Reference Manual
00809-0100-4889, Rev AA
Rosemount™ Xi
Advanced Electronics for Zirconium Oxide Flue Gas O2 Probes
July 2018
Essential Instructions
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 people, to prevent electrical shock and personal injury.
The information contained in this document is subject to change without notice.
NOTICE
The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic License for operation with Xi Electronics. The
AMS software must be upgraded to AMS 8.0 or above.
Contact Emerson's Global Service Center (GSC) at 1-800-833-8314 to upgrade the 375 Field Communicator software to System
Software 2.0 with Graphic License.
Preface
The purpose of this manual is to provide information concerning the components,
functions, installation, and maintenance of the Xi Electronics.
Some sections may describe equipment not used in your configuration. You 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 NOTICES found throughout
this publication.
WARNING!
Highlights an operation or maintenance procedure, condition, statement, etc. that if not strictly observed, could result in injury,
death, or long-term health hazards of personnel.
CAUTION!
Highlights an operation or maintenance procedure, practice, condition, statement, etc. that if not strictly observed, could result in
damage to or destruction of equipment or loss of effectiveness.
NOTICE
Highlights an essential operating procedure, condition, or statement.
Symbols
Earth (ground) terminal
:
Protective conduit or terminal
:
Risk of electrical shock
:
Warning: Refer to Instruction Manual
:
NOTICE
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.
Overview
The Xi is specifically designed to control a zirconium oxide probe for measuring oxygen,
usually the O2 remaining from a combustion process. Call the Rosemount Customer
Support Center (CSC) to get recommendations for other oxygen probes: 800 854 8257 (US
and Canada).
The Xi electronics has several main functions:
1. Heater Control: The electronics receives a type K thermocouple input from an O2 probe and switches power on and off to
the probe's heater in order to maintain a temperature setpoint of 1357 °F (736 °C).
2. Signal Conditioning: The electronics receives the raw millivolt signal from the O2 sensing cell and then linearizes and
amplifies the signal to provide a linear 4-20 mA output signal used for recording or as in input into a DCS system for control
purposes.
3. Calibration: A bottled calibration gas of known value is typically flowed into the probe's sensor to verify that it is reading
correctly. If the signal is out of calibration, the calibration gas is used to adjust the 4-20 mA output signal. During calibration,
the Xi prompts the technician to flow two calibration gases into the probe and, with the calibration gases flowing,
automatically adjusts the O2 signal. With the addition of a Single Probe Sequencer (SPS), the Xi electronics can also switch
the calibration gases on and off.
4. Diagnostics: Multiple alarms are available for display. The alarm displays are intended to assist a technician in locating where
an instrument problem may reside.
The electronics has been verified to operate the following probes:
• Westinghouse 218 and World Class
• Rosemount Oxymitter
• Yokogawa
Technical Support Hotline
For assistance with technical problems, please call the Customer Support Center (CSC).
The CSC is staffed 24 hours a day, 7 days a week.
Phone: 1-800-433-6076, 1-440-914-1261
In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Emerson's field service throughout the U.S. and
abroad.
Phone: 1-800-654-RSMT (1-800-654-7768)
Emerson may also be reached via the Internet through email and the World Wide Web:
Email: GAS.CSC@emerson.com
World Wide Web: www.Emerson.com/RosemountGasAnalysis
Warranty
RosemountTM 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 period of one year after the date of shipment,
Rosemount 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 OR FITNESS FOR PURPOSE).
The remedy(ies) provided above shall be purchase'rs sole remedy(ies) for any 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 deterioration 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 but not manufactured by it will be subject to the same warranty as is extended to Rosemount by
the original manufacturer.
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, the sensor being supplied with ac power and reference air will not be subjected to component
deterioration.
Contents
Contents
Chapter 1 Description and specifications ........................................................................................1
1.1 Component checklist ...................................................................................................................1
1.2 System overview ..........................................................................................................................2
1.2.1 Scope ............................................................................................................................2
1.2.2 System configurations .................................................................................................. 3
1.2.3 Automatic calibration ....................................................................................................4
1.2.4 Communication options ............................................................................................... 4
1.3 Specifications .............................................................................................................................. 6
Chapter 2 Install .............................................................................................................................9
2.1 System considerations ...............................................................................................................10
2.2 Mechanical installation .............................................................................................................. 10
2.2.1 Mount .........................................................................................................................10
2.3 Electrical installation ..................................................................................................................13
2.3.1 Optional flame safety interlock ................................................................................... 16
2.3.2 Wire the traditional architecture cable connections .................................................... 17
Chapter 3 Configure .....................................................................................................................19
3.1 Verify installation .......................................................................................................................19
3.1.1 Xi configuration .......................................................................................................... 19
3.2 Set test gas values ......................................................................................................................20
3.2.1 Setting test gas values using Field Communicator .......................................................20
3.3 Alarm relay output configuration ...............................................................................................20
3.3.1 Configuring alarm relays with the Xi keypad/display ....................................................21
3.3.2 Configuring autocalibration with the Field Communicator ..........................................21
3.4 Configure analog output ............................................................................................................22
3.4.1 Configuring the analog output with the Xi keypad/display .......................................... 22
3.4.2 Configuring alarm relays with the Field Communicator ...............................................23
3.5 Autocalibration setup ................................................................................................................ 23
3.6 Optional advanced features inside the Xi ................................................................................... 23
3.6.1 Extended process temperature range to 1472 °F (800 °C) ............................................24
3.6.2 Stoichiometer ............................................................................................................. 24
3.6.3 Programmable reference ............................................................................................ 24
Chapter 4 Startup and operation .................................................................................................. 27
4.1 Overview ................................................................................................................................... 27
4.2 Startup ...................................................................................................................................... 27
4.2.1 Operation via Xi ...........................................................................................................28
4.2.2 Error conditions ...........................................................................................................28
4.2.3 Xi Controls .................................................................................................................. 28
4.2.4 Password protection ................................................................................................... 32
4.3 System parameter descriptions ................................................................................................. 33
4.4 Probe parameter descriptions ....................................................................................................36
4.5 Operation via HART/AMS ........................................................................................................... 41
4.5.1 Field communicator signal line connections ................................................................41
4.5.2 Field Communicator menu trees .................................................................................42
4.6 Offline and online operations .....................................................................................................44
4.7 Calibration - general .................................................................................................................. 45
Reference Manual i
Contents
4.8 O2 calibration ............................................................................................................................ 45
4.8.1 O2 calibration with Xi .................................................................................................. 46
4.8.2 O2 calibration with Xi and Field Communicator ........................................................... 47
4.9 D/A trim .....................................................................................................................................48
4.9.1 D/A trim with Xi ...........................................................................................................48
Chapter 5 Troubleshooting .......................................................................................................... 49
5.1 Overview of operating principles ............................................................................................... 49
5.2 General ......................................................................................................................................50
5.2.1 Grounding ...................................................................................................................50
5.2.2 Electrical noise ............................................................................................................ 50
5.2.3 Electrostatic discharge ................................................................................................51
5.3 Alarm indications .......................................................................................................................51
5.4 Identifying and correcting fault indications ................................................................................52
5.5 Calibration passes, but still reads incorrectly ..............................................................................54
5.5.1 Probe passes calibration, O2 still reads high .................................................................54
5.5.2 Probe passes calibration, O2 still reads low .................................................................. 55
5.5.3 How do I detect a plugged diffuser? ............................................................................ 55
5.5.4 Can I calibrate a badly plugged diffuser? ......................................................................55
Chapter 6 Maintenance and service ..............................................................................................57
6.1 Overview ................................................................................................................................... 57
6.2 Maintenance intervals ................................................................................................................57
6.3 Calibration .................................................................................................................................58
6.3.1 Automatic calibration ................................................................................................. 58
6.3.2 Manual calibration ...................................................................................................... 58
6.4 Replacement parts .....................................................................................................................58
6.5 Xi components replacement ......................................................................................................58
6.5.1 I/O board replacement ................................................................................................60
6.5.2 AC relay board replacement ........................................................................................64
6.5.3 Power supply board replacement ................................................................................65
6.5.4 Xi front panel replacement ..........................................................................................67
6.5.5 DR board replacement ................................................................................................ 69
Chapter 7 Replacement parts ....................................................................................................... 73
7.1 Xi electronics ............................................................................................................................. 73
7.2 Calibration components ............................................................................................................ 74
Chapter 8 Optional accessories .................................................................................................... 75
8.1 HART handheld 375/475 Field Communicator ...........................................................................75
8.2 Asset Management Solutions (AMS) .......................................................................................... 76
8.3 By-Pass Packages ....................................................................................................................... 76
8.4 Rosemount SPS 4001B Single Probe Autocalibration Sequencer ................................................77
8.5 Rosemount IMPS 4000 Intelligent Multiprobe Test Gas Sequencer ............................................ 78
8.6 O2 calibration gas ...................................................................................................................... 79
8.7 OxyBalance Display and Averaging System ................................................................................ 80
Appendices and reference
Appendix A XPS information ...........................................................................................................81
A.1 XPS equipment description ........................................................................................................81
A.1.1 Remote XPS for 44 V probes - 6A00358G01 ................................................................ 81
A.1.2 Remote XPS for 115 V probes - 6A00358G03 .............................................................. 82
ii Xi
Contents
A.1.3 Integral XPS 6A00365G01 with Xi (for 44 V probes) .................................................... 83
A.1.4 Other XPS uses ............................................................................................................83
A.2 Specifications ............................................................................................................................ 90
A.3 Recommended spare parts ........................................................................................................ 90
Appendix B Service support ............................................................................................................ 91
Reference Manual iii
Contents
iv Xi
Description and specifications
1 Description and specifications
1.1 Component checklist
A typical Rosemount O2 Combustion Flue Gas Transmitter should contain all the items
shown in Figure 1-1. A complete Oxygen Analyzer system will include some or all of the
equipment shown. However, this manual describes item H only.
Use the product matrix (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 your
options and features. Ensure the features and options specified by your order number are
on or included with the unit.
Reference Manual 1
Description and specifications
Typical system packageFigure 1-1:
A. Quick Start Guide
B. Weld plate
C. Traditional architecture cable
D. O2 probe
E. Reference Air Set (not used if SPS 4001B or IMPS 4000 is used)
F. HART® 375/475 Field Communicator package (optional)
G. Optional SPS 4001B or IMPS 4000 Autocalibration Sequencer
H. Xi Advanced Electronics
1.2
System overview
1.2.1 Scope
This Instruction Manual supplies details needed to install, start up, operate, and maintain
the Xi Electronics. Signal conditioning electronics output a 4-20 mA signal representing
the O2 value. This information, plus additional details, can be accessed with the HART
Model 375/475 Field Communicator or Asset Management Solutions (AMS) software..
2 Xi
1.2.2 System configurations
Traditional architecture, HART ,and Xi communications
Some customers prefer not to mount electronics onto the probe, so a traditional
architecture version is offered. This probe sends raw millivolt signals via a 7-conductor
cable to the Xi electronics, Figure 1-2, which does all heater control and signal conditioning
in addition to its display/keypad functions. The Xi Advanced Electronics is offered to
support direct replacement probes with either 120 volt or 44 volt heaters.
Direct replacement probe with traditional architecture electronicsFigure 1-2:
Description and specifications
O2 probe with Xi Electronics and autocalibration sequencerFigure 1-3:
Reference Manual 3
Description and specifications
1.2.3 Automatic calibration
Calibrations consist of introducing bottled gases of known value into the probe so the
electronics can make automatic adjustments to the O2 readings to match the bottled gas
value. 0.4% O2 and 8% O2 (balance nitrogen) gases are recommended. Never use nitrogen
or instrument air as calibration gases.
Flowmeters (for calibration gases) and regulators and flowmeters (for reference air) are
available as loose components, mounted into an optional manual calibration switching
panel or as a fully automated calibration system, Figure 1-3, where calibration solenoids are
switched from the Xi Electronics. See IM-106-340AC, SPS 4000B Single Probe
Autocalibration Sequencer or IM-106-400IMPS, IMPS 4000 Intelligent Multiprobe Test Gas
Sequencer, for additional details.
