Rosemount X-STREAM XS O2 Combustion Flue Gas Transmitter Hazardous Area-Rev 1.0 Manuals & Guides

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area
X-STREAM O

Combustion

2

Flue Gas Transmitter

http://www.raihome.com

HIGHLIGHTS OF CHANGES

Effective November 30, 2009 Rev 1.0

Page Summary

General Updates Updated master Table of Contents, Section Tables of Content, and Index. Updated IM

page header revision level and release date throughout manual.
Page v Revised text of 2nd step 3 and Xi Mounting description of Installation Summary.
Page 1-6 Added new descriptive onto end of first paragraph.
Page 1-6 Revised view in Figure 1-5.
Page 1-10 Updated Environmental Specifications.- Transmitter Probe Process Temperature Limits;

Added Agency Certifications
Page 1-11 Revised final three Specification table entries.
Page 1-12 Codes 21, 22, 23 - changed ’ATEX’ to read ’ATEX/IECEx’
Page 1-13 Added Codes 21, 22, 23 to Electronics.
Page 1-14 Revised Remote Type Code 04. Added Remote Type Code 05.
Page 2-2 3rd Warning - Changed ’XZ’ to read ’XS’.
Page 2-3 Changed Note text to read ’T ype 4X and IP66.’
Page 2-4 Changed A TEX description in 1st bu lleted text list. Added ATEX description to 2nd bulleted

text list. Changed 300°C (572°F) to read 200°C (392°F).
Page 2-6 Revised Figure 2-3.
Page 2-17 Added more descriptive text to end of Optional Flame Safety Interlock topic.
Page 2-21 Changed ’Yew’ to all upper case ’YEW’.
Page 2-24 Revised view in Figure 2-23.
Page 2-25 Added 2nd sentence to 1st NOTE.
Page 3-1 Corrected erroneous item numbers cited in steps 1 thru 4.
Page 3-2 Revised Figure 3-1 view . Added Set Test Gas Values topic. Moved ’Calibration’ discussion

to section four of this manual.
Pages 3-3 thru 3-5 Added Alarm Relay Output Configuration from Section 4 and Analog Output Configuration

and Autocalibration Setup topics.
Page 3-6 Added 2nd paragraph to OPtional Advanced Features Inside the Xi.
Page 4-2 Changed 850 Deg to read 800 Deg in Note. Changed ’SPS or IMPS’ to read ’SPS

4001B or IMPS 4000.’
Page 4-5 Revised Figure 4-2, sheet 2.
Page 4-16 Revised Figure 4-7, sheet 1.
Page 4-19 Revised Figure 4-8, sheet 2.
Page 4-20 Added Calibration - General topic from page 3-2 of previous revision. Added new text to

end of O
Page 6-16 Revised Figure 6-12 to match view on subject core information label.,
Page 6-19 Revised view in Figure 6-16.
Page 7-2 Added 4 replacement parts to end of Table 7-1. Revised Table 7-2 listing.

Calibration discussion.

2

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O

Transmitter

2

Table of Contents

Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

SECTION i
Introduction

SECTION 1
Description and
Specifications

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Can You Use the Quick Start Guide? . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Probe Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Installation Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

Quick Start Guide for X-STREAM Systems. . . . . . . . . . . . . . . . . . . . . . vi

Quick Reference Guide Manual Calibration Instructions. . . . . . . . . . . . vii

375 Field Communicator Fast Key Sequences . . . . . . . . . . . . . . . . . . viii

Technical Support Hotline: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Probe Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Diffusion Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

SECTION 2
Installation

http://www.raihome.com

System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hazardous Area Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Selecting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Optional Xi Enhanced Interface Installation . . . . . . . . . . . . . . . . . 2-10

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

X-STREAM Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Optional Xi Enhanced Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Optional Flame Safety Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Traditional Architecture Cable Connections . . . . . . . . . . . . . . . . . 2-17

Direct Replacement (DR) Probe Connections . . . . . . . . . . . . . . . 2-21

DR Probe to Yokogawa Electronics Connections . . . . . . . . . . . . 2-21

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Reference Air Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Calibration Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

SECTION 3
Configuration of
Hazardous Area X­STREAM O2 Transmitter

SECTION 4
Startup and Operation

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Xi Configuration (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Alarm Relay Output Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Analog Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Autocalibration Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Optional Advanced Features Inside the Xi . . . . . . . . . . . . . . . . . . . . . 3-5

Extended Process Temperature Range to 800°C (1472°F). . . . . . 3-6

Stoichiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Programmable Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Operation Via Xi Enhanced Interface . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Startup Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Xi Enhanced Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Password Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

System Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Probe Parameter Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Operation Via HART/AMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Field Communicator Signal Line Connections

(No Xi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Field Communicator Signal Line Connections

(with Xi). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Field Communicator Menu Trees. . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Off-line and On-line Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Calibration - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

O2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Calibration without Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

O

2

Calibration with Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

O

2

Calibration with Xi and Field Communicator . . . . . . . . . . . . . . 4-23

O

2

D/A Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

D/A Trim without Xi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

D/A Trim with Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

SECTION 5
Troubleshooting

TOC-2

Overview of Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Alarm Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Identifying and Correcting Fault Indications. . . . . . . . . . . . . . . . . . . . . 5-4

Calibration Passes, but Still Reads Incorrectly . . . . . . . . . . . . . . . . . . 5-5

Probe Passes Calibration, O2 Still Reads High . . . . . . . . . . . . . . . 5-5

Probe Passes Calibration, O2 Still Reads Low . . . . . . . . . . . . . . . 5-7

How do I detect a plugged diffuser?. . . . . . . . . . . . . . . . . . . . . . . . 5-7

Can I calibrate a badly plugged diffuser?. . . . . . . . . . . . . . . . . . . . 5-7

Instruction Manual

IM-106-910, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

SECTION 6
Maintenance and Service

SECTION 7
Replacement Parts

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

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Removal and Installation of Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

X-STREAM O2 Transmitter Probe Repair. . . . . . . . . . . . . . . . . . . . . . 6-5

Sensor Core or Diffuser Replacement . . . . . . . . . . . . . . . . . . . . . . 6-5

Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Replace Contact Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Cell Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Replace Contact & Thermocouple Assembly. . . . . . . . . . . . . . . . 6-13

Replacing Gas/Air Hoses, O-rings and Spacers . . . . . . . . . . . . . 6-14

Electronics Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Blind Cover(s) Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Xi Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

I/O Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

AC Relay Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Power Supply Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . 6-26

Xi Front Panel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

DR Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

O2 Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Xi Enhanced Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Calibration Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

SECTION 8
Optional Accessories

APPENDIX A
Safety Data

APPENDIX B
Return of Material

HART Handheld 375 Field Communicator . . . . . . . . . . . . . . . . . . . . . 8-1

Asset Management Solutions (AMS). . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

By-Pass Packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SPS 4001B Single Probe Autocalibration Sequencer . . . . . . . . . . . . . 8-3

IMPS 4000 Intelligent Multiprobe Test Gas Sequencer. . . . . . . . . . . . 8-4

Calibration Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

O

2

OxyBalance Display and Averaging System . . . . . . . . . . . . . . . . . . . . 8-6

Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

MSDS - Refractory in Items 1 and 2, Figure 6-1 . . . . . . . . . . . . . . . .A-24

Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

TOC-3

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

TOC-4

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O

Transmitter

2

X-STREAM Oxygen Transmitters

READ THIS PAGE BEFORE PROCEEDING!

ESSENTIAL
INSTRUCTIONS

Emerson Process Management designs, manufactures and tests its prod uct s
to meet many national November 2009and 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 Rosemount Analytical products. Failure to follow the proper
instructions may cause any one of the following situations to occur: Loss of
life; personal injury; property damage; damage to this instrument; and
warranty invalidation.

• Read all instructions
product.

• If you do not understand any of the instructions, contact your
Emerson Process Management representative for clarification.

• Follow all warnings, cautions, and instructions
supplied with the product.

• Inform and educate your personnel in th e proper inst a llation, o peration,
and maintenance of the product.

• Install your equipment as specified in the Installation Instructions

of the appropriate Instruction Manual and pe r a pplicable loca l and
national codes. Connect all products to the proper electrical and

pressure sources.

• To ensure proper performance, use qualified personnel
operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson Process Management.
Unauthorized parts and procedures can affect the product's
performance, place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire,
electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers

are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without notice.

prior to installing, operating, and servicing the

marked on and

to install,

http://www.raihome.com

NOTES:

The 375 Field Communicator must be upgraded to System Software 2.0 with
Graphic License for operation with the X-STREAM O
software must be upgraded to AMS 8.0 or above.

Contact Emerson Process Management’s Global Service Center (GSC) at
1-800-833-8314 to upgrade the 375 Field Communi cator software to System
Software 2.0 with Graphic License.

Transmitter. The AMS

2

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

ii

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O

Hazardous Area

Transmitter

2

Section i Introduction

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page iii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iii

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page iv

Can You Use the Quick Start Guide? . . . . . . . . . . . . . . . . page iv

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page iv

Probe Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page iv

Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page v

Quick Start Guide for X-STREAM Systems . . . . . . . . . . . page vi

Quick Reference Guide Manual Calibration Instructions page vii

375 Field Communicator Fast Key Sequences . . . . . . . . page viii

PREFACE The purpose of this manual is to provide information concer ning component s,

functions, installation and maintenance of th e Hazardous Area X-STREAM O
Transmitter.

2

Some sections may describe equipment not used in your configuration. The
user should become thoroughly familiar with the operation of this module
before operating it. Read this instruction manual completely.

DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS, and NOTES

found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.

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

NOTE

Highlights an essential operating procedure, condition, or statement.

http://www.raihome.com

Hazardous Area
X-STREAM O2 Transmitter

SYMBOLS

:

EARTH (GROUND) TERMINAL

:

PROTECTIVE CONDUCT OR TERMINAL

:

RISK OF ELECTRICAL SHOCK

:

WARNING: REFER TO INSTRUCTION MANUAL

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.

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

NOTE TO USERS

CAN YOU USE THE
QUICK START GUIDE?

Use this Quick Start Guide if...

1. Y our system uses a Hazardous Area X-STREAM O
the SPS 4001B or IMPS 4000 autocalibration options.

2. Your system does not use traditional architecture or remote electronics.
(Refer to Section 1: Description and Specifications for a description of
"traditional architecture").

3. You are familiar with the installation requirements for the Hazardous
Area X-STREAM O

If you cannot use the Quick Start Guide, turn to Section 2: Installation, in
this Instruction Manual.

