tighten the cable grip nut.
3.
Connect the incoming 90 to 250 VAC ±10%, 50/60 Hz line voltage leads
to the terminal strip and ground lug as indicated in Figure 2-2.
4.
Route the signal wiring cable through the front cable grip. Ensure
adequate wire length to connect all signal wires per Figure 2-2, then
tighten the cable grip nut. Use shielded twisted pair wiring. Terminate
the shield at the SPS 4001B.
Disconnect and lock out power before connecting the unit to the power supply. Failure to
lock out power could result in serious injury or death.
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) in close proximity and marked for this equipment which will
disconnect all current-carrying conductors during a fault situation. This circuit breaker
should also include a mechanically operated isolating switch. If not, then another external
means of disconnecting the supply from the equipment should be located close by. Circuit
breakers or switches must comply with recognized standards such as IEC 947.
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SPS 4001B
2-5
5.
Connect the 5V (5 mA maximum) logic I/O leads from the Oxymitter
4000 to the terminal strip as indicated in Figure 2-2. Use shielded
twisted pair wiring. Terminate the shield at the Oxymitter 4000.
6.
To set up the SPS 4001B to initiate a calibration from a remote location,
connect the 5 VDC input leads to the terminal strip as shown in
Figure 2-2.
7.
Relay output connections are available on the unit to signal when the
Oxymitter 4000 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. Connect
the relay output wires to the terminal strip as shown in Figure 2-2. Use
shielded twisted pair wiring. Terminate the shield at the SPS 4001B.
8.
Once all connections are made, close the enclosure cover and tighten
the cover screws.
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July 2018
SPS 4001B
2-6
L1
N
GROUND
NC
}
CAL
}
HA
CAL
IN C
GROUND
LUG
GND
Figure 2-2. Electrical
Connections
90 - 250 VAC,
50/60 HZ LINE
VOLTAGE INPUT
OPTIONAL
5 VDC (SELF-POWERED)
TO REMOTE MOMENTARY
CLOSURE CONTACT
INPUT CONNECTION
5 VDC (5 mA MAXIMUM)
LOGIC I/O
CONNECTION TO
OXYMITTER 4000
INIT
NDSHAKE
OPTIONAL
5 - 30 VDC TO
RELAY OUTPUT
CONNECTIONS
FAIL
AL
EARTH GROUND
CABLE SHIELDS
37740003
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July 2018
SPS 4001B
Section 3 Operation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1
Calibration Requirements . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1
Reference Air Flow Setup . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3
Calibration Gas Flow Setup . . . . . . . . . . . . . . . . . . . . . . . . page 3-3
Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3
Semi-automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . page 3-4
OVERVIEW This section specifies the requirements to set up an Oxymitter 4000
calibration and how to verify the calibration gas flow setup. It also explains the
differences between automatic and semi-automatic calibrations and how to
initiate them.
CALIBRATION
REQUIREMENTS
Calibration Gas Tanks
Two tanks of precision calibration gas mixtures are required. Recommended
calibration gases are nominally 0.4% and 8.0% oxygen in nitrogen.
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.
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