1.2.4 Communication options
Data communications
An operator can configure and troubleshoot the O2 probe system in one of two ways:
1. Using the Xi Advanced Electronics; the Xi carries the following optional advanced
features:
• Fully automatic calibration
• Flame safety interface
• High temperature operation [above 1292 °F (700 °C) standard temperature]
• Stoichiometer feature provides the ability to indicate O2 efficiency when the
combustion process goes into reducing conditions (0% O2).
• Programming reference provides advanced accuracy when measuring at or near
O2 level (20.95% O2).
2. Using the HART interface, the Xi's 4-20 mA output line transmits an analog signal
proportional to the oxygen level. The HART output is superimposed on the 4-20 mA
output line. This information can be accessed through the following:
• Rosemount 375/475 Field Communicator - The handheld communicator
requires Device Description (DD) software specific to the Xi. The DD software will
be supplied with many 375/475 units, but can also be programmed into existing
units at most Emerson service offices. See Chapter 4 for additional information.
• Personal computer (PC) - The use of a personal computer requires AMS software
available from Emerson.
• Delta V and Ovation Distributed Control System (DCS) with AMS-inside
capability.
NOTICE
The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic
License for operation with the Xi. The AMS software must be upgraded to AMS 8.0 or
above.
Contact Emerson's Global Service Center (GSC) at 1-800-833-814 to upgrade the 375
Field Communicator software to System Software 2.0 with Graphic License.
4 Xi
Description and specifications
3. The Xi can also transmit HART information wirelessly via a wireless THUM Adapter,
Figure 1-4. The THUM Adapter threads into the Xi conduit ports and converts the
4-20 mA O2 signal to a wireless protocol. All other HART information is also
transmitted.
In addition to the wireless THUM Adapter, a hard-wire connection of the 4-20 mA
signal to the DCS may be used at the same time. More detailed information
regarding the application of the THUM Adapter is available in Product Data Sheet
00813-0100-4075. Note that the THUM Adapter may also be used with the
Oxymitter, mounted integral to the probe, or to the Oxymitter remote electronics.
Wireless THUM AdapterFigure 1-4:
Optional OxyBalance display and averaging system
Receives up to eight 4-20 mA signals from individual Xi units. Trends individual outputs
and calculates four programmable averages as additional 4-20 mA outputs. OxyBalance
graphic displays are shown in Figure 1-5. See IM-106-4050, OxyBalance Oxygen Display and
Averaging System, for additional details.
Reference Manual 5
Description and specifications
OxyBalance displaysFigure 1-5:
1.3 Specifications
SpecificationsTable 1-1:
Measurement specifications
Net O2 range 0 to 50% O2 user scalable
-2 to 50% O2 user scalable with stoichiometer
Lowest detectable limit 0.01% O
Signal stability ±0.03% O
Accuracy in reducing conditions ±10% of reading or 0.1% O
System responses in reducing conditions Going from oxidizing to reducing -T90 in 120 seconds
Going from reducing to oxidizing -T90 in 30 seconds
Ambient temperature effect on Xi 4-20 mA signal Less than 0.0025% O2 per degree Celsius
Environmental specifications
Xi Advanced Electronics Type 4X/IP66 polycarbonate material
Ambient temperature limits -4 to 122 °F (-20 to 50 °C)
-4 to 158 °F (-20 to 70 °C) as measured by electronics
Xi LCD display: ambient temperature limits -4 to 131 °F (-20 to 55 °C)
2
2
2
6 Xi
Description and specifications
Specifications (continued)Table 1-1:
General purpose certifications
Installation specifications
Mounting Panel, wall, or pipe
Reference air 0.5 scfh (0.25 l/min), clean, dry, instrument-quality air
(20.95% O2), regulated to 5 psi (34 kPa)
Calibration Semi-automatic or automatic
Cal gases 0.4% O2 and 8% O2, balance N
Traditional architecture cable 200 ft (61 m) maximum length
Transmitter electrical power 12 - 24 Vdc (loop-powered from control room or Xi)
Electrical power for Xi 100 - 240 Vac ±10%, 50/60 Hz
Power consumption of Xi 12 VA maximum or 776 VA maximum with traditional arch-
tecture, 120 V probes
450 VA maximum with traditional architecture, 44 V
probes
Alarm relay outputs Two provided - 2 Amperes, 30 Vdc, Form-C
Optional loss of flame input Internally powered input to remove heater power actuated
via dry contact output from user's flame scanner
Emerson has satisfied all obligations from the European legislation to harmonize the product requirements in Europe.
All static performance characteristics are with operating
variables constant. Specifications subject to change without notice.
2
Product matrix, Xi advanced electronicsTable 1-2:
Xi Xi Advanced Electronics
Code Remote type
01 Single channel
(1)
02 Single channel, accepting a loss-of-flame input to remove heater power with flame
status relay
03 Dual channel
(1)
(1)
04 Single channel traditional architecture for 120 V probes
05 Single channel traditional architecture for 44 V probes
Code Mounting
00 No hardware
01 Panel mount kit with gasket
02 2 in. pipe/wall mount kit
Reference Manual 7
Description and specifications
Code Cable
00 No cable
10 20 ft (6 m) cable
11 40 ft (12 m) cable
12 60 ft (18 m cable)
13 80 ft (24 m cable)
14 100 ft (30 m) cable
15 150 ft (45 m) cable
16 200 ft (60 m) cable
Code Stoichiometer function
00 None
01 Single channel (stoichiometer cell also required in probe)
02 Dual channel (stoichiometer cell also required in probe)
Code Programmable reference function
00 None
01 Single channel
02 Dual channel
Product matrix, Xi advanced electronics (continued)Table 1-2:
Code 800 deg C process function
00 None
01 Single channel
02 Dual channel
1. Requires XPS transmitter, P/N 6A00358G03
Note
All static performance characteristics are with operating variables constant. Specifications subject to
change without notice.
8 Xi
2 Install
WARNING!
Before installing this equipment, read Safety Instructions. Failure to follow safety instructions
could result in serious injury or death.
WARNING!
ELECTRICAL HAZARD
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.
WARNING!
HAZARDOUS AREAS
The Xi Advanced Electronics can be installed in general purpose areas only. Do not install the Xi
in hazardous areas or in the vicinity of flammable liquids.
Install
WARNING!
ELECTRICAL HAZARD
If external loop power is used, the power supply must be a safety extra low voltage (SELV)
type.
NOTICE
All unused ports on the probe housing and Xi enclosure should be plugged with a suitable
filling.
Reference Manual 9
Install
2.1 System considerations
A typical system installation for an Xi or O2 probe is shown in Figure 2-1.
Typical system installationFigure 2-1:
A. Gases
B. Duct
C. Adapter plate and flange
D. Instrument air supply (reference air)
E. Pressure regulator
F. Flowmeter
G. Calibration gas
H. Line voltage
I. 4 to 20 mA signal
J. Rosemount 6888Xi Advanced Electronics (optional)
K. Stack
2.2
Mechanical installation
2.2.1 Mount
The Xi Advanced Electronics is available in a panel mounting, wall mounting, or pipe
mounting configuration.
10 Xi
Install
Refer to Figure 2-2 or Figure 2-3 for the panel, wall, or pipe mounting details.
Procedure
1. Ensure all components are available to install the Xi.
2. Select a mounting location near or removed from the O2 probe.
Consider the temperature limitations of the Xi (see Section 1.3) when selecting the
mounting location.
3. Mount the Xi at a height convenient for viewing and operating the interface.
Approximately 5 ft (1.5 m) is recommended.
4. The keypad window on the Xi may have interior and exterior protective membranes.
Remove the protective membranes prior to use of the Xi enclosure.
NOTICE
Failure to remove the protective membranes may cause the display to appear distorted.
The membrane may be difficult or impossible to remove after extended use at elevated
temperatures.
Reference Manual 11
Install
Xi Advanced Electronics - panel mounting detailsFigure 2-2:
12 Xi
Install
Xi Advanced Electronics - wall/surface and pipe mounting detailsFigure 2-3:
2.3 Electrical installation
All wiring must conform to local and national codes. Multiple wiring diagrams are shown in
this section. Always refer to the diagrams that apply to your transmitter configuration and
disregard all other wiring diagrams.
Reference Manual 13
Install
WARNING!
ELECTRIC SHOCK
Disconnect and lock out power before connecting the power supply. Failure to lock out power
could result in serious injury or death.
WARNING!
ELECTRIC SHOCK
Install all protective covers and safety ground leads after installation. Failure to install covers
and ground leads could result in serious injury or death.
WARNING!
ELECTRIC SHOCK
To meet the safety requirements of IEC 1010 (EC requirement) and ensure safe operation of this
equipment, connection to the main electrical power supply must be made through a circuit
breaker (min 10 A) which will disconnect all current-carrying conductors during a fault
situation. This circuit breaker should also include a mechanically operated isolating switch. If it
does not, locate another external means of disconnecting the power supply close by. Circuit
breakers or switches must comply with a recognized standard such as IEC 947.
Note
Line, voltage, signal, and relay wiring must be rated for at least 105 °C (221 °F).
NOTICE
If a metal conduit is used with the Xi, the conduit should be reliably bonded to protective earth.
The grounding plate inside the Xi is not bounded to PE and does not provide adequate
grounding.
1. Remove cover screws from the front cover of the Xi. Swing down the front cover of
the interface box.
2. Pull out the I/O board on the right-hand side of the card rack inside the Xi. If your
system is configured to operate two transmitter probes, there are two I/O interface
boards.
3. See Figure 2-4. Connect the 4-20 mA signal wires at J4 of the I/O board. Attach the
supplied ferrite clamp over the 4-20 mA OUT wires that extend past the shield.
NOTICE
Installation of the ferrite clamp over the 4-20 mA OUT wires is required for compliance
with the European EMC directive.
14 Xi
Install
Signal connections at I/O boardFigure 2-4:
Alarm indicator relay terminalsFigure 2-5:
4. Terminate the shield of the 4-20 mA signal wires at the designated ground terminal
of the Xi. Do not allow bare shield wires to contact the circuit boards. Insulate the
shield wires prior to termination.
5. Connect the signal wires from the SPS or IMPS (if used) to the applicable terminals of
J3. Refer to the SPS or IMPS instruction manual for wiring details.
6. Connect the signal wires for the flame status input (if used) to the applicable
terminals of J2. The flame status sensing device is supplied by the customer. Refer to
the applicable OEM documents for signal wiring details.
7. Connect the customer's alarm indicator devices to the alarm indicator relay
terminals. See Figure 2-5 for the alarm indicator relay terminals.
8. Reinstall the I/O board in the card rack of the Xi.
Reference Manual 15
Install
Power connections - Xi Advanced ElectronicsFigure 2-6:
2.3.1
9. If your system is configured for two channel operation, repeat steps 2 through 7 to
connect the other signal wires.
10. Remove the connector from the power supply board located on the left-hand side of
the card rack inside the Xi.
11. See Figure 2-6. Connect the line, or L1, wire to the L1 terminal and the neutral, or L2,
wire to the N terminal.
12. Reinstall the power supply connector in the power supply board.
13. Close and fasten the Xi cover.
Optional flame safety interlock
A flame safety interlock by Emerson is available for the heater power disconnect whenever
there is a loss of the process flame or a heater runaway condition (heater overtemperature) in the O2 probe. A simplified wiring diagram for the flame safety interlock is
shown in Figure 2-7. The input is internally powered by the Xi and is actuated via a dry
contact output from the user's flame scanner. A closed contact indicates a flame is
present. An open contact indicates a loss of flame.
16 Xi
Install
Flame safety interlock - wiring diagramFigure 2-7:
2.3.2 Wire the traditional architecture cable connections
A traditional architecture configuration is used to provide for remote location of the
transmitter electronics. All electronics are housed inside the Rosemount 6888Xi. A multiconductor power/signal cable connects between the probe and the Rosemount 6888Xi.