If this equipment is a direct replacement (DR) version of the Hazardous
Area X-STREAM O
electronics.

Transmitter.

2

Transmitter, refer to the manual for your Legacy

2

Transmitter without

2

OVERVIEW The X-STREAM is Rosemount Analytical's latest in-situ probe offering

intended for combustion flue gas service. Similar to our previous Wor ld Class
and Oxymitter probes, there is no sampling system. The sensing cell is
mounted to the end of a probe (18", 3', or 6’ long) that is directly inserted into
the flue gas stream.

The sensing cell is of similar design to the World Class and Oxymitte r cells,
utilizing the zirconium oxide sensing principle. The cell is heated and
maintained at a 736°C (1357°F)
signal proportional to the partial pressure difference of oxygen between the
reference side of the cell (usually instrument air at 20.95% O
process side of the cell (usually combustion flue gasses). For more
information on sensing cell operation, see the Overview of Operating
Principles in Section 5: Troubleshooting.

setpoint, and generates a logarithmic MV

), and the

2

PROBE ARRANGEMENT The probe consists of a "probe tube" and a "sensor core". The probe tube is

basically an empty stainless steel tube that mounts to the flue gas duct via a
2½" NPT male pipe thread, or a 2" 150# ANSI flange mount. Two housings
with covers contain the transmitter electronics and the se nsing core. A conduit
port is provided for bringing in AC line voltage for the heater, and for the 4-20

sensing signal loop wires. Ports for cal gas an d reference gas are al so

mA O

2

provided.

iv

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O

The sensor core contains all the active components of the analyzer. They
include:

1. the diffusion element filter at the end of the probe

2. the ZrO

3. the heater to heat the cell

4. a type K thermocouple

5. ceramic insulated wires for carrying the T/C and Cell signals,

6. transmitter electronics to control the heater and condition the raw mV
probe signals to a linear 4-20 mA O2 signal for use in the user's control
or data acquisition system.

Operator interface for setup, calibration, indication, and diagnostics is
available by several means:

1. HART communications through a 375 Field Communicator

2. HART communications through Emerson's AMS

3. An optional Xi Enhanced Interface. The Xi can act as interface to one or
two X-STREAM probes. The Xi also carries advanced features such as
elevated process temperature capability, autocalibration via an SPS
solenoid box, a stoichiometer feature for indicating the level of oxygen
deficiency in reducing conditions, and prog ram m ab le re fe re nce to
enhance accuracy at near ambient levels of O

sensing cell

2

Transmitter

2

.

2

INSTALLATION
SUMMARY

Probe Mounting - A standard 6-inch square weld plate with a 2-½ inch NPT

probe port must be welded to the duct wall. Optionally, a traditional stud plate
to accept a 150# ANSI flange must be welded to the duct wall. See the
drawings in Section 2: Installation.

Xi Mounting - Pipe, wall, or panel mount.
Reference Air - Ferrule fittings for ¼" tubing. Reference air should be clean,

dry instrument air regulated to 5 psi (34 kPa) minimum, 8 psi (54 kPa)
maximum, and a flow of 0.5 scfh (0,25

Calibration Gas - Ferrule fittings for ¼" tubing. If cal gas lines are
permanently connected, a check or blocking valve should be used at the
probe to ensure that flue gases do not flow back through the lines.

Heater Power - 100-240 VAC, 50/60 Hz ±10%, via ½-inch NPT conduit port.
Transmitter Electronics (without Xi) - "Loop powered" from the control

room by the 4-20 mA signal.
Transm itter Electronics with Optional Xi - 100-240 VAC, 50/60 Hz

via ½-inch bulkhead fitting.

A 4-20mA signal from transmitter is powered from the Xi.
A 4-20 mA signal to the control room can be loop- powered from

the control room or from the Xi.

/hr) maximum.

±10%,

v

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

QUICK START GUIDE
FOR X-STREAM
SYSTEMS

1. Install the probe with transmitter electronics in an appropriate location
on the stack or duct. Refer to Section 2: Installation for additional
information on selecting a location for the Hazardous Area X-STREAM

Transmitter.

O

2

2. Connect reference air to the Hazardous Area X-STREAM O
Transmitter.

3. Connect HART communications, either through a handheld
communicator like the Rosemount 375 Field Communicator, or through
Emerson's AMS Suite PC software, or on an AMS-aware DCS.

NOTE

For a transmitter with optional Xi Enhanced Interface, the 375 Field
Communicator must be connected only to the 4 to 20 mA signal loop between
the Xi and the control room or data acquisition system. Connecting the 375
Field Communicator between the transmitter and Xi will cause communication
errors and affect system operation.

4. Apply AC power to the cell heater.Then connect the loop-power for the

transmitter electronics.

NOTE

Although the transmitter electronics are loop-powered, they are not
intrinsically safe.

2

5. Allow approximately 45 minutes for the cell heater to warm up to the
736°C (1357°F)
default value of 3.5 mA throughout this warm-up period. Once warm, the
probe will be reading oxygen, and the 4-20 mA signal will be a reading
based on the default range of 0-10% O

6. Perform a manual calibration. Refer to "Quick Reference Guide Manual
Calibration Instructions" that follow. Proceed through all setup menus,
including calibration setup. Calibrate the probe with cal gas and record
the slope, impedance, and cell constant on a copy of the Calibration
Record shown on page 5-8 of this manual.

heater setpoint. The 4-20 mA signal will remain at a

.

2

vi

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Figure 1. X-STREAM Integral Electronics Wiring Diagram

Hazardous Area

X-STREAM O

Transmitter

2

QUICK REFERENCE
GUIDE MANUAL
CALIBRATION
INSTRUCTIONS

Performing a Manual Calibration with a 375 Field Communicator

Use the following procedure to perform a calibration using the 375 Field
Communicator. If necessary, use the menu tree in Figure 4-7 or Figure 4-8
(sheet 2 of 2) for reference.

NOTE

To select a menu item: 1) use the up and do wn arr ow keys to scr oll to the
menu item and press the right arrow key or 2) use the number keypad to
select the menu item number. To return to a preceding menu, press the left
arrow key.

1. From the O
access the O

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

2. In the first O2 CAL screen, a "Loop should be removed from automatic
control" warning appears. To avoid a potentially dangerous operating
condition remove the Hazardous Area X-STREAM O
any automatic control loops and press OK.

3. Follow the 375 Field Communicator display prompts to perform the O
cal procedure.

CALIBRA TION screen, select menu item 1, O2 CAL, to

2

calibration procedure.

2

Transmitter fr om

2

2

vii

Hazardous Area
X-STREAM O2 Transmitter

375 FIELD
COMMUNICATOR
FAST KEY SEQUENCES

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

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: [phone]
In addition to the CSC, you may also contact Field W atch. Field Watch

coordinates Emerson Process Management’s field service throughout the
U.S. and abroad.

Phone: [phone]-RSMT (1-800-654-7768)
Emerson Process Management may also be reach ed via th e In ternet thr ough

e-mail and the World Wide Web:
e-mail: [e-mail]
World Wide Web: www.raihome.com

viii

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O

Hazardous Area

Transmitter

2

Section 1 Description and Specifications

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-3

System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-4

System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-4

Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-7

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-7

Probe Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-9

Diffusion Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-9

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-10

COMPONENT
CHECKLIST

A typical Rosemount Analytical Hazardous Area X-STREAM O2 Combustion
Flue Gas Transmitter should contain the items shown in Figure 1-1. Record
the part number , serial number, and order number for each component of your
system in the table located on the back cover of this manual.

Also, 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 the various options and features of the
Hazardous Area X-STREAM O
specified by your order number are on or included with the unit.

Transmitter. Ensure the features and options

2

SYSTEM OVERVIEW
Scope This Instruction Manual is designed to supply details needed to install, start

up, operate, and maintain the Hazardou s Area X-STREAM O
system. Signal conditioning electronics output s a 4-20 mA signal rep resenting

value. This information, plus additional details, can be accessed with

an O

2

the handheld HART Model 375 Field Communicator or Asset Management
Solutions (AMS) software. Also, a fully functional Xi Enhanced Interface
(optional) for setup, calibration, diagnostics, and enhanced features is
available.

The Xi Enhanced Interface communicates with the probe transmitter
electronics via HART communications riding on the 4 to 20 mA signal comin g
from the transmitter. This communication will be disrupted if a 375 Field
Communicator is connected to this circuit. Connect the field communicator
only to the 4 to 20 mA signal loop between the Xi Enhanced Interface and the
control room or data acquisition system.

Transmitter

2

http://www.raihome.com

Hazardous Area
X-STREAM O2 Transmitter

Figure 1-1. Typical System Package

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

1. Instruction Manual

2. Hazardous Area X-STREAM O

3. Weld Plate

4. Traditional Architecture Cable (Optional)

5. Reference Air Set (not used if SPS 4001B or IMPS 4000 is used)

6. HART® 375 Field Communicator Package (Optional)
*7. Optional SPS 4001B or IMPS 4000 Autocalibration Sequencer (Requires use of Xi Enhanced Interface option)
*8. Xi Enhanced Interface (Optional)

*Note: For use in non-hazardous areas only. See Section 2, Installation for details.

1-2

Transmitter with Integral Electronics (or optional DR Probe)

2

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

System Description The Hazardous Area X-STREAM O

net concentration of oxygen in an industrial combustion process; i.e., the
oxygen remaining after all fuels have been burned. The probe utilizes an "in
situ" zirconium oxide sensor placed on the end of a permanently mounted
probe that is positioned within an exhaust duct or stack. There is no sampling
system required.

The equipment measures oxygen percentage by reading the voltage
developed across a heated electrochemical cell, which consists of a small
yttria stabilized, zirconia disc. Both sides of the disc are coated with porous
metal electrodes. When operated at an elevated temperature the millivolt
output voltage of the cell is given by the following Nernst equation:

EMF = KT log10(P1/P2) + C

Where:

1. P2 is the partial pressure of the oxygen in the measured gas on one
side of the cell.

2. P1 is the partial pressure of the oxygen in the reference air on the
opposite side of the cell.

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

NOTE

Clean, dry, instrument air (20.95% oxygen) is required as reference air.