Use the following procedure to connect the traditional architecture probe to the
Rosemount 6888Xi.
NOTICE
The traditional architecture cable is provided at the specified length and is ready for
installation. The cable glands must be properly terminated to maintain EMC/EMI noise
protection.
Procedure
1. Run the 7-conductor cable between the traditional architecture probe and the
installation site for the Rosemount 6888Xi. Use new cable conduit or trough as
needed.
2. Install the cable and lead wires to the probe per manufacturer's instructions.
3. Install the cable at the probe housing and at the Rosemount 6888Xi enclosure
according to the following procedure:
a. Unscrew the locking nut from the gland assembly and slide the locking nut back
along the cable.
b. Pull the gland body away from the plastic insert.
Use care not to damage the cable shield braid.
Reference Manual 17
Install
c. Insert the cable wires into the proper entry port in either the probe housing or
the Rosemount 6888Xi enclosure.
d. At the probe housing, apply Teflon® tape or similar sealing compound to the
tapered pipe threads. Thread the gland body into the probe housing until
properly seated.
e. At the Rosemount 6888Xi enclosure, insert the gland body into the left front
cable port from the inside of the enclosure. Use the rubber O-ring provided to
seal the cable port.
f. Ensure the cable shield braid is evenly formed over the gray insert.
When properly formed, the braid should be evenly spaced around the
circumference of the insert and not extend beyond the narrow diameter portion.
g. Carefully press the gray insert into the gland body. The grooves on the insert
should align with similar grooves inside the gland body. Press the insert in until it
bottoms out in the gland body.
h. Slide the locking nut up and thread it onto the gland body. Tighten the locking
nut so the rubber grommet inside the plastic insert compresses against the cable
wall to provide an environmental seal.
4. At the Rosemount 6888Xi, connect the cable leads to the connectors on the
transmitter I/O board.
18 Xi
3 Configure
3.1 Verify installation
WARNING!
ELECTRIC SHOCK
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.
WARNING!
ELECTRIC SHOCK
If external loop power is used, the power supply must be a safety extra low voltage (SELV)
type.
Configure
3.1.1 Xi configuration
Refer to Figure 3-1 for the configuration of jumpers JP1 through JP8. The jumper
configuration for your I/O board depends on the system design and system components
used in your installation.
The setting of switch SW4 and the configuration of jumpers JP1 through JP8 must be
verified on the I/O board in the Xi. All four dip switches on switch SW4 must be set to the
Off position, as shown.
I/O board jumper configurationFigure 3-1:
Reference Manual 19
Configure
3.2 Set test gas values
Use a Field Communicator or the Xi to set test gas values for calibration.
An Xi shipped from the factory has test gas values for low and high set to 0.4% and 8%
respectively. This same process must be performed any time a replacement transmitter
board, I/O board, or DR board is installed.
Setting test gas values using Xi display/keypad
Procedure
1. Press the MENU button once.
2. From the main menu, select PROBE 1.
3. From PROBE 1, select DETAILED SETUP.
4. From the DETAILED SETUP menu, select CAL SETUP.
5. From CAL SETUP, select Cal Gas 1. Enter the percent O2 used for the low O2 test gas.
6. From CAL SETUP, select Cal Gas 2. Enter the percent O2 used for the high O2 test gas.
7. Press the Left arrow key several times to return to the main menu.
8. Repeat steps 2 through 6 for PROBE 2 if configured for dual channel.
3.2.1 Setting test gas values using Field Communicator
1. Use the Field Communicator software to access the HART menu.
2. From the DEVICE SETUP menu, select DETAILED SETUP.
3. From the DETAILED SETUP menu, select CAL SETUP.
4. From CAL SETUP, select Cal Gas 1. Enter the percent O2 used for the low O2 test gas.
5. From CAL SETUP, select Cal Gas 2. Enter the percent O2 used for the high O2 test gas.
3.3
Alarm relay output configuration
The Xi has two dry contact Form-C alarm relay output signals that can be configured in
eight different modes through the Xi keypad display or the 375/475 Field Communicator.
A list of possible configurations is shown in Table 3-1. Each alarm relay can be configured
separately.
If the Xi is configured with the optional flame safety interlock, Alarm 2 is configured with
Heater Relay and prewired to the AC relay board. In this condition, the relay configuration
cannot be changed to any other setting. If the Xi is not configured with the optional flame
safety interlock, Heater Relay is not valid and cannot be chosen for Alarm 2.
20 Xi
Configure
Alarm relay output configurationsTable 3-1:
Mode Configuration
No alarm
Unit alarm The output is configured for a unit alarm.
Low O2 alarm The output is configured for a low O2 alarm.
Low O2/unit alm The output is configured for a unit alarm and a low O2 alarm.
Cal recommended The output is configured for a calibration recommended display.
Cal rec/unit alm
Low O2/cal rec The output is configured for a low O2 alarm and a calibration recom-
Low O2/unit/cal rec The output is configured for a low O2 alarm, a unit alarm, and a cali-
Heater relay The output is configured for flame safety interlock.
(1) The default configuration for Alarm 2
(2) The default configuration for Alarm 1
(1)
(2)
The output is not configured for any alarm condition.
The output is configured for a unit alarm and a calibration recommended display.
mended display.
bration recommended display.
3.3.1 Configuring alarm relays with the Xi keypad/display
1. Press the MENU button once.
2. From the main menu, select PROBE 1.
3. From PROBE 1, select DETAILED SETUP.
4. From the DETAILED SETUP menu, select ALARM RELAY.
5. From ALARM RELAY, select as follows:
• Alm Relay1 - Alarm 1 mode
• Alm Relay2 - Alarm 2 mode
• Low O2 Alm SP - Low O2 alarm setpoint
• High Temp Alm SP - High temperature alarm setpoint
6. Press the Left arrow key several times to return to the main menu.
7. Repeat steps 2 through 6 for PROBE 2 if configured for dual channel.
3.3.2
Configuring autocalibration with the Field Communicator
1. Use the 375/475 Field Communicator software to access the HART menu.
2. From the DEVICE SETUP menu, select DETAILED SETUP.
3. From the DETAILED SETUP menu, select CAL SETUP.
4. From CAL SETUP, select Auto Cal.
5. Press the Right arrow key to change the state from NO to YES.
Reference Manual 21
Configure
3.4 Configure analog output
The analog output signal from the Rosemount 6888A can be configured for the 4-20 mA
range and fault condition. A separate configuration is set up when the Rosemount 6888A
is used with the optional Rosemount 6888Xi Advanced Electronics. When the Rosemount
6888A is used without the Rosemount 6888Xi, this parameter must be set to NO. If it is set
to YES and a Rosemount 6888Xi is not connected, the Rosemount 6888A triggers an alarm
and forces the analog output to the fault level. If the Rosemount 6888A is used later with a
Rosemount 6888Xi, the Rosemount 6888Xi automatically sets this parameter to YES.
An Rosemount 6888A shipped from the output has the analog outputs set to 4 to 20 mA
range with a 3.5 mA alarm level. You must complete the same process any time
transmitter board is replaced.
1. Use the 375/475 Field Communicator to access the main HART menu.
2. From the main menu, select CONFIGURE.
3. From the CONFIGURE menu, select MANUAL SETUP.
4. From the MANUAL SETUP menu, select ANALOG OUTPUT.
5. From the ANALOG OUTPUT menu, select from the following parameters; then press
ENTER.
• O2 LRV: O2 value at lower analog output value (0% at 4 mA, non-configurable)
• O2 URV: O2 value at upper analog output value (50% max at 20 mA)
• Output Range: Range of analog output (4-20 mA, non-configurable)
• Alarm level: O2 alarm level (3.5 mA or 21.1 mA)
• Xi Mode: Selects whether or not the Rosemount 6888A is used with a Rosemount
6888Xi (should always be set to NO for a stand-alone Rosemount 6888A)
3.4.1
6. Use the stylus to enter the value; then press ENTER when finished.
7. Use the stylus to select SEND to update the Rosemount 6888A.
Configuring the analog output with the Xi keypad/ display
1. Press the MENU button once.
2. From the main menu, select PROBE 1.
3. From PROBE 1, select DETAILED SETUP.
4. From the DETAILED SETUP menu, select ANALOG OUTPUT.
5. From ANALOG OUTPUT, select the following parameters:
• O2 LRV - O2 value at the lower analog output value (0 mA or 4 mA)
• O2 URV - O2 value at the upper analog output value (20 mA)
• AO Range - Range of the analog output (0-20 mA or 4-20 mA)
• Signal Alarm Level - O2 alarm level (3.5 mA or 21.1 mA)
22 Xi
Configure
3.4.2 Configuring alarm relays with the Field Communicator
1. Use the 375/475 Field Communicator software to access the HART menu.
2. From the DEVICE SETUP menu, select DETAILED SETUP.
3. From the DETAILED SETUP menu, select ALARM RELAY.
4. From ALARM RELAY, select as follows:
• Alm Relay1 - Alarm 1 mode
• Alm Relay2 - Alarm 2 mode
• Low O2 Alm SP - Low O2 alarm setpoint
• High Temp Alm SP - High temperature alarm setpoint
5. From CAL SETUP, select Cal Gas 2. Enter the percent O2 used for the high O2 test gas.
3.5 Autocalibration setup
If autocalibration is desired, the Xi must be used with either an SPS 4001B or IMPS 4000.
The Xi must be properly configured before autocalibration can take place. Refer to the
applicable SPS 4001B or IMPS 4000 instruction manual for details on performing
autocalibration. Refer to Chapter 4 for details on manual calibration procedures.
3.6
An Xi is shipped from the factory without autocalibration configured. This same process
must be performed any time a replacement I/O board is installed.
Optional advanced features inside the Xi
Advanced features available inside the Xi are typically ordered as part of the initial
package. However, these advanced features are also available for field retrofit.
An Xi is shipped from the factory with the optional enhanced software features enabled
based on the configuration.
WARNING!
The I/O board is shipped from the factory without any of the enhanced software features
activated. These features must be activated once the new board has been installed and before
the remote interface is put into service.
WARNING!
If the existing I/O board has been operated with the stoichiometric enhanced software feature,
this feature must be activated in the new board before the remote interface is put back into
service. Failure to do so will cause a false analog output signal to the DCS.
Reference Manual 23
Configure
NOTICE
For enhanced software feature option upgrades or to enable the feature to duplicate the
existing configuration, contact Emerson at 1-800-433-6076. Reference the following:
• 6A00269G01: Enhanced software option upgrade, stoichiometric function
• 6A00269G02: Enhanced software option upgrade, programmable reference function
• 6A00269G03: Enhanced software option upgrade, 800 °C process function
3.6.1 Extended process temperature range to 1472 °F (800 °C)
The Oxygen Analyzer employs a heater and thermacouple to maintain a temperature
setpoint at 1357 °F (736 °C). Temperature control is maintained within ±1 °C to process
temperatures of about 1300 °F (705 °C). This is satisfactory for most applications, but
excursions to higher temperatures can occur in some processes. In these instances, the
heater is turned off and the process temperature is used to heat the sensing cell.
The oxygen reading is adjusted immediately to compensate for the varying process
temperatures. Cell life will be reduced by continuous operation at temperatures above
1300 °F (705 °C). If process temperatures are expected to be continuously above 1300 °F
(705 °C), Emerson recommends the use of an optional bypass or probe mounting jacket
accessory. The extended temperature range feature is selected in the Xi product matrix,
but may not be purchased as a field retrofit.
3.6.2
3.6.3
Stoichiometer
Process upsets can sometimes cause a combustion process to go into sub-stoichiometric
or reducing conditions. The oxygen readings from one or more probes may decline all the
way to zero. The stoichiometer cell will measure the amount of oxygen deficiency during
these reducing conditions. The trends in your DCS can be set up for a lower range limit of
-1 or -2% oxygen to depict the level of oxygen deficiency.
You can see if your control recovery actions are having the desired effect. These types of
events do not occur frequently, but knowing the parameters of the situation prevents
over-correcting while coming out of the reducing condition. The stoichiometer feature
requires purchasing the acid resistant stoichiometer cell and the stoichiometer feature
inside the Xi.
NOTICE
Make sure the DCS is configured for the same range as the Xi. For instance: -1% O2 to 10% O2.
Programmable reference
The zirconium oxide sensing technology has historically measured process oxygen by
using ambient or instrument air as a reference (20.95% oxygen). The sensor develops most
of its signal at the low oxygen levels typically found in combustion flue gases (2 to 4%
oxygen) and is most accurate at these levels. When measuring near 20.95% O2, the sensor
develops only a few millivolts of signal, and accuracy degrades.
24 Xi
Configure
The programmable reference feature permits you to use a bottled reference gas of low
oxygen value (0.4% oxygen recommended). When measuring at or near 21% oxygen, a
strong negative oxygen signal results with much improved accuracy. A bottle of reference
gas typically lasts about a month at the low flows required. Typical applications would be:
• Flue gas recirculation - controlling the mixing of flue gases into the burner windbox
ahead of the burner to reduce NOx emissions.
• Moisture monitoring - measuring the amount of moisture coming off of industrial
dryers by noting that the dilution effect water vapor has on the normal 20.95%
ambient drying air (non-combusion drying processes only).
• Enriched oxygen concentration - pure oxygen is sometimes mixed in with the
combustion air to increase heat at the flame. This is used in steel and other metals
reduction processes and in some catalyst regenerators.
Reference Manual 25
Configure
26 Xi
4 Startup and operation
4.1 Overview
Interface to the Xi for setup, calibration, and diagnostics can be via a 375/475 Field
Communicator or Asset Management System.
Setup, calibration, and diagnostic operations differ depending on the selected interface for
communications with the transmitter.
4.2 Startup
The O2 probe takes approximately 45 minutes to warm up to the 736 °C (1357 °F) heater
setpoint. The 4-20 mA signal remains at a default value of 3.5 mA through this warmup
period. Once warm, the O2 reads oxygen, and the 4-20 mA signal's reading is based on the
default range of 0-10% O2.
Startup and operation
NOTICE
The Xi offers optional advanced features, such as elevated process temperature capability to
1472 °F (800 °C), autocalibration via an SPS solenoid vox, a stoichiometer feature for indicating
the level of oxygen defiency in reducing conditions, and programmable reference to enhance
accuracy at near ambient levels of O2.
Reference Manual 27
Startup and operation
Xi display (typical)Figure 4-1:
4.2.1 Operation via Xi
The following procedures describe operations using the Xi to set up and calibrate the
system. Additional operating instructions are included in the SPS 4001B or IMPS 4000
instruction manual, if applicable to your system.
4.2.2
4.2.3
Error conditions
If there is an error condition at startup, an alarm message is displayed. Refer to Chapter 5 to
determine the cause of the error. Clear the error and cycle power. The %O2 and
temperature display should return without the alarm message.
Xi Controls
The Xi can be used to change the software and alarm settings, to adjust the high and low
gas settings, and to initiate the calibration sequence. Refer to the following control
descriptions. Use the control keys on the front panel of the Xi (Figure 4-1) to navigate and
edit the Xi menu (Figure 4-2).
• MENU toggles between three main menu options: System, Probe1, and Probe2 (if
available). The top level of the selected main menu is displayed.
• DIAG toggles between the Alarms list of the three main menus. All faults and
warnings related to the selected main menu device are displayed.
• ENTER saves newly entered data and returns you to the previous menu level.
28 Xi
Startup and operation
• EXIT returns you to the previous menu level without saving newly entered data.
When navigating the menu tree, pressing EXIT returns you to the main menu.
• Up/Down keys scroll up and down through menu items. During data entry, the Up/
Down keys increment and decrement the data values.
• Left arrow key returns you to the previous menu level. During data entry, the Left
arrow key moves the cursor one digit to the left.
• Right arrow key advances you to the next menu level and, when a menu item is
highlighted, selects the item from a list of menu options. During data entry, the
Right arrow key moves the cursor one digit to the right.
Reference Manual 29
Startup and operation
Xi menuFigure 4-2:
30 Xi
Startup and operation
Reference Manual 31
Startup and operation
4.2.4 Password protection
Beginning with Xi system software version 1.05 or higher, the main display and diagnostic
screens of the Xi can be viewed at any time, but further access and unauthorized
configuration changes can be prevented by enabling a password protection feature.
However, the Xi is shipped with password protection disabled.
Password protection can be enabled by selecting System Main Menu > Configure > LCD >
Enable Password (see Figure 4-2).
32 Xi
The factory default upon enabling the password protection is ROSE, but the password can
consist of any 4 alpha/numeric characters.
If you forget the password, call Rosemount technical support at 800-433-6076 to gain
access to a master password.
A Lock icon is displayed at the top right corner of the main display when password
protection is in effect.
The password protection relocks itself after a certain number of seconds with no button
pushes (defined as revert time in the same LCD setup menu). You can also force the front
panel to be locked by selecting System Main Menu > Log Off. The Log Off selection
performs on function if the password feature is disabled.
The Xi has a Reset function that reestablishes all factory default conditions, including the
password protection feature, i.e., the password protection falls back to a disabled
condition after a reset.
4.3 System parameter descriptions
Startup and operation
Among the parameters available through the Xi and 375/475 Field Communicator menus
are a number of system parameters. The system parameters define variables that configure
the Xi in the transmitter system. System parameters are described in the following table.
System parametersTable 4-1:
CPU Parameter name Units Parameter description
Y Version --- Software version number for the CPU
board
Y Build Num --- Software build number for the CPU
board
Y Comm Status --- Communication status between the
CPU and I/O boards
Y Restart Cntr --- Software restarts counter for the CPU
board
N Pol Addr --- Polling address - address used to identi-
fy a field device; changeable by user
N Serial Number --- I/O board serial number
N Features --- Available advanced software features
for the I/O board.
ON: feature supported.
OFF: feature not supported.
N EE Erase Count --- This is for nonvolatile memory diagnos-
tic only.
Reference Manual 33
Startup and operation
System parameters (continued)Table 4-1:
CPU Parameter name Units Parameter description
Y Num Probe --- Number of probes configuration:
If set to 1, use One Probe configuration
for the main display.
If set to 2, use Two Probes configuration
for the main display.
Y Probe Sel --- This parameter is applicable only if the
Num Probe configuration is set to 2. It defines which probe is to be displayed.
Y Probe 1 Enable --- Probe 1 state. If enabled, the probe
menu will be displayed; otherwise it will
not be displayed. (No, Yes)
Y Probe 2 Enable --- Probe 2 state. If enabled, the probe
menu will be displayed; otherwise it will
not be displayed (No,Yes)
Y LineX Probe --- Probe number for line x. (1, 2)
Y Line 1 Data --- Main display, line 1 data; 0 displays PV
(O2), 1 displays SV (O2 temp)
Y Line 2 Data --- Main display, line 1 data; 0 displays PV
(O2), 1 displays SV (O2 temp)
Y Line 3 DataL --- Main display, line 3 left hand side data:
0 displays PV (O2)
1 displays SV (O2 temp)
2 displays TV (cell imp)
3 displays 4 V (cell mV)
4 displays CJC temp
5 displays AO
6 displays OP mode
7 displays Tag
Y Line 3 DataR --- Main display, line 3 right hand side data
0 displays PV (O2)
1 displays SV (O2 temp)
2 displays TV (cell imp)
3 displays 4 V (cell mV)
4 displays CJC temp
5 displays AO
6 displays OP mode
7 displays Tag
34 Xi
Startup and operation
System parameters (continued)Table 4-1:
CPU Parameter name Units Parameter description
Y Line 4 DataL --- Main display, line 4 left hand side data
0 displays PV (O2)
1 displays SV (O2 temp)
2 displays TV (cell imp)
3 displays 4 V (cell mV)
4 displays CJC temp
5 displays AO
6 displays OP mode
7 displays Tag
Y Line 4 DataR --- Main display, line 4 right hand side data
0 displays PV (O2)
1 displays SV (O2 temp)
2 displays TV (cell imp)
3 displays 4 V (cell mV)
4 displays CJC temp
5 displays AO
6 displays OP mode
7 displays Tag
Y Revert time min Xi display reverts to main display time.
Also locks screen if password protection
is enabled.
Y Language --- 0 displays English
1 displays Spanish
2 displays German
Y Contrast --- Display contrast (120 to 200)
Y Alarms --- See Chapter 5
Y Password --- Security password
Y Enable password --- Enables/disables security password pro-
tection
Reference Manual 35
Startup and operation
4.4 Probe parameter descriptions
Among the parameters available through the Xi and 375/475 Field Communicator menus
are a number of Probe Parameters. The probe parameters define variables that configure a
specific probe in the transmitter system. Probe parameters are described in the following
table:
Probe parametersTable 4-2:
TX I/O Parameter name Units Parameter description
Y Y O2 % Current oxygen concentra-
tion value (O2%). The value
should reflect the last good
O2 value if it is in the Lock
state during calibration.
Y Y O2 Temp ° C Current O2 sensor tempera-
ture.
Y Y CJC Temp ° C Current cold junction tem-
perature.
N Y Elec Temp ° C Current electronic tempera-
ture measured at the I/O
board.
Y Y O2 Cell mV Raw mV value for ZrO2 sen-
sor.
N Y TC Volt mV O2 T/C voltage.
Y Y Cell Imp Ohm Cell impedance/sensor re-
sistance measured.
Y Y Htr Volt Volt Heater voltage
Y Y CPU Volt Volt Transmitter CPU voltage.
Y Y O2 AO mA Analog output value repre-
sents the O2 concentration
measurement.
N Y O2 AO% % O2 analog output percent-
age for O2 AO
Y Y O2 Temp Max ° C This is the highest O2 sensor
temperature reached since
last reset.
Y Y CJC Temp Max ° C This is the highest tempera-
ture reached at the cold
junction since last reset.
N Y Elec Temp Max ° C This is the highest tempera-
ture reached at the I/O board
since last reset.
Y Y Htr Volt Max ° C This is the highest heater
voltage reached since last reset.
36 Xi
Startup and operation
Probe parameters (continued)Table 4-2:
TX I/O Parameter name Units Parameter description
Y Y Htr Duty Cycle --- O2 heater duty cycle. Value
between 0 and 1.
Y Y PID SP ° C PID temperature set point.
Y Y Htr Ramp Rate ° C/s Heater ramp rate calculated
in degree C per second.
N Y Flame Stat In --- Flame input state. (OFF/ON)
N Y SPS/IMPS In --- SPS/IMPS input state. (OFF/
ON)
N Y SPS/IMPS out --- SPS/IMPS output state. (OFF/
ON)
N Y Alm Relay 1 Out --- Alarm Relay 1 output state.
N Y Alarm Relay 2 Out --- Alarm Relay 2 output state.
(OFF/ON)
Y Y OP Mode --- Device operating mode: PO
= Power up; WU = Warm up
(analog output is railed); NM
= Normal operation; CA =
Calibrating (analog output
can be tracking or locked at
last good value based on AO
Tracks configuration; AL =
Alarm detected (recoverable); SF=Alarm detected
(non-recoverable)
Y Y Tag --- Device tag
Y Y Device ID --- Unique device ID number
(HART)
Y Y PV is --- Primary variable assignment
(HART)
Y Y SY is --- Secondary variable assign-
ment (HART)
Y Y TY is --- Third variable assignment
(HART)
Y Y QV is --- Fourth variable assignment
(HART)
Y Y Cal Slope mV/Dec Current calibration slope.
This is the slope value that
was calculated as a result of
the last successful calibration.
Reference Manual 37
Startup and operation
Probe parameters (continued)Table 4-2:
TX I/O Parameter name Units Parameter description
Y Y Cal Const mV Current calibration constant.
This is the constant value
that was calculated as a result of the last successful calibration.
Y Y Cal Imp Ohm Cell impedance. This is the
sensor resistance that was
calculated as a result of the
last successful calibration.