Transmitter is designed to measure the

2

When the cell is at operating temperature and there are unequal oxygen
concentrations across the cell, oxygen ions will travel from the high oxygen
partial pressure side to the low oxygen partial pressure side of the cell. The
resulting logarithmic output voltage is approximately 50 mV per decade. The
output is proportional to the inverse logarithm of the oxygen concentration.
Therefore, the output signal increases as the oxygen concentration of the
sample gas decreases. This characteristic enables the Hazardous Area
X-STREAM O
concentrations found in combustion flue gases.

NOTE

Since the sensing cell is heated, and utilizes platinum electrodes that have
catalyzing properties, the Hazardous Area X-STREAM O
burn any residual fuel remaining in the flue gases from incomplete
combustion components (usually CO). This secondary combustion at the
sensing cell will consume a portion of any remaining oxygen (2CO + O

), and measures the net oxygen remaining after this secondary

2CO

2

combustion inside the cell occurs.

If your combustion process contains significant CO, or other residual fuel
components, the Oxygen reading may be depressed, or read zero.

Transmitter to provide exceptional sensitivity at low oxygen

2

Transmitter cell will

2

>

2

1-3

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

The sensor cell will read the O
volume of flue gases including water vapor. Therefore, it may be considered
an analysis on a "wet" basis. In comparison with older methods such as the
portable apparatus, which provide s an analysis on a "dry" gas basis, the "wet"
analysis will, in general, indicate a lower percentage of oxygen. The
difference will be proportional to the water content of the sampled gas stream.

The transmitter electronics controls probe temperature and provides an iso­lated 4-20 mA output that is proportional to the measured oxygen concentra­tion. The probe heater can accept voltages of 100-240 VAC ±10%
Hz. Therefore, no setup procedures for power a re requ ired. Th e oxygen sen s­ing cell is maintained at a constant temperature by modulating the duty cycle
of the probe heater portion of the electronics. The electronics accepts millivolt
signals generated by the sensing cell and the thermoco uple produces the ou t­puts to be used by the users computer or data acquisition system. The output
is an isolated 4-20 mA linearized current.

concentration as a percentage of the total

2

and 50/60

System Features 1. The cell output voltage and sensitivity increase as the oxygen

concentration decreases.

2. HART communication is standard; to use the HART capability you must
have either:

a. 375 Field Communicator.
b. Asset Management Solutions (AMS) software for the PC.

3. An optional Xi Enhanced Interface allows continuous O
interface capability.

4. Field replaceable cell, heater, thermocouple, and diffusion element.

5. The Hazardous Area X-STREAM is constructed of rugged 316L or 304
stainless steel for all wetted parts.

6. The heater is adaptable for line voltages from 100-240 VAC ±10%;
therefore, no configuration of heater voltage is necessary.

display and full

2

System Configurations Integral Transmitter Electronics, HART Communications

Hazardous Area X-STREAM O
6'. The blue electronics housing contains a signal conditioning electronics to
control the cell heater, and to condition the raw cell signal into a linear 4-20
mA signal, with HART digital communications. This arrangement has no dis­play or keypad, and depends on a HART 375 communicator or AMS for con­figuring the electronics, calibrating the probe, displaying O
diagnosing probe problems. This Hazardous Area X-STREAM configuration
is represented in Figure 1-2.

1-4

probes are available in lengths of 18", 3', and

2

2

information, and

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Figure 1-2. Hazardous Area X-STREAM with Integral Transmitter Electronics

X-STREAM O2 Transmitter

Hazardous Area

Figure 1-3. Hazardous Area X-STREAM with Integral Transmitter Electronics and Optional Xi Enhanced Interface

Integral Transmitter Electronics, HART and Xi Communications

The optional Xi enhanced interface (Figure 1-3) provides a local display/key­pad for setting up, calibrating, and displaying O
problems. The Xi also offers additional features including a "Calibration
Recommended" diagnostic, fully automatic calibration, optional flame safety
interface (single probe version only), extended process temperature capabil­ity , stoichiometer , and programmable reference. These additional features will
be discussed in other sections of this manual. The Xi can be purchased to
operate a single probe, or as a dual channel unit to run two probes.

, and for diagnosing probe

2

1-5

Hazardous Area
X-STREAM O2 Transmitter

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 an Xi electronics (Figure 1-4) which does all heater
control and signal conditioning in addition to it's display/keypad functions. The
optional Xi Enhanced Interface is offered to support direct replacement
probes with either 120 volt or 44 volt heaters.

Figure 1-4. Hazardous Area X-STREAM with Traditiona l Architecture Electronics

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Figure 1-5. Hazardous Area X-STREAM with Xi Enhanced Interface and Autocalibration Sequencer

1-6

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

Hazardous Area

Automatic Calibration Calibrations consist of introducing bottled gases of known value into the probe

so the electronics can make automatic adjustments to the O
match the bottled gas value. 0.4% O
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 automatic calibration system
(Figure 1-5) where calibration solenoids are switched from the Xi enhanced
interface. See IM-106-340AC, SPS 4000B Single Probe Autocalibration
Sequencer or IM-106-400IMPS, IMPS 4000 Intelligent Multiprobe Test Gas
Sequencer , for additional details. These a utomatic calibration accessories are
for use in non-hazardous areas only.

and 8% O2 (balance nitrogen) gases

2

readings to

2

Communication Options X-STREAM communications are accomplished by a customer-supplied 375

Field Communicator and/or the optional Xi Enhanced Interface. Graphic
displays are available via the optional OxyBalance Display and Ave raging
System.

Data Communications

An operator can configure and diagnostically troubleshoot the Hazardous
Area X-STREAM in one of two ways:

1. Using the Xi Enhanced Interface. The optional Xi Enhanced Interface
allows local communication with the electronics. The Xi also carries the
following optional advanced features:

• Fully automatic calibration

• Optional flame safety interface (single probe version only)

• High temperature operation [above 700°C (1292°F) standard
temperature].

• Stoichiometer feature provides the ability to indicate O
when the combustion process goes into reducing conditions
(0% O

• Programmable reference provides enhanced accuracy when
measuring at or near O

2. Using the HART Interface. The Hazardous Area X-STREAM O
Transmitter's 4-20 mA outp ut 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 Analytical Model 375 Field Communicator - The
handheld communicator requires Device Description (DD) software
specific to the X-STREAM. The DD software will be supplied with
many Model 375 units but can also be programmed into existing units
at most Emerson Process Management service offices. See
Section 4, Startup and Operation, for additional information.

• Personal Computer (PC) - The use of a personal computer requires
AMS software available from Emerson Process Management.

• Delta V and Ovation Distributed Control System (DCS) with
AMS-inside capability.

).

2

level (20.95% O2).

2

efficiency

2

2

1-7

Hazardous Area
X-STREAM O2 Transmitter

NOTES:

The 375 Field Communicator must be upgraded to System Software 2.0 with
Graphic License for operation with the Hazardous Area X-STREAM O
Transmitter. The AMS software must be upgraded to AMS 8.0 or above.

Contact Emerson Process Management’s Global Service Center (GSC) at
1-800-833-8314 to upgrade the 375 Field Communi cator software to System
Software 2.0 with Graphic License.

Optional OxyBalance Display and Averaging System

Receives up to eight 4-20 mA signals from individual probes. Trends
individual outputs and calculates four programmable averages as additional
4-20 mA outputs. OxyBalance graphic displays are shown in Figure 1-6. See
IM-106-4050, OxyBalance Oxygen Display and Averaging System, for

additional details.
Figure 1-6. OxyBalance
Displays

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

2

Analytical

38890063

1-8

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

PROBE OPTIONS
Diffusion Elements Snubber Diffusion Assembly

The standard snubber diffusion assembly (Figure 1-7) is satisfactory for most

applications, however the snubber diffuser should not be used in flue gas

temperatures above 500
Figure 1-7. Snubber Diffusion

Assembly

Ceramic Diffusion Assembly

The ceramic diffusion assembly (Figure 1-8) is the traditional design for the

probe. Used for over 25 years, the ceramic diffusion assembly provides a

greater filter surface area.

°C (932°F).

Hazardous Area

38960041

Figure 1-8. Ceramic Diffusion
Assembly

Figure 1-9. Hastelloy Cup-Type
Diffusion Assembly

Cup-Type Diffusion Assembly

The cup-type diffusion assembly (Figure 1-9) is typically used in high

temperature applications where frequent diffusion element plugging is a

problem. The cup-type diffusion assembly is available with a 40 micron,

sintered, Hastelloy element.

1-9

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

SPECIFICATIONS

Measurement Specifications

Net O2 Range: 0 to 50% O2 user scalable

-2 to 50% O
Accuracy in Oxidizing Conditions: ±0.75% of reading or 0.05% O
Lowest Detectable Limit: 0.01% O
Signal Stability: ±0.03% O
Process Temperature Effect: less than 0.05% O2 from 100° to 700°C

System Speed of Response to
Calibration Gas:

Calibration Validity: Presentation of calibration gases matches the normal
Accuracy in Reducing Conditions: ±10% of reading or 0.1% O

System Response in Reducing
Conditions:

Ambient Temperature Effect on
Transmitter 4-20 mA Signal:

Ambient Temperature Effect on Xi
4-20 mA Signal:

Environmental Specifications

Transmitter Probe: Process-wetted materials are 316L or 304 Stainless

Process Temperature Limits: 0° to 800°C (32° to 1472°F)*

Transmitter Electronics Housing: Low copper aluminum Type 4X/IP66, with reference air

Ambient Temperature Limits: -40° to 80°C (-40° to 176°F), Transmitter

Process Mounting Temperature: 200°C (392°F) Maximum

Xi Enhanced Interface: Type 4X/IP66, Polycarbonate Material

Ambient Temperature Limits: -20° to 50°C (-4° to 122°F)
Xi LCD display:

Ambient Temperature Limits -20° to 55°C (-4° to 131°F)

Agency Certifications

Model XS-O2XP (without process end flame arrestor)

Electronics Options
11, 12, 13

(212° to 1292°F)
Initial response in less than 3 seconds

∞

T in less than 8 seconds
Response to process gas changes will vary depending
on velocity and particulate loading of the diffuser

process to within ±0.02% O

going from oxidizing to reducing -T90 in 120 seconds
going from reducing to oxidizing -T

less than 0.005% O
less than 0.0025% O2 per degree Celsius

*Reduced cell life can be expected if operated
continuously at temperatures above 705°C (1300°F)
[optional bypass and jacket accessories permit
operation to 1050°C (1922°F)]

exhaust port piped to clean, dry area

-40° to 85°C (-40° to 185°F) as measured by electronics

-40° to 100°C (-40° to 212°F), DR Probe (Model

XS-O2XP only)

-20° to 70°C (-4° to 158°F) as measured by electronics

user scalable with stoichiometer

2

2

2

per degree Celsius

2

, whichever is greater

2

2

2

in 30 seconds

90

1-10

Electronics Options

21, 22, 23

Special Condition of Use 200°C (392°F) maximum flange mounting temperature

Model XS-O2XPFA (with process end flame arrestor)

Electronics Options
01, 02, 03

Standards:

EN 60079-0:2006
EN 60079-1:2007

Standards:

EN 60079-0:2004
EN 60079-1:2003

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

Agency Certifications

Electronics Options
21, 22, 23

Special Condition of Use 200°C (392°F) maximum flange mounting temperature

Model XI

General Purpose Only

Installation Specifications

Probe Mounting:
Vertical or Horizontal

Probe Lengths and
Approximate Shipping Weights

Calibration: Semi-automatic or automatic
Cal Gases: 0.4% O2 and 8% O2, balance N
Reference Air:

(required)

Calibration Gas Line 300 ft (91 m) maximum length
Calibration Gas Flow: 5 scfh (2,5
Heater Electrical Power: 100-240 VAC ±10%, 50/60 Hz,

Traditional Architecture Cable: 200 ft (61 m) maximum length
Power Consumption of Probe
Heater:
Transmitter Electrical Power:

2½” NPT or flanged spool pieces are available, P/N
3D39761G02, to offset transmitter housing from hot
ductwork.

18 in (457 mm) 25 lbs. (11,3 Kg)

3 ft (0,91 m) 27 lbs. (12,2 Kg)
6 ft (1,83 m) 38 lbs. (17,2 Kg)

Optional ANSI/DIN Flange 10 lbs. (4,5 Kg)

0.5 scfh (0,25 /min), clean, dry, instrument-quality air

(20.95% O2), regulated to 5 psi (34 kPa)

/min) @ 5 psi (34 kPa)

1/2 in. -14 NPT conduit ports

776 VA maximum during warm-up

12 - 24 VDC (loop-powered from control room or Xi)

Standards:

EN 60079-0:2006
EN 60079-1:2004

Standards:

EN 60079-0:2004
EN 60079-1:2007

2

Electrical Power for Xi: 100-240VAC ±10%, 50/60 Hz
Power Consumption of Xi: 12 VA maximum or

Alarm Relay Outputs: Two provided - 2 Amperes, 30 VDC, Form-C
Optional Loss of Flame Input: Internally powered input to remove heater power.

Emerson Process Management has satisfied all obligations coming from the
European legislation to harmonize the product requirements in Europe.
performance characteristics are with operating variables constant. Specifications
subject to change without notice.

776 VA maximum with Traditional Architecture, 120V
Probes
450 VA maximum with Traditional Architecture, 44V
Probes

Actuated via dry contact output from user’s flame
scanner.

1

All static

1-11

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Table 1-1. Product Matrix, Hazardous Area O

XS-O2XPFA X-STREAM O2 Transmitter - Flameproof - with Process End Flame Arrestor

Code Probe Type

1 Snubber Diffuser, Standard Sensing Cell
2 Snubber Diffuser, Acid-Resistant Stoichiometer Sensing Cell
3 Ceramic Diffuser, Standard Sensing Cell
4 Ceramic Diffuser, Acid-Resistant Stoichiometer Sensing Cell
5 Hastelloy Diffuser, Standard Sensing Cell
6 Hastelloy Diffuser, Acid-Resistant Stoichiometer Sensing Cell

Code Probe Length

1 18" Probe
2 3’ Probe
3 6’ Probe

Code Mounting Plate

00 None
02 New Installation - Square Weld Plate with 2-1/2 inch NPT Threaded Hole
03 Flange for OXT/WC Hazardous Area Mounting (ANSI/DIN)
04 New Installation - Square Weld Plate with 2", 150# Studs and Flange
05 New Installation - Square Weld Plate with DIN Studs and Flange
08 Adapter for existing ANSI 3", 150# flange
09 Adapter for existing ANSI 4", 150# flange
10 Adapter for existing ANSI 6", 150# flange
11 Adapter for existing ANSI 3", 300# flange
12 Adapter for existing ANSI 4", 300# flange
13 Adapter for existing DIN 100 PN25/40 flange
99 Special Adapter

Transmitter with Process End Flame Arrestor

2

Code Electronics

01 Transmitter Electronics - HART, FM Certified, Class I, Zone 1,

AEx d IIB+H2, T3

02 Direct Replacement Probe, No Electronics, FM Certified, Class I, Zone 1,

AEx d IIB+H2, T3

03 Direct Replacement Probe for use with YEW Electronics, FM Certified, Class I, Zone

1, AEx d IIB+H2, T3

21 Transmitter Electronics - HART, ATEX/IECEx Certified, Class I, Zone 1,

Ex d IIB+H2, T3

22 Direct Replacement Probe, No Electronics, ATEX/IECEx Certified, Class I, Zone 1,

Ex d IIB+H2, T3

23 Direct Replacement Probe for use with YEW Electronics, ATEX/IECEx Certified,

Class I, Zone 1,AEx d IIB+H2, T3

Code Manual Calibration Accessories

00 None
01 Calibration and Reference Air Flowmeters with Reference Air

Regulator/Filter

02 Panel Mounted Reference Air Flowmeters with Reference Air

Regulator/Filter

XS-O2XPFA 1 1 00 01 01 Example

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Instruction Manual

Hazardous Area

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

Table 1-2. Product Matrix, Hazardous Area O2 Transmitter without Process End Flame Arrestor

XS-O2XP X-STREAM O2 Transmitter - Flameproof - No Process End Flame Arrestor

Code Probe Type

1 Snubber Diffuser, Standard Sensing Cell
2 Snubber Diffuser, Acid-Resistant Stoichiometer Sensing Cell
3 Ceramic Diffuser, Standard Sensing Cell
4 Ceramic Diffuser, Acid-Resistant Stoichiometer Sensing Cell
5 Hastelloy Diffuser, Standard Sensing Cell
6 Hastelloy Diffuser, Acid-Resistant Stoichiometer Sensing Cell

Code Probe Length

1 18" Probe
2 3’ Probe
3 6’ Probe

Code Mounting Plate

00 None
02 New Installation - Square Weld Plate with 2-1/2 inch NPT Threaded Hole
03 Flange for OXT/WC Hazardous Area Mounting (ANSI/DIN)
04 New Installation - Square Weld Plate with 2", 150# Studs and Flange
05 New Installation - Square Weld Plate with DIN Studs and Flange
08 Adapter for existing ANSI 3", 150# flange
09 Adapter for existing ANSI 4", 150# flange
10 Adapter for existing ANSI 6", 150# flange
11 Adapter for existing ANSI 3", 300# flange
12 Adapter for existing ANSI 4", 300# flange
13 Adapter for existing DIN 100 PN25/40 flange
99 Special Adapter

Code Electronics

11 Transmitter Electronics - HART, CSA Certified, Class I, Zone 1,

AEx/Ex d IIB+H2, T3

12 Direct Replacement Probe, No Electronics, CSA Certified, Class I, Zone 1,

AEx/Ex d IIB+H2, T3

13 Direct Replacement Probe, YEW Electronics, CSA Certified, Class I, Zone 1,

AEx/Ex d IIB+H2, T3

21 Transmitter Electronics - HART, ATEX/IECEx Certified, Class I, Zone 1,

Ex d IIB+H2, T3

22 Direct Replacement Probe, No Electronics, ATEX/IECEx Certified, Class I, Zone 1,

Ex d IIB+H2, T3

23 Direct Replacement Probe, YEW Electronics, ATEX/IECEx Certified, Class I, Zone 1,

Ex d IIB+H2, T3

Code Manual Calibration Accessories

00 None
01 Calibration and Reference Air Flowmeters with Reference Air

Regulator/Filter

02 Panel Mounted Reference Air Flowmeters with Reference Air

Regulator/Filter

XS-O2XP 1 1 00 11 01 Example

1-13

Hazardous Area

Instruction Manual

IM-106-910C, Rev. 1.0

X-STREAM O2 Transmitter

November 2009

Table 1-3. Product Matrix, Xi Interface and Advanced Feature Electronics (For use in non-hazardous areas only.)

Xi X-STREAM O2 Remote

Code Remote Type

01 Single Channel X-STREAM Interface
02 Single Channel X-STREAM Interface, accepting a loss-of-flame input to remove heater power with flame status relay
03 Dual Channel X-STREAM Interface
04 Single Channel X-STREAM Traditional Architecture for 120V Probes
05 Single Channel X-STREAM Traditional Architecture for 44V Probes

Code Mounting

00 No Hardware
01 Panel Mount Kit with Gasket
02 2" Pipe/Wall Mount Kit

Code Cable

00 No Cable
10 20’ (6 m) Cable
11 40’ (12 m) Cable
12 60’ (18 m) Cable
13 80’ (24 m) Cable
14 100’ (30 m) Cable
15 150’ (45 m) Cable
16 200’ (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 Funct ion

00 None
01 Single Channel
02 Dual Channel

Code 800 Deg C Process Function

00 None
01 Single Channel
02 Dual Channel

Xi 01 01 00 01 01 01 Example

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Instruction Manual

Hazardous Area

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

Table 1-4. Product Matrix, X-STREAM O2 Autocalibration Accessories (For use in non-hazardous areas only.)

XSO2CAL X-STREAM O2 Autocalibration Accessories

Code Single Probe Sequencers Autocalibration Options

00 None
01 SPS 4001B Single Probe Sequencer, general purpose NEMA 4X, includes check valve for probe

Code Intelligent Multiprobe Sequencers (IMPS)

00 None
01 IMPS single-probe, general purpose NEMA 4X, includes check valve for probe
02 IMPS two-probe, general purpose NEMA 4X, includes check valve for probe
03 IMPS three-probe, general purpose NEMA 4X, includes check valve for probe
04 IMPS four-probe, general purpose NEMA 4X, includes check valve for probe
05 IMPS single-probe, 115V heated general purpose NEMA 4X, includes check valve for probe
06 IMPS two-probe, 115V heated general purpose NEMA 4X, includes check valve for probe
07 IMPS three-probe, 115V heated general purpose NEMA 4X, includes check valve for probe
08 IMPS four-probe, 115V heated general purpose NEMA 4X, includes check valve for probe
09 IMPS single-probe, 220V heated general purpose NEMA 4X, includes check valve for probe
10 IMPS two-probe, 220V heated general purpose NEMA 4X, includes check valve for probe

11 IMPS three-probe, 220V heated general purpose NEMA 4X, includes check valve for probe

12 IMPS four-probe, 220V heated general purpose NEMA 4X, includes check valve for probe

XSO2CAL 00 04 Example

Table 1-5. Calibration Gases

Part Number Description

1A99119G01 Two disposable calibration gas bottles - 0.4% and 8% O

nitrogen - 550 liters each*
1A99119G02 Two flow regulators for calibration gas bottles
1A99119G03 Bottle rack

Note:

*Calibration gas bottles cannot be shipped via airfreight.