N Y Prev Slope mv/Dec Previous calibration slope.
There are ten calibration results. 1 is the most recent,
and 10 is the least recent calibration slope.
N Y Prev Const mV Previous calibration con-
stant. There are ten calibration results. 1 is the most recent, and 10 is the least recent calibration constant.
N Y Prev Cal Imp Ohm Previous cell impedance.
This is the sensor resistance
that was calculated as a result of the previous successful calibration. There are ten
calibration results. Index 1 is
the most recent, and Index
10 is the least recent sensor
resistance measured.
N Y Failed Slope mV/Dec Failed calibration slope.
N Y Failed Const mV Failed calibration constant.
Y Y Cal Result mV Calibration result.
N Y Delta Imp --- Delta impedance since last
calibration.
N Y Cal Step --- This represents the step the
calibration cycle is in.
N Y Time remain sec Time remaining in the
present calibration cycle
state.
Y Y O2 slope mV/Dec O2 slope. This is the slope
value that will be used to calculate O2.
Y Y O2 Const mV O2 constant. This is the con-
stant value that will be used
to calculate O2.
38 Xi
Startup and operation
Probe parameters (continued)Table 4-2:
TX I/O Parameter name Units Parameter description
N Y T90 filter sec Analog output T90 time. It
represents the time to take a
step change in oxygen to
reach 90% of the final value
at the filter output.
N Y O2 Cell Ref % O2 sensor reference gas per-
centage. It allows a sensor
reference gas other than air.
N Y O2 Temp SP deg C O2 sensor set point. It allows
measurement of oxygen
with an elevated sensor temperature. (0 =736 deg C set
point; 1 = 834 deg C set
point)
N Y Features --- Advanced software features
(0=Stoichiometer; 1=Programmable Reference;
2=Elevated Temperature)
Y Y O2 URV % Primary variable (O2%) upper
range value
Y Y O2 LRV % Primary variable (O2% lower
range value)
N Y O2 AO Range --- Analog output polarity. (0 =
4-20 mA; 1 = 20-4 mA)
Y Y O2 Alarm Level --- O2 alarm level. (0 = 3.5 mA; 1
= 21.1 mA)
N Y Alarm Relay 1 --- Alarm Relay 1 mode. (no
alarm; unit alarm; low O
alarm; low O2/unit alarm; Cal
recommended; Cal recommended/unit alarm; low O2/
Cal recommended, low O2/
unit alarm/Cal recommended.)
N Y Alarm Relay 2 --- Alarm Relay 2 mode. (no
alarm; unit alarm; low O
alarm; low O2/unit alarm; Cal
recommended; Cal recommended/unit alarm; low O2/
Cal recommended, low O2/
unit alarm/Cal recommended; Heater relay)
N Y Low O2 Alm % Low O2 alarm threshold.
2
2
Reference Manual 39
Startup and operation
Probe parameters (continued)Table 4-2:
TX I/O Parameter name Units Parameter description
N Y Hi Temp Alm % High temperature alarm
threshold.
N Y AO Tracks --- Analog output track O2 sen-
sor measurement during a
calibration. (No, Yes)
N Y Auto Cal --- Enable/disable automatic
calibration.
No = Set to manual calibration mode.
Yes = Set to automatic calibration mode.
N Y Start On CalRec --- Start automatic calibration
on Cal Recommended state.
(No, Yes)
Y Y Cal Gas 1 % Test Gas 1 value. This is the
actual value of the gas being
applied during the Test Gas 1
phase of a calibration.
Y Y Cal gas 2 % Test Gas 2 value. This is the
actual value of the gas being
applied during the Test Gas 2
phase of a calibration.
Y Y Gas Time sec Test Gas application time.
This is the length of time test
gases are applied to the O
probe during low or high
Test Gas phase of a calibration.
Y Y Purge Time sec Test Gas purge time. This is
the length of time before the
output will be returned to
the process reading after a
calculation.
N Y Cal Interval hr Automatic calibration inter-
val. The number 9999 disables the automatic timed
calibration.
N Y Next Cal Time hr Automatic calibration inter-
val. The number 9999 disables the automatic timed
calibration.
Y Y T EE Val --- Transmitter board nonvola-
tile memory diagnostic
2
40 Xi
Startup and operation
Probe parameters (continued)Table 4-2:
TX I/O Parameter name Units Parameter description
N Y IO EE Val --- I/O board nonvolatile memo-
ry diagnostic
Y Y Version --- Software version number for
the transmitter.
N Y Version --- Software version number for
the I/O board.
Y Y T Restart Cntr --- Software restarts count for
the transmitter.
N Y IO Restart Cntr --- Software restarts count for
the I/O board.
Y Y Alarms --- Current alarms (see
Chapter 5).
4.5 Operation via HART/AMS
The 375/475 Field Communicator is a handheld communications interface device. It
provides a common communications link to all microprocessor-based instruments that are
HART compatible. The handheld communicator contains a liquid crystal display (LCD) and
21 keys. A pocket-sized manual, included with the 375/475 Field Communicator, details
the specific functions of all the keys.
The 375/475 Field Communicator accomplishes its task using a frequency shift keying
(FSK) technique. With the use of FSK, high-frequency digital communications signals are
superimposed on the Xi's 4-20 mA current loop. The 375/475 Field Communicator does
not disturb the 4-20 mA signal, as no net energy is added to the loop.
NOTICE
The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic License
for operation with the Xi. The AMS software must be upgraded to AMS 8.0 or above for
operation with the Xi.
Contact Emerson's Global Service Center (GSC) at 1-800-833-8314 to upgrade the 375 Field
Communicator software to System Software 2.0 with Graphic License.
4.5.1
Field communicator signal line connections
When working at the Xi, the 375/475 Field Communicator can be connected directly to
test points TP21 and TP22 on the Xi I/O board as shown in Figure 4-3. The AM+ and AMtest points are provided to monitor the 4-20 mA signal without breaking into the loop.
Reference Manual 41
Startup and operation
375/475 Field Communicator connection at the XiFigure 4-3:
4.5.2 Field Communicator menu trees
Connect the 375/475 Field Communicator in the Xi (Xi-to-DCS) 4-20 mA signal loop or to
the Xi terminals shown in Figure 4-3 and refer to Figure 4-4 for the 375/475 Field
Communicator Xi menu tree.
42 Xi
Startup and operation
375/475 Field Communicator Xi menu treeFigure 4-4:
Reference Manual 43
Startup and operation
4.6 Offline and online operations
The 375/475 Field Communicator can be operated both offline and online.
44 Xi
Offline operations are those in which the communicator is not connected to the O2 probe.
Offline operations include interfacing the 375/475 Field Communicator with a PC (refer to
applicable HART documentation regarding HART/PC applications).
In the online mode, the 375/475 Field Communicator is connected to the 4-20 mA analog
output signal line. The communicator is connected in parallel to the O2 probe or in parallel
to the 250 ohm load resistor.
4.7 Calibration - general
New O2 cells may operate for more than a year without requiring calibration, but older
cells may require recalibration every few weeks as they near the end of their life.
A CALIBRATION RECOMMENDED alarm provides notice of when a calculation is required. This
strategy ensures that the O2 reading is always accurate and eliminates many unnecessary
calibrations based on calendar days or weeks since previous calibration.
The O2 probe(s) can be calibrated manually through the handheld 375/475 Field
Communicator or the Xi. Fully automatic calibration can be performed automatically using
the Xi and the SPS 4001B Single Probe Autocalibration Sequencer or the IMPS 4000
Intelligent Multiprobe Sequencer.
Startup and operation
4.8 O2 calibration
This section covers manual calibration. For automatic calibration details, see the
Instruction Manual for the SPS 4001B Single Probe Autocalibration Sequencer or the IMPS
4000 Intelligent Multiprobe Test Gas Sequencer.
Calibration can be performed using three basic calibration methods. The methods
available to you for use depend on the configuration of your system. The sections that
follow describe how to perform a calibration for two basic system configurations shown in
Figure 4-5.
Included in the calibration procedures are instructions for setting up the calibration
parameters. Setup of the calibration parameters should be performed before the first O
calibration. Thereafter, perform calibration setup only as needed to change the calibration
parameters or to reset the parameters following the replacement of primary system
components.
Before calibrating, verify that the configuration gas parameters are correct. Refer to
Chapter 3.
2
Reference Manual 45
Startup and operation
Calibration methods, simplifiedFigure 4-5:
4.8.1 O2 calibration with Xi
For systems with configuration 1, shown in Figure 4-5, use the following procedure to
perform a calibration using the Xi. If necessary, use the Xi menu tree in Figure 4-2 for
reference.
NOTICE
To select a menu item, use the up and down arrow keys to scroll to the menu item and press
the right arrow key to select the menu item. To return to a preceding menu, press the left
arrow key.
Procedure
1. From the Main Menu, select SYSTEM to access the Xi System menu.
2. From the Xi SYSTEM menu, scroll down and select DETAILED SETUP.
3. Select menu item 4, CAL SETUP, to input the cal gas and flow times.
4. Return to the SYSTEM menu and select the last menu item, CALIBRATION, to access
the CALIBRATION menu.
5. From the O2 CALIBRATION options, select Start Cal to start the O2 calibration
procedure.
46 Xi
WARNING!
Failure to remove the Xi from automatic control loops prior to performing this
procedure may result in a dangerous operating condition.
In the first Start Cal screen, a "Loop should be removed from automatic control"
warning appears.
6. Remove the Xi from any automatic control loops to avoid a potentially dangerous
operating condition and press OK.
7. Follow the Xi display prompts to perform the O2 cal procedure.
4.8.2 O2 calibration with Xi and Field Communicator
For systems with configuration 2, shown in Figure 4-5, use the following procedure to
perform a calibration of the system using the 375/475 Field Communicator. If necessary,
use the menu tree in Figure 4-2 for reference.
NOTICE
Startup and operation
To select a menu item, use the up and down arrow keys to scroll to the menu item and press
the right arrow key to select the menu item. To return to a preceding menu, press the left
arrow key.
Procedure
1. Select DEVICE SETUP.
2. From the DEVICE SETUP screen, select menu item 4, DETAILED SETUP.
3. Select menu item 3, CAL SETUP, to input the cal gas and gas flow times.
4. Return to the DEVICE SETUP screen and select menu item 2, DIAG/SERVICE.
5. From the DIAG/SERVICE screen, select menu item 3, CALIBRATION, to access the O
CALIBRATION screen.
6. From the O2 CALIBRATION screen, select menu item 1, O2 CAL, to access the O
2
calibration procedure.
WARNING!
Failure to remove the Xi from automatic control loops prior to performing this
procedure may result in a dangerous operating condition.
In the first O2 CAL screen, a "Loop should be removed from automatic control"
warning appears.
2
7. Remove the Xi from any automatic control loop to avoid a potentially dangerous
operating condition and press OK.
8. Follow the handheld 375/475 Field Communicator display prompts to perform the
O2 cal procedure.
Reference Manual 47
Startup and operation
4.9 D/A trim
The D/A trim procedure is used to calibrate the 4-20 mA output signal to a precision mA
measurement device.
The procedure that follow describe how to perform a D/A trim for the basic system
configuration shown in Figure 4-6. Only the signal to the DCS needs to be trimmed.
D/A trim methods, simplifiedFigure 4-6:
4.9.1 D/A trim with Xi
For systems with configuration 1, shown in Figure 4-6, use the handheld 375/475 Field
Communicator to access the D/A trim procedure according to the instructions that follow.
Refer to the 375/475 Field Communicator Xi menu tree in Figure 4-2.
Procedure
1. From the DEVICE SETUP screen, select menu item 2, DIAG/SERVICE, to access the
diagnostics and service menu options.
2. Select menu item 3, CALIBRATION, to access the calibration menu options.
3. Select menu item 3, 4-20 mA SIG, to access the 4-20 mA SIGNAL screen.
4. Select menu item 1, D/A TRIM, to start the trim procedure.
48 Xi
5 Troubleshooting
5.1 Overview of operating principles
When the Zirconium Oxide sensing cell is heated to its setpoint [1357 °F (736 °C)], the cell
generates a voltage that represents the difference between the process O2% and the
reference O2% inside the probe (20.95% O2 instrument air).