, balance

2

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Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

1-16

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Section 2 Installation

System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2

Hazardous Area Considerations . . . . . . . . . . . . . . . . . . . . page 2-4

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-5

Selecting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-5

Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-6

Optional Xi Enhanced Interface Installation . . . . . . . . . . . page 2-10

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-13

X-STREAM Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-13

Electrical Installation - X-STREAM O

Power Connections - Xi Enhanced Interface . . . . . . . . . .page 2-16

Traditional Architecture Cable Connections . . . . . . . . . .page 2-17

DR Probe - Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .page 2-20

DR Probe to Yokogawa Electronics Connections . . . . . .page 2-21

DR Probe Wired to the YEW Electronics . . . . . . . . . . . . . page 2-22

Reference Air Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-23

Calibration Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-25

Hazardous Area

X-STREAM O

Transmitter . . . . .page 2-14

2

Transmitter

2

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

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.

The X-STREAM Xi Enhanced Interface can be installed in general purpose areas only. Do
not install the Xi in hazardous areas or in the vicinity of flammable liquids.

T o maintain explosion-proof protection the X-STREAM O2 Transmitter must not be mounted
to any surface or flange that exceeds 200°C (392°F).

http://www.raihome.com

Hazardous Area
X-STREAM O2 Transmitter

T o maint ain explosion-proof protection the X-STREAM O2 Transmitter Model XS-O2XP must
not be installed in processes classified as hazardous areas. The model XS-O2XP
Transmitter is for use in non-hazardous areas only.

The Hazardous Area X-STREAM O2 Transmitter and probe with abrasive shield are heavy.
Use proper lifting and carrying procedures to avoid personal injury.

For X-STREAM O2 Transmitter Model XS-O2XP (without process side flame arrestor), the
non-process side of the analyzer can be placed in a hazardous rated area according to the
product label. The flue gas side of the probe of the Model XS-O2XP shall not be installed in
processes that are rated as hazardous.

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

SYSTEM
CONSIDERATIONS

For X-STREAM O2 Transmitter Model XS-O2XPFA (with process side flame arrestor), both
the non-process and process sides of the analyzer can be installed in hazardous rated areas
according to the product label. The process side of the probe should be considered a
potential ignition source if an explosive gas mixture is present.

If external loop power is used, the power supply must be a safety extra low voltage (SELV)
type.

To maintain explosion-proof protection of the X-STREAM O2 Transmitter, all cable entry
devices and blanking elements for unused apertures must be certified flameproof, suitable
for the conditions of use and be properly installed.

NOTE

All unused ports on the probe housing and Xi enclosure should be plugged
with a suitable fitting.

A typical system installation for the Hazardous Area X-STREAM with integral
electronics is shown in Figure 2-1.

A source of instrument air is required at the X-STREAM for reference air
flow [0.5 scfh (0,25

/min)]. Since the unit is equipped with an in place

calibration feature, provisions can be made to permanently connect
calibration gas bottles to the transmitter.

2-2

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Figure 2-1. Typical System
Installation

Hazardous Area

X-STREAM O2 Transmitter

If the calibration gas bottles will be permanently connected a check valve is
required next to the calibration fittings on the probe. This check valve is to
prevent breathing of the calibration gas line and subsequent flue gas
condensation and corrosion. The check valve is in addition to the stop valve
on the calibration gas bottles or the solenoid valves in the SPS 4001B or
IMPS 4000.

If the Xi Enhanced Interface option is not used, the 4 to 20 mA signal from the
probe will be loop-powered from the DCS. A 375 Field Communicator or AMS
is required to set up and operate the probe.

The optional Xi Enhanced Interface communicates with the probe transmitter
electronics via HART communications riding on the 4 to 20 mA signal comin g
from the transmitter. If using the 375 Field Communicator, it must be
connected to the 4 to 20 mA signal loop between the Xi and the control room
or data acquisition system. Connecting the 375 Field Communicator be tween
the transmitter and Xi will cause communication errors and affect system
operation.

NOTES:

The transmitter electronics is rated Type 4X and IP66 and is capable of
operation at temperatures from -40 to 85°C (-40 to 185°F).

Retain the packaging in which the X-STREAM arrived from the factor y in case
any components are to be shipped to another site. This packaging has been
designed to protect the product.

2-3

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

HAZARDOUS AREA
CONSIDERATIONS

Figure 2-2. In-Situ Probe
Orientation

The Hazardous Area X-STREAM O2 probe system (Figure 2-2) is an in-situ
device. The process end of the probe places a heated (736°C) sensing cell
directly into the process; usually the flue gas duct downstream of a
combustion process. The electronics end of the probe remains in the ambient
environment outside of the duct.

The instrument is configured in two versions. One version (XS-O2XPFA)
includes a process-side flame arrestor in front of the heated sensing cell and
is approved as follows:

• FM to NEC Class I, Zone 1, AEx d IIB +H2 T3 (US)

• FM to NEC Class I , Div. 1, Group B, C, D T3

• ATEX to Class I, Zone 1, Ex d IIB + H2 T3 (EU)

The second version (XS-O2XP) does not use the process-sid e flame arrestor.
It carries the following approvals:

• CSA to NEC Class I, Zone 1, AExd IIB + H2 T3 (US)

• CSA to NEC Class I, Zone 1, Ex d II B + H2 T3 (Canada)

• ATEX to Class I, Zone 1, Ex d IIB + H2 T3 (EU)

This version of the probe is to be used in situations where the process flue
gases are not considered to be hazardous.

Note that the hot sensing cell is controlled to 736°C (1357°F) and should be
considered as a potential ignition source if an explosive gas mixture is
permitted to come into contact with the hot cell. Rosemount Analytical
recommends consulting with National Fire Protection Agency NFPA 85
recommendations for a systemic appro ac h to furnace protection.

The Hazardous Area X-STREAM Xi electronics offers an optional feature that
provides power to the probe heater via an external contact from a flame safety
or burner management system.

The X-STREAM Transmitter is rated T3, meaning that the probe mounting
threads or flange does not exceed 200°C (392°F). (Process side flange
maximum temperature 200°C [392°F]).

2-4

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

Hazardous Area

MECHANICAL
INSTALLATION

Selecting Location 1. Figure 2-3 through Figure 2 -10 provide reference illustrations for the

mechanical installations of the equipment.

2. The location of the X-STREAM O
most important for maximum accuracy in the oxygen analyzing process.
The X-STREAM must be positioned so the gas it measures is
representative of the process. Best results are normally obtained if the
X-STREAM is positioned near the center of the duct (40-60% insertion).

3. Wider ducts may require several X-STREAM unit s since the O
due to stratification. A point too near the wall of the duct, or the inside
radius of a bend, may not provide a representative sample because of
the very low flow conditions.

4. The sensing point should be selected so the process gas temperature
falls within a range of 0 to 704°C (32 to 1300°F).

Transmitter in the stack or flue is

2

can vary

2

Do not allow the temperature of the X-STREAM electronics to exceed 85°C (185°F) or
damage to the unit may result.

5. The X-STREAM probe can operate to 850°C (1562°F) with an optiona l
Xi Enhanced Interface, though continued operation at these
temperatures will reduce cell and probe life. The temperature of the
integral electronics transmitter must not exceed 85°C (185°F) as
measured inside the electronics housing.

6. Check the flue or stack for holes and air leakage. The pr esence of this
condition will substantially affect the accuracy of the oxygen reading.
Therefore, either make the necessary repairs or install the X-STREAM
probe upstream of any leakage.

7. Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance. Allow adequate clearance
for removal of the X-STREAM probe.

2-5

Hazardous Area
X-STREAM O2 Transmitter

Figure 2-3. Probe Installation Details

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Probe Installation .

2-6

The probe was specially packaged to prevent breakage due to handling. Do not remove the
padding material from the probe until immediately before installation.

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

1. Ensure all components are available to inst all the X-STREAM O2 probe.
Refer to the probe installation details in Figure 2-3.

2. Stan dard mounting uses a 6-inch squ are weld plate with a 2-½ inch NPT
probe port welded to the stack or duct wall.

3. If using the optional ceramic diffusion element, the vee deflector must
be correctly oriented. Before inserting the X-STREAM probe, check th e
direction of gas flow in the duct. Orient the vee deflector so the apex
points upstream toward the flow (Figure 2-4).

4. If using the standard 6-in. square weld plate with a 2-½ in. NPT probe
port (Figure 2-5) or an optional flange mounting plate (Figure 2-6) weld
or bolt the plate onto the duct. The through hole di ameter in th e stack or
duct wall and refractory material must be at least 3-1/2 in. (89 mm).

Figure 2-4. Vee Deflector Orie ntation with Ceramic and Hastelloy Diffuser

X-STREAM O2 Transmitter

Hazardous Area

Figure 2-5. Square Weld Plate

2-7

Hazardous Area
X-STREAM O2 Transmitter

Figure 2-6. OXT/WC Retrofit Mounting Flange (threads onto probe)

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Figure 2-7. Optional Adapter Plate

2-8

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

5. Insert probe through the opening in the mo unting flange and bolt the unit
to the flange.

Do not thread the probe by turning the blue electronics housing. Use a pipe wrench on the
probe tube between the housing and threaded fitting. Do not overtighten.

Failure to use anti-seize compound or Teflon tape on threads could result in thread galling,
probe damage, and excessive difficulty in removal of probe. Do not overtighten the probe.

6. Install anti-seize compound on the pipe threads and screw the probe
into the adapter. Remember, this is a low-pressure seal that requires
very little torque; do not overtighten the probe tube.

7. The electrical conduit ports should be facing down fo r a horizontal probe
installation. In vertical probe installations, orient the probe so the system
cable drops vertically from the probe. Ensure the electrical conduit is
routed below the level of the circuit card. See Figure 2-8. This drip loop
minimizes the possibility that moisture will accumulate in the housing.