When flowing calibration gases, the raw cell millivolt value should represent the levels on
the chart in Figure 5-1. Note that the raw cell millivolt value increases logarithmically as the
O2 concentration decreases.
Troubleshooting
Figure 5-1:
O2 sensor mV reading vs %O2 at 1357 °F (736 °C) (Reference air,
20.95% O2)
O2% EMF (mV)
100 -34
20 1.0
15 7.25
10 16.1
9 18.4
Reference Manual 49
Troubleshooting
O2% EMF (mV)
8 21.1
7 23.8
6 27.2
5 31.2
4 36.0
3 42.3
2 51.1
1 66.1
0.8 71.0
0.6 77.5
0.5 81.5
0.4 86.3
0.2 101.4
0.1 116.6
0.01 166.8
5.2 General
WARNING!
ELECTRIC SHOCK
Install all protective equipment covers and ground leads after troubleshooting. Failure to
install covers and ground leads could result in serious injury or death.
Consider the following equipment conditions, features, and requirements when
troubleshooting a problem.
5.2.1
5.2.2
Grounding
It is essential that adequate grounding precautions are taken when installing the system.
Thoroughly check both the probe 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.
Electrical noise
The Xi 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. Ensure all cable shields are connected to earth.
50 Xi
5.2.3 Electrostatic discharge
Electrostatic discharge can damage the ICs used in the electronics. Before removing or
handling the circuit boards, ensure you are at ground potential.
5.3 Alarm indications
The first indication of a problem at the O2 measuring system usually comes from the
operators running the process. Critical alarms that render the O2 measurement unusable
will force the 4-20 mA analog output signal representing O2 to go to a default condition, as
follows:
Troubleshooting
4-20 mA signal alarm level
0 mA Transmitter unpowered or completely failed
3.5 mA Critical alarm - transmitter reading unusable (factory de-
3.8 mA Reading under range (Example - you set range to 2-10%.
4 to 20 mA Normal operation
20.5 mA Reading over range (Example - range is 0-10%. Current
>21 mA Critical alarm - transmitter reading is unusable (you can
Transmitter condition
fault)
Current reading is 1.9%.)
reading is 12%.)
choose this alarm level instead of the factory default level
of 3.5 to 3.6 mA).
NOTICE
To ensure correct operation, you should make sure that the Digital Control System is
configured to interpret these signal levels correctly.
Once an alarm condition is identified, the Rosemount 910Xi offers a number of diagnostics
to interprest the specific alarm.
Alarm indications are available via the optional Rosemount 6888Xi or the 375/475 Field
Communicator and Rosemount's Asset Management software. 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.
Reference Manual 51
Troubleshooting
5.4 Identifying and correcting fault indications
There are two types of alarms: recoverable and non-recoverable. If an existing alarm is
recoverable, the alarm-active indication disappears when the alarm condition no longer
exists. If an alarm is not recoverable, the alarm indication continues to be displayed after
the cause of the alarm condition is corrected. AC power to the transmitter must be cycled
to clear a non-recoverable alarm.
Alarm messages are displayed on the Rosemount 910Xi display window when the alarm
status display is accessed via the Rosemount 910Xi menu. A listing of the alarm/fault
messages and the related fault status descriptions are shown in Table 5-1.
Fault conditions that give no fault indication and that allow the probe to pass calibration
are listed and discussed after Table 5-1.
Diagnostic/Unit Alarm Fault DefinitionsTable 5-1:
Message Status Alert Self clearing Rail A out
NV Memory
Fail
Factory Mode On Xi box I/O board, SW4, position 1 is set on
Board Temp
High
O2 Htr Ramp
Rate
O2 Sensor
Open
O2 TC Open The O2 cell heater thermocouple voltage is
O2 Temp Low The heater temperature is below the minimum
O2 Temp High The heater temperature is above the defined
A checksum error was detected in the nonvolatile memory configuration data when the unit
was turned on.
ON. On transmitter electronics board, SW1, position 1 is set to ON. This setting should only be
used in the factory.
The transmitter electronic board reading is
above 259 °F (126 °C) or the Rosemount 910Xi
unit I/O board temperature reading is above
187 °F (86 °C).
The O2 sensor heater ramp rate is greater than
the max allowed ramp rate, indicating a run
away heater condition.
The cell impedance voltage is reading less than
-1.1 Vdc, indicating the O2 sensor wires may be
disconnected or the O2 sensor junction may be
open.
reading more than the hardware configured
threshold voltage. This indicates the thermocouple wires may be disconnected of the thermocouple junction may be open.
temperature. The predefined low temperature
threshold is 1339 °F (726 °C).
temperature threshold. The high temperature
threshold is defined by the High Alarm SP parameter. The default value is 1382 °F (750 °C).
Failed No Yes
No
Failed No Yes
No
Maint Yes Yes
Maint Yes Yes
Maint Yes Yes
Maint Yes
52 Xi
Troubleshooting
Diagnostic/Unit Alarm Fault Definitions (continued)Table 5-1:
Message Status Alert Self clearing Rail A out
O2 T/C Shorted
O2 T/C Reversed
O2 Htr Failure The O2 sensor heater temperature is not re-
No Flame The Flame Status Relay Input is set to the OFF
Xmtr Disconnect
Cal Recommended
Cal Failed A calibration error occurred during the last cali-
Cell Imp High The O2 sensor impedance/cell resistance value
CPU Voltage
Low
CPU Voltage
High
Htr Voltage
Low
Htr Voltage
High
Low O2 The O2 reading is below the Low O2 Alm SP. Yes
The O2 sensor heater temperature thermocouple voltage is shorted.
The O2 sensor heater temperature thermocouple voltage is reading a negative voltage, indicating the thermocouple wire connections may
be reversed.
sponding to the controller and can't reach final
temperature set by the device, indicating the O
heater may have failed.
state, indicating that it is not safe to operate the
O2 heater and the heater should be turned off.
Communication failures detected between
transmitter and the I/O board, indicating the
transmitter has been disconnected from the I/O
board.
Probe calibration is recommended. The cell impedance is above 100 ohms and has shifted 50
ohms since the last calibration; the accuracy of
the O2 reading may be compromised.
bration. The measured slope or constant is outside the acceptable range. (Slope: 34.5 to 57.5
mv/decade) (Constant ±20 mv)
measurement is greater than 2000 Ohms, indicating the cell may be beyond its useful life.
The CPU voltage is less than 2.7 V, indicating
the CPU voltage is too low.
The CPU voltage is more than 3.3 V, indicating
the CPU voltage is too high.
The heater voltage for the O2 cell heater is below 35 volts.
The heater voltage for the O2 cell heater is
above 264 volts.
Maint Yes Yes
Maint Yes Yes
Yes
2
Yes
Yes
Yes
Maint Yes No
Maint Yes No
Yes
Yes
Adv Yes No
Yes
Reference Manual 53
Troubleshooting
5.5 Calibration passes, but still reads incorrectly
There are a few fault conditions where no alarm indication is present and the probe passes
calibration, but the O2 reading may still be incorrect.
An incorrect flow rate of calibration gases can cause a shifted calibration. If the flow rate of
calibration gases is too low, process gases can mix in with the calibration gases, causing a
mixture at the cell that is different from what is noted on the calibration gas bottles.
Always set the calibration flow rate when a new diffuser is installed and never readjust this
flow rate until another new diffuser is installed. For applications with heavy particulate
loading, see Section 5.5.2.
If reference air is not supplied or is improperly supplied, the calibration may read
incorrectly.
5.5.1 Probe passes calibration, O2 still reads high
External reference air leak
There may be a leak that is permitting ambient air to mix with the process gases. Since
many combustion processes are slightly negative in pressure, ambient air can be drawn
into the cell area, biasing the O2 reading upward.
1. Make sure that the calibration gas is capped tightly between calibrations.
2. If autocal is used, make sure the check valve is sealing properly.
Probe Leakage PathsFigure 5-2:
Internal reference air leak
See Figure 5-2. There may be a leak inside the O2 probe itself, permitting the reference air
(20.95% O2) to mix with the process gases at the cell. To confirm this leak condition,
pressurize the inside (reference side) of the probe by plugging the reference air exhaust
54 Xi
port with your finger for one minute. (The conduit ports where the signal and power wires
pass may also need to be sealed.) The O2 reading should decrease slightly. If the O
reading increases during this test, there is a leak inside the probe.
1. Acid condensation inside the probe can degrade the hose that carries the cal gas to
the cell. Inspect this hose. Dislodging or improper installation of the cal gas or
reference air hose can cause a leakage path.
2. The sensing cell is fastened to the end of the probe tube and uses a corrugated
washer to separate the process gases from the ambient reference air. The
corrugated washer may be damaged by corrosion. Discard used washer.
NOTICE
Always install a new corrugated washer whenever you remove the sensing cell from the probe.
5.5.2 Probe passes calibration, O2 still reads low
The diffusion element at the end of the probe is a passive filter. It plugs very slowly,
because there is no active flow being drawn across it. In applications that have a heavy
particulate loading (coal or wood fired boilers, cement and lime kilns, catalyst
regeneration, recovery boilers, etc.) this diffusion element will eventually plug.
Troubleshooting
2
5.5.3
5.5.4
NOTICE
It is important not to pressurize the sensing cell during calibrations by flowing excessive cal
gas against a plugged diffuser. Always use a two-stage regulator for setting calibration gas
pressure. Calibration flow rates should be set only when a new diffuser is installed. As the
diffuser plugs, do not adjust the flow rates upward.
How do I detect a plugged diffuser?
The O2 cell's speed of response will degrade. The O2 trend in the control room will become
smoother.
When calibrating, the calibration gas flow rate will be noted to be lower. Never readjust
this flow upwards to correct for a plugged diffuser. Adjust this flow only when a new
diffuser is installed.
Always note the time it takes for the cell to recover to the normal process value after the
cal gas is removed. As the diffuser plugs, this recovery time will get longer and longer. Use
a calibration record to record and track calibration response times.
Can I calibrate a badly plugged diffuser?
It may not be possible to immediately replace a plugged diffuser while the process is online.
Reference Manual 55
Troubleshooting
You can calibrate the probe without pressurizing the cell by adjusting the calibration gas
flow rate downward before calibration. For instance, say the process is at 3%, and the first
calibration gas is 8%. Adjust the flow of cal gas downward until the reading begins to
migrate from 8% to lower values, indicating that the process gases are now mixing with the
calibration gases.
Adjust the flow rate back up until this mixing is just eliminated. Calibrate at this flow rate.
Replace the diffuser at the first opportunity.
WARNING!
ELECTRIC SHOCK
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.
56 Xi
6 Maintenance and service
6.1 Overview
This section identifies the calibration methods available and provides the procedures to
maintain and service the Xi.
WARNING!
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 Maintenance intervals
The maintenance interval required is quite variable, depending on the type of service the
analyzer is placed into. The zirconium oxide sensing cell is non-depleting and has no
specific shelf life or a defined life in flue gas operation. The cell of a probe that is mounted
inside a boiler that is burning natural gas may shift very little over several years. Acidic
compounds are the main aggressors to the sensing cell, typically SO2 resulting from sulfur
contained in coal and heavy oil fuels and also HCl from the combustion of plastics in
municipal incinerators and in industrial thermal oxidizers. Sensing cells may experience
significant degradation and signal shift in this type of service, particularly if the operating
levels of O2 are very low (below 1% O2).
Maintenance and service
A calibration check is generally recommended on a quarterly basis (every 3 months) by
flowing bottled gas to the probe. (Make sure that the operations personnel are notified
when doing this and also make sure that the O2 control loop is placed in manual mode). If
the probe readings vary significantly from the bottle values, then a formal calibration
should be conducted as noted in Chapter 4.
The Xi offers a calibration recommended diagnostic that indicates when the probe needs to
be calibrated.