8. If insulation was removed to access the duct work for probe mounting,
make sure the insulation is replaced afterward. See Figure 2-8.

If the ducts will be washed down during outage MAKE SURE to power down the probes
and remove them from the wash area.

2-9

Hazardous Area
X-STREAM O2 Transmitter

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

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Optional Xi Enhanced
Interface Installation

The optional Xi Enhanced Interface is available in a panel mounting, wall
mounting, or pipe mounting configuration. Refer to Figure 2-9 or Figure 2-10
for the panel, wall, or pipe mounting details.

The X-STREAM Xi Enhanced Interface can be installed in general purpose areas only. Do
not install the Xi in hazardous areas or in the vicinity of flammable liquids.

1. Ensure all components are available to install the Xi.

2. Select a mounting location near or removed from the transmitter.
Consider the temperature limitations of the Xi (see "Specifications")
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 Enhanced In terface may have interior a nd
exterior protective membranes. Remove the protective membranes
prior to use of the Xi enclosure. 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.

2-10

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Figure 2-9. Xi Enhanced Interface - Panel Mounting Details

Hazardous Area

X-STREAM O2 Transmitter

2-11

Hazardous Area
X-STREAM O2 Transmitter

Figure 2-10. Xi Enhanced Interface - Wall/Surface and Pipe Mounting Details

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

2-12

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

ELECTRICAL
INSTALLATION

X-STREAM Transmitter

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.

Disconnect and lock out power before connecting the power supply.

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

To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation
of this equipment, connection to the main electrical power supply must be made through a
circuit breaker (min 10A) which will disconnect all current-carrying conductors during a fault
situation. This circuit breaker should also include a mechanically operated isolating switch.
If not, then another external means of disconnecting the supply from the equipment should
be located close by. Circuit breakers or switches must comply with a recognized standard
such as IEC 947.

The Xi Enhanced Interface can be installed in general purpose areas only. Do not install the
Xi in hazardous areas or in the vicinity of flammable liquids.

To maintain explosion-proof protection of the X-STREAM O2 Transmitter , all cable entry
devices and blanking elements for unused apertures must be certified flameproof, suitable
for the conditions of use and be properly installed.

NOTE

To maintain proper earth grounding ensure a positive connection exists
between the transmitter housing and earth. The connecting ground wire must
be 14 AWG minimum. Refer to Figure 2-11.

NOTE

Line voltage, signal, and relay wiring must be rated for at least 105°C
(221°F).

2-13

Hazardous Area
X-STREAM O2 Transmitter

NOTE

If metal conduit is used with the Xi Enhanced Interface the conduit should be
reliably bonded to protective earth. The grounding plate inside the Xi is not
bonded to PE and does not provide adequate grounding.

1. Refer to Figure 6-1 for all equipment item numbers in parentheses.
Remove right cover (11) from transmitter.

2. Connect the line (L1 wire) to the L1 terminal, the neutral (L2 wire) to the
L2/N terminal, and the ground wire to the ground lug (Figure 2-11). The
X-STREAM automatically accepts 100-240 VAC ±10% line voltage and
50/60 Hz. No setup is required.

3. Connect the 4-20 mA signal wires at the transmitter. Use a shielded
twisted wire pair. Do not allow bare shield wires to contact the circuit
boards. Insulate the shield wires prior to termination.

4. Terminate the shield only at the transmitter electronics housing unless
using a Xi Enhanced Interface. When using the Xi Enhanced Interface,
terminate the shield at both ends.

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

NOTE

The 4-20 mA signal represents the O
probe-mounted electronics. Superimposed on the 4-20 mA signal is HART
information accessible through a 375 Field Communicator or AMS software.

5. Install right cover (11) on transmitter.

6. Follow the remaining electrical installation instructions only if the Xi
Enhanced Interface is included with your system configuration.

Figure 2-11. Electrical Installation - X-STREAM O

Transmitter

2

value and also powers the

2

2-14

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

Optional Xi Enhanced
Interface

Figure 2-12. Signal Connections Xi Enhanced Interface

1. Remove cover screws from the front cover of the Xi Enhanced Interface.
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 Enhanced Interface. If your system is configured to operate two
transmitter probes there are two I/O interface boards.

3. See Figure 2-12. 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 extent past the shield.

NOTE

Installation of the ferrite clamp over the 4-20 mA OUT wires is required for
compliance with the European EMC Directive.

Figure 2-13. Alarm Indicator Relay Terminals

2-15

Hazardous Area
X-STREAM O2 Transmitter

4. Terminate the shield of the 4-20 mA signal wires at the designated
ground terminal of the Xi Enhanced Interface. 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 2-13 for the alarm indicator relay terminals.

8. Reinstall the I/O board in the card rack of the Xi Enhanced Interface.

9. If your system is configured to operate two transmitter probes, repeat
steps 2 through 7 to connect the other probe signal wir es.

10. Remove the connector from the power supply board located on the
left-hand side of the card rack inside the Xi Enhanced Interface.

11. See Figure 2-14. 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 cover of the Xi Enhanced Interface.

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Figure 2-14. Power Connections - Xi Enhanced Interface

2-16

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

Optional Flame Safety
Interlock

Figure 2-15. Flame Safety Interlock - Wiring Diagram

A flame safety interlock by Emerson Process Management is available for
heater power disconnect whenever there is a loss of the process flame or a
heater runaway condition (heater over-temperature) in the X-STREAM O
Transmitter. A simplified wiring diagram for the flame safety interlock is shown
in Figure 2-15. This input is internally powered by the Xi Enhanced Interface
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.

2

T raditional Architecture
Cable Connections

A traditional architecture X-STREAM O2 Transmitter configuration is used to
provide for remote location of the transmitter electronics. All electronics are
housed inside the Xi Enhanced Interface. A multi-conductor power/signal
cable connects between the probe and the Xi. Use th e follo wing p ro cedur e to
connect the traditional architecture probe to the Xi Enhanced Interface.

NOTE

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.

2-17

Hazardous Area
X-STREAM O2 Transmitter

1. Run the 7-conductor cable between the Hazardous Area X-STREAM
traditional architecture probe and the installation site for Xi Enhanced
Interface. Use new cable conduit or trough as needed.

2. Remove covers from the probe.

3. Install the cable and lead wires in the left-hand conduit port in the
bottom of the probe housing.

4. Install the cable at the probe housing and at the Xi enclosure according
to the following procedure:

a. Unscrew locking nut from gland assembly (Figure 2-16) and slide

locking nut back along cable.

b. Pull the gland body away from the plastic insert. Use care not to

damage the cable shield braid.

c. Insert the cable wires into the proper entry port in either the probe

housing or the Xi 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 Xi enclosure, insert the gland body into the lef t front cab le 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.

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Figure 2-16. Traditional Architecture Cable Gland Assembly

2-18

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

5. Connect the cable lead wires to the probe connector, Figure 2-17.

6. At the Xi Enhanced Interface, connect the cable leads to the connectors
on the transmitter I/O board as indicated in Figure 2-18.

Figure 2-17. X-STREAM Probe Wiring - Traditional Architecture

Hazardous Area

X-STREAM O2 Transmitter

2-19

Hazardous Area
X-STREAM O2 Transmitter

Figure 2-18. Transmitter Board Connections at Xi - Traditional Architecture

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Figure 2-19. DR Probe - Wiring Diagram

2-20

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

Direct Replacement (DR)
Probe Connections

DR Probe to Yokogawa
Electronics Connections

A direct replacement probe is available for connection to an existing
electronics package. Use the following procedure to co nnect a DR probe to
the transmitter electronics.

1. Remove covers from probe.

2. Feed all DR probe wiring through line power conduit of probe. Add new
lead wire junction box and conduits as needed.

3. Connect DR probe heater power leads to DR probe connector,
Figure 2-19.

4. Connect O

The DR probe can be wired to work with Yokogawa electronics. Connect the
cabling from the Yokogawa electronics terminal to the probe terminal as
shown in Figure 2-20. Review the following information. If needed, replace the
CJC board mounted inside the RD probe.

Yokogawa used two types of CJC devices in their probes. The older style
used a transistor type device and the newer version used a resistance
thermocouple device (RTD). Each device performs differently in providing a
temperature feedback signal and cannot be interchanged.

The DR probe is provided with two Cold Junction Compensation (CJC)
boards for use with Yokogawa electronics. The type of Yokogawa electronics
used will dictate which CJC board should be installed in the DR probe.

NOTE

These instructions are not all inclusive of the possible Yokogawa electronics
currently in use. Other electronics or CJC devices may exist. Refer to the
following instructions as an aid in selecting the proper CJC board.

signal and thermocouple wires to DR probe connector.

2

Transistor Type CJC Board (P/N 3D39505G01)
Identification: Metal can or potted device at Q1
YEW Probes: Z021D (Suffix varies)
Yew Electronics: Z8A Averager

AV8C Averager
AV550 Averager
(properly programmed)

Misapplication: Electronics will read near 25

but the reading will slowly decrease as the

temperature rises.
RTD Type CJC Board (P/N 3D39505G02)
Identification: 2-lead resistive (RTD) device at Q1

(bent over and bonded to board)
YEW Probes: ZR22 (Suffix varies)
YEW Electronics: AV550 Averager (properly programmed)

ZR402 Analyzer

Misapplication: Electronics will read near 200

°C at ambient,

°C at ambient.

2-21

Hazardous Area
X-STREAM O2 Transmitter

Figure 2-20. DR Probe Wired to the YEW Electronics

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

2-22

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

Hazardous Area

PNEUMATIC
INSTALLATION

Reference Air Package After the X-STREAM is installed, connect the reference air set to the

X-STREAM unit. Refer to the schematic diagram in Figure 2-21 and the
mounting dimensions in Figure 2-22 for a locally assembled reference air
supply.

Instrument Air (Reference Air): 5 psi (34 kPa) minimum, 8 psi (54 kPa)
maximum at 0.5 scfh (0,25
hydrocarbons. Regulator outlet pressure should be set at 5 psi (34 kPa).
Reference air can be supplied by the reference air set or the optional SPS
4001B or IMPS 4000.