Combustion processes that have a high level of ash or other particulate content will cause
the diffusion element on the end of the probe to plug off. A badly plugged diffuser causes
a slower speed of response to changing O2 levels in the process. This can usually be seen
on the recorded trends in the control room.
When performing a calibration check or actual calibration, the calibration flow meter may
read lower if the diffuser is badly plugged. (Never increase the flow rate back up, however,
as this can cause a shifted calibration. Adjust the calibration flow rate only when a new
diffuser is installed). Always record the response time back to the process after the
calibration gases are removed.
During plant outages, conduct a visual inspection of the probe, paying particular attention
to condensed components. To reduce or eliminate condensation, insulate the probe
installation, including the probe mount, flange, and dual blue housings.
Reference Manual 57
Maintenance and service
6.3 Calibration
The Xi can calibrate an O2 probe manually through the front panel display or via a
handheld 375/475 Field Communicator or automatically through the SPS 4001B Single
Probe Autocalibration Sequencer or the IMPS 4000 Intelligent Multiprobe Test Gas
Sequencer.
6.3.1 Automatic calibration
The Xi can be used with the SPS 4001B or IMPS 4000 in order to perform an auto/semiautomatic calibration. Refer to the SPS 4001B or IMPS 4000 Instruction Manual for further
details on how to configure and perform an automatic manual calibration.
6.3.2 Manual calibration
Refer to Section 4.7 to perform a manual calibration.
6.4 Replacement parts
Refer to Chapter 7 for individual replacement parts and part replacement kits. Part
replacement kits are available for each of the components discussed in this section.
6.5
Xi components replacement
Each of the following procedures details how to replace a specific component of the Xi.
Most of these procedures include component setup instructions that must be performed
before returning the related O2 probe to service. Refer to Figure 6-1 and Figure 6-2 for
illustrations of the Xi components.
Component replacement kits are available for each of the components replaced in this
repair section. Refer to Chapter 7 for kit part numbers.
58 Xi
Maintenance and service
Xi componentsFigure 6-1:
Reference Manual 59
Maintenance and service
Xi front panel componentsFigure 6-2:
6.5.1 I/O board replacement
Use the procedure that follows to replace and set up the I/O board in the Xi.
WARNING!
ELECTRIC SHOCK
Disconnect and lock out power before working on any electrical components.
CAUTION!
The I/O board is shipped from the factory without any of the enhanced software features
activated. These features must be activated once the new board has been installed and before
the Remote Interface is put into service.
60 Xi
Maintenance and service
CAUTION!
If the existing I/O board has been operated with the Stoichiometric enhanced software feature,
this feature must be activated in the new board before the Xi Electronics is put back into
service. Failure to do so will cause a false analog output signal to the DCS.
Procedure
1. Loosen the four screws securing the Xi cover.
The screws are captive and do not need to be completely removed.
2. Swing the Xi cover down to expose the inner components.
3. Disconnect the 110-pin ribbon cable from the I/O board.
A new cable is supplied in the replacement kit and should be used if the old one is
damaged.
4. Tag and disconnect wiring for Alarm Outputs, Flame Status Input, and/or SPS/IMPS
as applicable.
5. Slide the I/O board part way out of the Xi enclosure.
6. Disconnect the 4-position plug for the transmitter probe and output wiring. Remove
the I/O board completely from the Xi enclosure.
7. See Figure 6-3. Set jumpers JP1, JP2, JP5, JP7, and JP8 to their proper positions using
the old I/O board as a guide.
I/O board jumper and switch settingsFigure 6-3:
8. Set switch SW4 to their proper positions using the old I/O board as a guide.
9. Partially slide the new I/O board into the Xi enclosure. Ensure the board is correctly
aligned within the slots in the enclosure.
10. Connect the 4-position plug for the transmitter probe and output wiring. Slide the
I/O board completely into the Xi enclosure.
Reference Manual 61
Maintenance and service
11. Reinstall wiring for Alarm Outputs, Flame Status Input, and/or SPS/IMPS as
applicable.
See Figure 6-4 and Figure 6-5 for wiring diagrams. See Figure 6-6 for I/O board
positions in the Xi enclosure.
I/O board wiring connectionsFigure 6-4:
I/O board flame safety interlock wiringFigure 6-5:
62 Xi
Maintenance and service
I/O board positions in the enclosureFigure 6-6:
12. Connect the ribbon cable to the I/O board.
A new cable is supplied and should be used if the old one is damaged.
13. Swing the Xi cover up in place and tighten the four screws.
14. Prior to operating the O2 probe and the Xi, all optional software enhancements
(previously enabled or not) must be enabled.
Notify Rosemount and reference the following part numbers to enable the software
related options.
Reference Manual 63
Maintenance and service
Part number Software option
6A00269G01 Enhanced software option upgrade, stoichiometric function
6A00269G02 Enhanced software option upgrade, programmable reference function
6A00269G03 Enhanced software option upgrade, 850 °C process function
NOTICE
For enhanced software upgrades or to enable optional software features previously
used in your Xi configuration, contact Rosemount at 1-800-433-6076.
15. Recalibrate the O2 probe according to the applicable calibration instructions in
Chapter 4.
6.5.2 AC relay board replacement
Use the procedure that follows to replace and set up the AC relay board in the Xi.
WARNING!
Disconnect and lock out power before working on any electrical components.
Procedure
1. Loosen the four screws securing the Xi cover.
The screws are captive and do not need to be completely removed.
2. Swing the Xi cover down to expose the inner components.
3. Tag and disconnect wiring for the Relay In.
4. Slide the AC relay board part way out of the Xi enclosure.
5. Tag and disconnect the 3-position plugs for the AC input and transmitter probe
heater wiring. Remove the AC relay board completely from the enclosure.
6. Partially slide the new AC relay board into the Xi enclosure. Ensure the board is
correctly aligned within the slots in the enclosure.
7. Connect the two 3-position plugs for the AC input and transmitter probe heater
wiring. Slide the AC relay board fully into the Xi enclosure.
8. Reinstall wiring for Relay In.
See Figure 6-7 for wiring diagram.
64 Xi
Maintenance and service
I/O and AC relay board flame safety interlock wiringFigure 6-7:
6.5.3
9. Swing the cover up in place and tighten the four screws.
CAUTION!
Installing and configuring an AC relay board for the flame status interlock function will
dedicate alarm output 2 for this function. Once configured for flame status interlock, the
software will override any previous alarm assignments for alarm output 2 and not allow
it to be used for any other function.
Power supply board replacement
Use the procedure that follows to replace the power supply board in the Xi. Use this
procedure to replace an original linear power supply board or the current configuration
switching power supply board.
WARNING!
ELECTRIC SHOCK
Disconnect and lock out power before working on any electrical components.
Procedure
1. Loosen the four screws securing the Xi cover.
The screws are captive and do not need to be completely removed.
2. Swing the Xi cover down to expose the inner components.
Reference Manual 65
Maintenance and service
3. Refer to the wiring diagram in Figure 6-8. Unplug the AC input wiring plug from the
power supply board.
A new plug is supplied in the replacement kit and should be used if the existing plug
is damaged.
Power supply board wiringFigure 6-8:
4. Disconnect the 14-pin ribbon cable from the power supply board.
5. Remove the two long screws that secure the bracket (9, Figure 6-1) to the Xi
enclosure.
6. Hold the AC input wiring to the right and slide the power supply board out of the Xi
enclosure.
7. Install the new mounting bracket (9, Figure 6-1) on the new power supply board (10,
Figure 6-1).
A new bracket and mounting screws are provided in the replacement kit.
8. Slide the power supply board into the mating slots in the Xi enclosure. Make sure the
board is correctly aligned in the slots.
9. Install and tighten the bracket mounting screws.
Two new screws are provided in the replacement kit and should be used if the
existing screws are damaged.
10. Connect the ribbon cable to the power supply board.
A new ribbon cable (7, Figure 6-1) is provided in the replacement kit and should be
used if the existing cable is damaged.
66 Xi
11. Connect the AC power plug to the power supply board.
12. Swing the Xi cover up and tighten the four mounting screws.
6.5.4 Xi front panel replacement
Use the procedure that follows to replace the front panel on the Xi. Replacement kits with
and without the CPU board are available. Use the instructions that apply to the
replacement kit you have.
WARNING!
Disconnect and lock out power before working on any electrical components.
Replacing front panel assembly without CPU board
Complete the following steps to replace the front panel assembly without a CPU board.
1. Loosen the four screws securing the Xi cover.
The screws are captive and do not need to be completely removed.
2. Swing the Xi cover down to expose the inner components.
3. Disconnect the 14-pin ribbon cable going to the power supply board.
Maintenance and service
A new cable is supplied in the replacement kit and should be used if the old one was
damaged.
4. Disconnect the 10-pin ribbon cable(s) going to the I/O board(s).
One new cable is supplied in the replacement kit and should be used if either of the
ribbon cables are damaged.
5. Remove the wire hinge from the right side of the Xi cover.
A paper clip or similar device can be inserted into the hole on the left side of the
cover to push the hinge out of the cover. A new hinge pin is supplied in the
replacement kit and should be used if the old one is damaged.
6. Position the new front panel assembly in place and reinstall the hinge pin. Ensure the
hinge pin is fully seated into the Xi cover.
CAUTION!
EQUIPMENT DAMAGE
The new front panel assembly may be supplied with protective clear membranes over
the interior and exterior of the window. Failure to remove the exterior protective
membrane may cause the display to be distorted. The membrane may be difficult or
impossible to remove after extended use at elevated temperatures.
7. The keypad window on the new front panel may be supplied with interior and
exterior protective membranes. Remove the protective membranes prior to final
assembly and use of the Xi enclosure.
8. Reconnect the 10-pin ribbon cable from the I/O board.
Reference Manual 67
Maintenance and service
9. Reconnect the 14-pin ribbon cable from the power supply board.
10. Swing the Xi cover up in place and tighten the four screws.
11. If necessary, configure the appearance of the main display.
Refer to Chapter 3.
Replacing front panel assembly with CPU board
Complete the following steps to replace the front panel assembly with a CPU board.
1. Loosen the four screws securing the Xi cover.
The screws are captive and do not need to be completely removed.
2. Swing the Xi cover down to expose the inner components.
3. Disconnect the 14-pin ribbon cable going to the power supply board.
A new cable is supplied in the replacement kit and should be used if the old one was
damaged.
4. Disconnect the 10-pin ribbon cable(s) going to the I/O board(s).
One new cable is supplied in the replacement kit and should be used if either of the
ribbon cables are damaged.
5. Remove the wire hinge from the right side of the Xi cover.
A paper clip or similar device can be inserted into the hole on the left side of the
cover to push the hinge out of the cover. A new hinge pin is supplied in the
replacement kit and should be used if the old one is damaged.
6. Place the front panel assembly on the bench. Remove the four screws securing the
CPU board to the front cover.
NOTICE
Prior to disassembly, observe the position of the plastic bumper with rubber insert as it
is installed over the CPU board. The two longer screws are used at the top edge of the
CPU board passing through the bumper.
7. Lift the CPU board off of the front cover using care not to damage the board.
8. Disconnect the keypad overlay ribbon from the CPU board. Discard the used front
cover with the keypad overlay attached.
CAUTION!
EQUIPMENT DAMAGE
The new front panel assembly may be supplied with protective clear membranes over
the interior and exterior of the window. Failure to remove the exterior protective
membrane may cause the display to be distorted. The membrane may be difficult or
impossible to remove after extended use at elevated temperatures.
68 Xi
Maintenance and service
9. The keypad window on the new front panel may be supplied with interior and
exterior protective membranes. Remove the protective membranes prior to final
assembly and use of the Xi enclosure.
10. Clean the inside of the keypad overlay window and LCD display window to remove
fingerprints and accumulated dust.
Use only a soft cloth; do not use any detergents or chemicals.
11. Connect the keypad overlay ribbon cable on the new front panel assembly to the
CPU board.
Use care not to damage the board.
12. Position the CPU board in place in the front panel assembly.
13. Reinstall the bumper and 4 screws to secure the CPU board in place.
The two longer screws are used with the plastic bumper on the top edge of the CPU
board.
14. Position the front panel assembly and reinstall the hinge pin. Ensure the hinge pin is
fully seated into the Xi cover.
15. Reconnect the 10-pin ribbon cable from the I/O board.
16. Reconnect the 14-pin ribbon cable from the power supply board.
17. Swing the Xi cover up in place and tighten the four screws.
18. If necessary, configure the appearance of the main display.
6.5.5
Refer to Chapter 3.
DR board replacement
Use the procedure that follows to replace the DR board in the Xi that is connected to a
direct replacement probe.
WARNING!
ELECTRIC SHOCK
Disconnect and lock out power before working on any electrical components.
Procedure
1. Loosen the four screws securing the Xi cover.
The screws are captive and do not need to be completely removed.
2. Swing the Xi cover down to expose the inner components.
3. Slide the DR board part way out of the Xi enclosure.
4. Unplug the wiring harness plug from the connector J8 located on the bottom, lefthand side of the board.
Refer to Figure 6-9.
Reference Manual 69
Maintenance and service
DR board wiring, right-hand sideFigure 6-9:
70 Xi
Maintenance and service
5. Unplug the wiring harness plugs from the connectors J1, J2, and J3 located on the
top, right-hand side of the board. Refer to Figure 6-10.
DR board wiring, left-hand sideFigure 6-10:
6. Tag and disconnect the wiring to connector J4.
7. Remove the DR board from the Xi enclosure.
8. Partially slide the new DR board into the mating slots in the Xi enclosure. Make sure
the board is correctly aligned in the slots.
9. Refer to the wiring diagram in Figure 6-9. Reconnect the wiring to connector J4.
10. Connect the wiring harness plugs to connectors J1, J2, J3, and J8.
Reference Manual 71
Maintenance and service
11. Slide the DR board completely into the Xi enclosure.
12. Swing the Xi cover up and tighten the four mounting screws.
72 Xi
7 Replacement parts
7.1 Xi electronics
Replacement parts for XiTable 7-1:
Part number Description
6A00265G01 Kit, power supply board (obsolete - replaced by 6A00329G01)
6A00329G01 Kit, switching power supply board
6A00266G01 Kit, I/O board
6A00267G01 Kit, AC relay board
6A00328G01 Kit, DR board
6A00268G01 Kit, front panel with overlay and CPU board
6A00268G02 Kit, front panel with overlay
6A00269G01 Enhanced software option upgrade, Stoichiometric function
6A00269G02 Enhanced software option upgrade, programmable reference function
6A00269G03 Enhanced software option upgrade, 800 °C process function
6A00237H24 Kit, pipe and wall mount
6A00237H33 Kit, panel mount
6A00243G01 Ribbon cable, 10 pin (CPU board to I/O board)
6A00242G01 Ribbon cable, 14 pin (CPU board to power supply board)
6A00291H01 Insulator
6A00381G01 Kit, hole plug and gland
6A00285H01 Gasket, panel
6A00287H01 Gasket, cover
(1) If the existing I/O board has been operated with the Stoichiometric enhanced software feature, this feature
must be activated in the new board before the Xi is put back into service. Failure to do so will cause a false
analog output signal to the DCS.
(1)
Replacement parts
Reference Manual 73
Replacement parts
7.2 Calibration components
Replacement parts for calibration componentsTable 7-2:
Part number Description
1A99119G01 Calibration gas bottles -0.4% and 8% O2, balance nitrogen - 550 liters each
1A99119G02 Two flow regulators (for calibration gas bottles)
1A99119G03 Bottle rack
(1) Calibration gas bottles cannot be shipped via airfreight.
(1)
74 Xi
Optional accessories
8 Optional accessories
8.1 HART handheld 375/475 Field Communicator
375/475 Field CommunicatorFigure 8-1:
The 375/475 Field Communicator is an interface device that provides a common
communication link to HART-compatible instrument, such as the Xi. HART
communications protocol permits all the information available from the Xi-s electronics to
be transmitted over standard 4-20 mA signal wires. By attaching the 375/475 Field
Communicator at a termination point along the 4-20 mA signal line, you can diagnose
problems and configure and calibrate the Xi as if you were standing in front of the
instrument.
For more information, call Rosemount at 1-800-433-6076.
Reference Manual 75
Optional accessories
8.2 Asset Management Solutions (AMS)
Asset Management Solutions (AMS) software works in conjunction with the HART
communication protocol and offers the capability to communicate with all HART plant
devices from a single computer terminal.
For more information, call Rosemount at 1-800-433-6076.
8.3 By-Pass Packages
The specially designed Rosemount By-Pass Package for oxygen analyzers has proven to
withstand the high temperatures in process heaters while providing the same advantages
offered by the in situ sensor. Inconel steel tubes provide effective resistance to corrosion,
and the package uses no moving parts, air pumps, or other components common to other
sampling systems.
For more information, call Rosemount at 1-800-433-6076.
By-Pass PackagesFigure 8-2:
®
76 Xi
8.4 Rosemount SPS 4001B Single Probe Autocalibration Sequencer
Rosemount SPS 4001BFigure 8-3:
Rosemount specifically designed the SPS 4001B Single Probe Autocalibration Sequencer to
provide the ability to perform automatic or on-demand calculations. The Rosemount SPS
4001B is fully enclosed in a NEMA cabinet suitable for wall-mounting. This cabinet provides
added protection against dust and minor impacts.
The Rosemount SPS 4001B works in conjunction with the Rosemount 6888Xi, eliminating
out-of-calibration occurrences and the need to send a technician to the installation site.
For more information, call Rosemount at 1-800-433-6076.
Optional accessories
Reference Manual 77
Optional accessories
8.5 Rosemount IMPS 4000 Intelligent Multiprobe Test Gas Sequencer
Rosemount IMPS 4000Figure 8-4:
The Rosemount IMPS 4000 Intelligent Multiprobe Test Gas Sequencer is housed within an
IP56 (NEMA 4X) enclosure and has the intelligence to provide calibration gas sequencing
of up to four Rosemount 6888Xis to accommodate automatic and semi-automatic
calibration routines.
The sequencer works in conjunction with the CALIBRATION RECOMMENDED feature,
eliminating out-of-calibration occurrences and the need to send a technician to the
installation site. In addition, the Rosemount IMPS 4000 provides a remote contact input to
intiate a calibration from a remote location and relay outputs to alert when a calibration is
in progress, an O2 probe is out of calibration, calibration gases are on, and calibration
pressure is low.
For more information, call Rosemount at 1-800-433-6076.
78 Xi
8.6 O2 calibration gas
Calibration Gas BottlesFigure 8-5:
Optional accessories
Rosemount's O2 calibration gas and service kits have been carefully designed to provide a
more convenient and fully portable means of testing, calibrating, and servicing
Rosemount's oxygen analyzers. These lightweight, disposable gas cylinders eliminate the
need to rent gas bottles.
For more information, call Rosemount at 1-800-433-6076.
Reference Manual 79
Optional accessories
8.7 OxyBalance Display and Averaging System
OxyBalanceFigure 8-6:
The optional OxyBalance Display and Averaging System reviews up to eight 4-20 mA
signals from individual probes. It trends individual outputs and calculates four
programmable averages as additional 4-20 mA inputs.
For more information, call Rosemount at 1-800-433-6076.
80 Xi
Appendix A
XPS information
A.1 XPS equipment description
The XPS is primarily an interfacing electronics box installed between an O2 probe and the
Xi electronics. There are three variants of the XPS electronics box, each with specific
functions.
1. Remote XPS - 6A00358G01 for 44 V probes
2. Remote XPS - 6A00358G03 for 115 V probes
3. Integral XPS - 6A00365G01 for 44 V probes
A.1.1 Remote XPS for 44 V probes - 6A00358G01
XPS information
This version of the XPS is for use with Westinghouse/Rosemount World Class probes that
use a 44 volt heater and when the O2 probe uses a 120/240 V, 50/60 Hz power source. The
6A00358G01 version contains electronics to recieve and process multiple raw signals from
the probe.
Signal wires between the O2 probe and the G01 version XPS include the following:
1. Thermocouple - 2 conductors (type K lead wire)
2. Sensing cell - 2 conductors
3. Heater - 3 conductors
4. Shield
This version of the XPS provides for probe heater control and signal conditioning. The
signal conditioning electronics result in a linear 4-20 mA %O2 signal.
No operator interface is included. Thereby, the 4-20 mA signal typically goes to an Xi
advanced electronics unit. Alternately, a handheld HART 375/475 Field Communicator can
be used as the operator interface. However, the Xi or the field communicator must be the
dedicated communication device. The Xi and the field communicator cannot be used at
the same time.
For heater control, the G01 version of the XPS includes a transformer. The transformer
converts 120/240 Vac input power to the 44 Vac heater voltage used in the Westinghouse/
Rosemount World Class probe.
Reference Manual 81
XPS information
Remote XPS 6A00358G01 and 6A00358G03 mountingFigure A-1:
A.1.2 Remote XPS for 115 V probes - 6A00358G03
The 6A00358G03 version of the XPS is similar to the 6A00358G01 described above except
that it does not include the transformer. The 6A00358G03 version controls any
Westinghouse/Rosemount O2 probe that uses a 115 V heater. Applicable probes include
Models 218 and 218A, Oxymitter, X-STREAM, or 6888 probes.
82 Xi
XPS information
A.1.3 Integral XPS 6A00365G01 with Xi (for 44 V probes)
This XPS equipment configuration includes the XPS and an Xi Advanced Electronics unit
installed on a mounting plate. This configuration is intended to replace a world class
intelligent field transmitter (IFT) where the required input line voltage is 120/240 Vac,
particularly for 240 Vac applications.
Integral XPS with Xi and 6A00365G01 mountingFigure A-2:
A.1.4 Other XPS uses
The XPS units can be wired to two O2 probes and back to one dual-channel Xi. This avoids
having to purchase an Xi for each probe and eliminates one of two signal cables that would
otherwise be required to communicate between the Xi and XPS units.
Reference Manual 83
XPS information
Remote XPS 6A00358G01 wiring diagramFigure A-3:
84 Xi
XPS information
Reference Manual 85
XPS information
Remote XPS 6A00358G03 wiring diagramFigure A-4:
86 Xi
XPS information
Reference Manual 87
XPS information
Integral XPS 6A00365G01 wiring diagramFigure A-5:
88 Xi
XPS information
Reference Manual 89
XPS information
A.2 Specifications
Part number Description
6A00358G01 for 44 V
probes
6A00358G03 for 120 V
probes
6A00365G01 for 44 V
probes
General purpose certifications
120/240 V, 50/60 Hz, 140 VA, -4 to 131 °F (-20 to 55 °C), 95% relative
humidity, Type 4X, IP66
120/240 V, 50/60 Hz, 776 VA, -4 to 131 °F (-20 to 55 °C), 95% relative
humidity, Type 4X, IP66
120/240 V, 50/60 Hz, 140 VA, -4 to 131 °F (-20 to 55 °C), 95% relative
humidity, Type 4X, IP66
A.3 Recommended spare parts
Spare partsTable A-1:
Part number Description
1A99763H01 Kit, replacement enclosure mounting feet
6A00418G01 Kit, DR board
6A00419G01 Kit, toroid transformer
6A00420G01 Kit, fuses (Reference 3.15 A, 250 V, Littlefuse P/N 218 3.15)
90 Xi
Appendix B
Service support
To expedite the return process outside of the United States, contact the nearest
Rosemount™ representative.
Within the United States, call the Emerson™ Instrument and Valves Response Center using
the 1-800-654-RSMT (7768) toll-free number. This center, available 24 hours a day, will
assist you with any needed information or materials.
The center will ask for product model and serial numbers and will provide a Return of
Material Authorization (RMA) number. The center will also ask for the process material to
which the product was last exposed.
Service support
Reference Manual 91
00809-0100-4889
Rev AA
2018
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