Figure 2-21. Plant Air Schematic Diagram

/min) maximum; less than 40 parts per million total

Figure 2-22. Air Set, Plant Air Connection

2-23

Hazardous Area
X-STREAM O2 Transmitter

Figure 2-23. Manual Calibration Panel

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

2-24

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

Reference air components are included in the optional Manual Calibration
Panel (Figure 2-23), the SPS 4001 Single Probe Autocalibration Sequencer,
and the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer.

NOTES

The optional SPS 4001B or IMPS 4000 Sequencer can only be used when
the Xi Enhanced Interface option is sele cted. The Xi Enhanced Interface m ust
be properly configured for autocalibration. See Appendix 3: Configuration of
Hazardous Area X-STREAM O2 Transmitter.

See the SPS 4001B Single Probe Autocalibration Sequencer Instruction
Manual or the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer
Instruction Manual for wiring and pneumatic connections.

Hazardous Area

Calibration Gas Two calibration gas concentrations are used with the X-STREAM, Low Gas -

0.4% O
Calibration Panel is shown in Figure 2-23. See Figure 2-24 for the
X-STREAM probe calibration gas connection ports .

balance N2, and High Gas - 8% O2, balance N2. An optional Manual

2,

Figure 2-24. X-STREAM
Calibration Gas Connections

Do not use 100% nitrogen as a low gas (zero gas). It is suggested that gas for the low (zero)
be between 0.4% and 2.0% O
than 40 parts per million. Failure to use proper gases will result in erroneous readings.

Calibration Gas: 15 psig (103 kPa gage) maximum, 5 SCFH (2,5 L/min).
Establish the calibration gas flow only with a clean diffuser.

NOTE

Upon completing installation, make sure that the X-STREAM is turned on and
operating prior to firing up the combustion process. Damage can result from
having a cold X-STREAM unit exposed to the proc ess gases.

During outages, if possible, leave all X-STREAM units running to prevent
condensation and premature aging from thermal cycling.

. Do not use gases with hydrocarbon concentrations of more

2

If the ducts will be washed down during outage, MAKE SURE to power down the
X-STREAM units and remove them from the wash areas.

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Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

2-26

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O

Hazardous Area

Transmitter

2

Section 3 Configuration of Hazardous Area

V E RIFY INSTALLATION

X-STREAM O

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-1

Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1

Xi Configuration (if equipped) . . . . . . . . . . . . . . . . . . . . . .page 3-2

Set Test Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-2

Alarm Relay Output Configuration . . . . . . . . . . . . . . . . . .page 3-3

Analog Output Configuration . . . . . . . . . . . . . . . . . . . . . . page 3-4

Autocalibration Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-5

Optional Advanced Features Inside the Xi . . . . . . . . . . . .page 3-5

Extended Process Temperature Range to 800°C . . . . . . .page 3-6

Stoichiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-6

Programmable Reference . . . . . . . . . . . . . . . . . . . . . . . . . page 3-7

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.

Transmitter

2

If external loop power is used, the power supply must be a safety extra low voltage (SELV)
type.

Ensure the Hazardous Area X-STREAM O2 Transmitter and Xi are installed
and wired correctly according to Section 2: Installation.

Transmitter 1. Refer to Figure 6-1. Remove right cover (12) to expose the transmitter

electronics board (8).

2. Check the electronics board wiring (Figure 2-11). Be sure the power
and 4-20 mA signal are properly connected and secure. To avoid a
shock hazard, the power terminal cover must be installed.

3. Install right cover (12).

4. Remove the left cover (18). Verify that the reference air and calibration
gas hoses (Figure 6-3) are properly connected. Then, reinstall the left
cover (18).

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Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Xi Configuration
(if equipped)

Figure 3-1. I/O Board Jumper 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 X-STREAM 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 Enha nced Interface box. All fo ur dip
switches on switch SW4 must be set to the OFF position, as shown.

SET TEST GAS VALUES Use a Field Communicator or the optional Xi Enhanced Interface to set test

gas values for calibration.
A Hazardous Area X-STREAM Transmitter and Xi Enhanced Interface

shipped from the factory have test gas values for low and high set to 0.4%
and 8.0% respectively. This same process must be performed any time a
replacement Transmitter Boa rd, IO Board or DR Board is installed.

Set Test Gas Values Using Field Communicator - Transmitter Only or
Xi Enhanced Interface

1. Use the 375 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.

3-2

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

Set Test Gas Values Using Xi Enhanced Interface 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 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.

ALARM RELAY OUTPUT
CONFIGURATION

Table 3-1. Alarm Relay Output
Configurations

The Xi Enhanced Interface 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 Communicator . A list of p ossible configurations is shown in
Table 3-1. Each alarm relay output can be configured separately.

If the Xi Enhanced Interface 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 Enhanced Interface is not configured with the
optional Flame Safety Interlock, "Heater Relay" is not valid and cannot be
chosen for Alarm 2.

Mode Configuration

No Alarm* The output is not configured for any alarm condition.
Unit Alarm The output is configured for a Unit Alarm.

Alarm The output is configured for a Low O2 alarm.

Low O

2

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** The output is configured for a Unit alarm and a Calibration

Recommended display.

/Cal Rec The output is configured for a Low O2 alarm and a Calibration

Low O

2

Low O2/Unit/Cal Rec The output is configured for a Low O2 alarm, a Unit alarm, and a

Heater Relay The output is configured for Flame Safety Interlock.

* The default configuration for Alarm 2

** The default configuration for Alarm 1

Recommended display.

Calibration Recommended display.

Configuring Alarm Relays with the Field Communicator

1. Use the 375 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.

3-3

Hazardous Area
X-STREAM O2 Transmitter

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.

Configuring Alarm Relays with the Xi Enhanced Interface
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.

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

ANALOG OUTPUT
CONFIGURATION

The analog output signal from either the Hazardous Area X-STREAM
Transmitter or Xi Enhanced Interface can be configure d for the 4-20 mA range
and fault condition.

A Hazardous Area X-STREAM Transmitter and Xi Enhanced Interface
shipped from the factory have the analog outputs set to a 4 to 20 mA range
with a 3.5 mA alarm level. This same process must be performed any time a
replacement Transmitter Boa rd or IO Board is installed.

Configuring the Analog Output with the Field Communicator ­Transmitter Only or Xi Enhanced Interface

1. Use the 375 Field Communicator software to access the HART menu.

2. From the DEVICE SETUP menu, select DETAILED SETUP.

3. From the DETAILED SETUP menu, select ANALOG OUTPUT.

4. From ANALOG OUTPUT, set the following parameters:
Transmitter

O2 LRV - O2 value at the lower analog output value (0 mA or 4 mA)
O2 URV - O
O2 AO Range - Range of the analog output (0-20 mA or 4-20 mA)

Xi Enhanced Interface

O2 LRV - O2 value at the lower analog output value (0 mA or 4 mA)
O2 URV - O
O2 AO Range - Range of the analog output (0-20 mA or 4-20 mA)
Signal Alarm Level - O

value at the upper analog output value (20 mA)

2

value at the upper analog output value (20 mA)

2

alarm level (3.5 mA or 21.1 mA)

2

3-4

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

Configuring the Analog Output with the Xi Enhanced Interface
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, set the following parameters:

O2 LRV - O
O2 URV - O
AO Range - Range of the analog output (0-20 mA or 4-20 mA)
Signal Alarm Level - O

value at the lower analog output value (0 mA or 4 mA)

2

value at the upper analog output value (20 mA)

2

alarm level (3.5 mA or 21.1 mA)

2

AUTOCALIBRATION
SETUP

If autocalibration is desired, the Xi Enhanced Interface must be used with
either an SPS 4001B or IMPS 4000. The Xi Enhanced Inte rface 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 Section 4, Startup and Operation for
details on manual calibration procedures.

An Xi Enhanced Interface is shipped from the factory without autocalibration
configured. This same process must be performed any time a replacement
IO Board is installed.

Configuring Autocalibration with the Field Communicator

1. Use the 375 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.

Configuring Autocalibration with the Xi Enhanced Interface
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 CAL SETUP.

5. From CAL SETUP, select Auto Cal.

6. Press the RIGHT arrow key to change the state from NO to YES.

OPTIONAL ADVANCED
FEATURES INSIDE
THE XI

Advanced features available inside the Xi Enhanced Interface are typically
purchased with the Hazardous Area X-STREAM Transmitter. However, these
advanced features are also available for field retrofit.

A Xi Enhanced Interface is shipped from the factory with the optional
enhanced software features enabled based on the configuration.

3-5

Hazardous Area
X-STREAM O2 Transmitter

The IO 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.

If the existing IO 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.

NOTE

For enhanced software feature option upgrades or to enable the feature to
duplicate the existing configuration, contact Emerson Process Management
at 1-800-433-6076. Reference the following:

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

6A00269G01 Enhanced Software Option Upgrade, Stoichiometric Function
6A00269G02 Enhanced Software Option Upgrade, Programmable

Reference Function

6A00269G03 Enhanced Software Option Upgrade, 800°C Process

Function

Extended Process
Temperature Range to
800°C (1472°F)

The Hazardous Area X-STREAM Oxygen Analyzer employs a heater and
thermocouple to maintain a temperature setpoint at 736
Temperature control is maintained within ±1
about 705
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. It should be noted that cell life will be reduced by
continuous operation at temperatures above 705
temperatures are expected to be continuously above 705
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 also be purchased as a field retrofit.

°C (1300°F). This is satisfactory for most applications, but

°C to process temperatures of

°C (1300°F). If process

°C (1357°F).

°C, we recommend

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.

3-6

The operator can see if his control recovery actions ar e ha vin g th e de sir ed
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.

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

NOTE

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 oxyge n levels typically found
in combustion flue gasses (2-4% oxygen), and is most accurate at these
levels. When measuring near 20.95% O
millivolts of signal, and accuracy degrades.

The programmable reference feature permits the user 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 gasses into the burner
windbox prior ahead of the burner to reduce NOx emissions.

Moisture monitoring - measuring the amount of moisture coming off of
industrial dryers by noting the dilution effect water vapor has on the normal

20.95% ambient drying air. (Non-combustion 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 reg enerators.

, the sensor develops only a few

2

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Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

3-8

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O

Hazardous Area

Section 4 Startup and Operation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-1

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-1

Operation Via Xi Enhanced Interface . . . . . . . . . . . . . . . . page 4-2

Startup Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-2

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-3

Xi Enhanced Interface Controls . . . . . . . . . . . . . . . . . . . .page 4-3

Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-3

Xi Menu, Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-4

System Parameter Descriptions . . . . . . . . . . . . . . . . . . . . page 4-7

Probe Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . page 4-8

Operation Via HART/AMS . . . . . . . . . . . . . . . . . . . . . . . . . page 4-11

Field Communicator Signal Line Connections (No Xi) . . page 4-11
Field Communicator Signal Line Connections (with Xi) . page 4-15

Field Communicator Menu Trees . . . . . . . . . . . . . . . . . . . page 4-16

Off-line and On-line Operations . . . . . . . . . . . . . . . . . . . .page 4-16

Calibration - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-21

O2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-21

O

Calibration with Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4-22

2

O

Calibration with Xi and Field Communicator . . . . . . . page 4-23

2

D/A Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-24

D/A Trim without Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-24

D/A Trim with Xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4-25

Transmitter

2

OVERVIEW Interface to the Hazardous Area X-STREAM O

calibration and diagnostics can be via a 375 Field Communicator or Asset
Management System or with the optional Xi Enhanced Interface.

Star tup is common to all configurations of the Hazard ous Area X-STREAM O
Transmitter. Setup, calibration and diagnostic operations will differ depending
on the selected interface for communications with the transmitter. The
following covers operation via 375 Field Communicator with and without the
Xi Enhanced Interface and operation via the Xi Enhanced Interface without
HART.

STARTUP The Hazardous Area X-STREAM O

signal wiring is connected and heater power is supplied to the tra nsmitter. AC
line voltage to the heater should be connected first, followed by the 24 vdc
power/signal loop for the transmitter electronics.

Transmitter begins ope ration when the

2

Transmitter for setup,

2

2

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Hazardous Area
X-STREAM O2 Transmitter

The transmitter probe will take approximately 45 minutes to warm up to the

°C heater setpoint. The 4-20 mA signal will remain at a default value of

736

3.5 mA through this warm-up period. Once warm, the probe will be reading
oxygen, and the 4-20 mA signal will be reading based on the default range of
0-10% O

For the Hazardous Area X-STREAM O
Interface, the system will begin operation after heater power is connected to
the transmitter and 24 vdc loop-power/signal wiring is connecte d between the
transmitter and the Xi Enhanced Interface.

NOTE

The Xi Enhanced Interface can operate one or tw o Ha zar d ous Are a
X-STREAM O
advanced features such as elevated process temperature capability to 800
autocalibration via an SPS solenoid box, a stoichiometer fea ture for indicating
the level of oxygen deficiency in reducing conditions, and programmable
reference to enhance accuracy at near ambient levels of O2.

.

2

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Transmitter with the Xi Enhanced

2

Transmitters. The Xi Enhanced Interface also carries

2

°C,

Operation Via Xi
Enhanced Interface

The following procedures describe operations using the Xi Enhanced
Interface 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.

Startup Display The probe will take approximately 45 minutes to warm up to the 736°C heater

setpoint. The 4-20 mA signal display will remain at a default value of 3.5 mA
through this warm-up period. Once warm, the probe will be reading oxygen
and the 4-20 mA signal display will be the 0 to 10% O

Figure 4-1. Xi Enhanced
Interface Display (Typical)

value.

2

4-2

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

Hazardous Area

Error Conditions If there is an error condition at startup, an alarm message will be displayed.

Refer to Section 5: Troubleshooting to determine the cause of the error. Clear
the error and cycle power. The %O
less the alarm message.

and temperature display should return

2

Xi Enhanced Interface
Controls

The Xi Enhanced Interface 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 con trol 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 previous menu level.
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 dat a 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.

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 the Xi Menu, Figure 4-2).

The factory default upon enabling the password protection is ROSE, but the
password can consist of any 4 alpha/numeric characters.

If the user forgets the password, call Rosemount Analytical technical support
at 800-433-6076 to gain access to a master password.

A "Lock" icon will be displayed at the top right corner of the main display when
password protection is in effect.

The password protection will relock itself after a certain number of seconds
with no button pushes (defined as "revert time" in the same "LCD setup"
menu). Users can also force the front panel to be locked by selecting System
Main Menu> Log Off. The Log Off selection will perform no 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 will fall
back to a disabled condition after a reset.

4-3

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X-STREAM O2 Transmitter

Figure 4-2. Xi Menu, Sheet 1 of 3

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

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Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Figure 4-2. Xi Menu, Sheet 2 of 3

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X-STREAM O2 Transmitter

4-5

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X-STREAM O2 Transmitter

Figure 4-2. Xi Menu, Sheet 3 of 3

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

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November 2009

Hazardous Area

X-STREAM O2 Transmitter

SYSTEM PARAMETER
DESCRIPTIONS

Among the parameters available through th e Xi and 37 5 Field Communica to r
menus are a number of "System Parameters". The system parame ters define
variables that configure the Xi in the transmitter system. System parameters
are described in the following table.

PARAMETER

CPU

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 Poll Addr -- Polling Address - Address used to identify a Field Device; changeable by the user to control.
N Serial Number -- I/O board serial number.
N Features -- Available advanced software features for the I/O board.

N EE Erase Count -- This is for nonvolatile memory diagnostic only.
Y Num Probe -- Number of probes configuration:

Y Probe Sel -- This parameter is applicable only if the Num Probe configuration is set to 2. It defines which

Y Probe 1 Enable -- Probe 1 state. If enabled, the probe menu will be displayed otherwise it will not be displayed.

Y Probe 2 Enable -- Probe 2 state. If enabled, the probe menu will be displayed otherwise it will not be displayed.

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 (O
Y Line 3 DataL -- Main display, line 3 left hand side data:

Y Line 3 DataR -- Main display, line 3 right hand side data:

Y Line 4 DataL -- Main display, line 4 left hand side data:

Y Line 4 DataR -- Main display, line 4 right hand side data:

Y Revert Time min Xi display reverts to main display time. Also locks screen if password protection is enabled.
Y Language -- 0 displays English

Y Contrast -- Display contrast: (120 to 200)
Y Alarms -- See section 5, Troubleshooting, ”Alarm Indications”.
Y Password -- Security Password
Y Enable Password -- Enables/disables security password protection

NAME

UNITS PARAMETER DESCRIPTION

ON: feature supported.
OFF: feature not supported.

If set to 1, use One Probe configuration for the Main display.
If set to 2, use Two Probes configuration for the Main display.

probe is to be displayed.

(No, Yes)

(No, Yes)

0 displays PV (O
1 displays SV (O
2 displays TV (Cell Imp)
3 displays 4V (Cell mV)

0 displays PV (O
1 displays SV (O
2 displays TV (Cell Imp)
3 displays 4V (Cell mV)

0 displays PV (O
1 displays SV (O
2 displays TV (Cell Imp)
3 displays 4V (Cell mV)

0 displays PV (O
1 displays SV (O
2 displays TV (Cell Imp)
3 displays 4V (Cell mV)

1 displays Spanish
2 displays German

)

2

Temp)

2

)

2

Temp)

2

)

2

Temp)

2

)

2

Temp)

2

), 1 displays SV (O2 Temp)

2

4 displays CJC Temp
5 displays AO
6 displays OP Mode
7 displays Tag

4 displays CJC Temp
5 displays AO
6 displays OP Mode
7 displays Tag

4 displays CJC Temp
5 displays AO
6 displays OP Mode
7 displays Tag

4 displays CJC Temp
5 displays AO
6 displays OP Mode
7 displays Tag

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X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

PROBE PARAMETER
DESCRIPTIONS

Among the parameters available through the Xi and 375 Communicator
menus are a number of "Probe Parameters". The probe p arameters define
variables that configure a specific probe in the transmitter system. Probe
parameters are described in the following table.

PARAMETER

TX I/O

Y Y O2 % Current oxygen concentration value (O2%). The value should reflect the last good O2 value if it

Y Y O2 Temp degC Current O2 sensor temperature.
Y Y CJC Temp degC Current cold junction temperature.
N Y Elec Temp degC Current electronic temperature measured at the I/O board.
Y Y O2 Cell mV Raw mV value for ZrO
N Y TC Volt mV O2 T/C voltage.
Y Y Cell Imp Ohm Cell impedance/sensor resistance measured.
Y Y Htr Volt Volt Heater voltage.
Y Y CPU Volt Volt Transmitter CPU voltage.
Y Y O2 AO mA Analog output value represents the O2 concentration measurement.
N Y O2 AO% % O2 analog output percentage for O2 AO.
Y Y O2 Temp Max degC This is the highest O2 sensor temperature reached since last reset.
Y Y CJC Temp Max degC This is the highest temperature reached at the cold junction since last reset.
N Y Elec Temp Max degC This is the highest temperature reached at the IO board since last reset.
Y Y Htr Volt Max degC This is the highest heater voltage reached since last reset.
Y Y Htr Duty Cycle -- O2 heater duty cycle. Value between 0 and 1.
Y Y PID SP degC PID temperature set point.
Y Y Htr Ramp Rate degC/s Heater ramp rate calculated in degree C per second.
N Y Flame Stat In -- Flame status input state.

N Y SPS/IMPS In -- SPS/IMPS input state.

N Y SPS/IMPS Out -- SPS/IMPS output state.

N Y Alm Relay 1 Out -- Alarm Relay 1 output state.

N Y Alm Relay 2 Out -- Alarm Relay 2 output state.

Y Y OP Mode -- Device operating mode:

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 assignment. (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

Y Y Cal Const mV Current calibration constant. This is the constant value that was calculated as a result of the last

Y Y Cal Imp Ohm Cell Impedance. This is the sensor resistance that was calculated as a result of the last

N Y Prev Slope mV/Dec Previous calibration slope. There are ten calibration results. 1 is the most recent and 10 is the

N Y Prev Const mV Previous calibration constant. There are ten calibration results. 1 is the most recent and 10 is

NAME

UNITS PARAMETER DESCRIPTION

is in the "Lock" state during calibration.

sensor.

2

(OFF/ON)

(OFF/ON)

(OFF/ON)

(OFF/ON)

(OFF/ON)

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)

successful calibration.

successful calibration. It is valid between -4mV and +10mV.

successful calibration.

least recent calibration slope.

the least recent calibration constant.

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November 2009

PARAMETER

TX I/O

N Y Prev Cal Imp Ohm Previous Cell Impedance. This is the sensor resistance that was calculated as a result of

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 of 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 th e slope value that will be used to calculate O2.
Y Y O2 Const mV O2 constant. This is the constant value that will be used to calculate O2.
N Y T90 Filter sec Analog output T90 time. It represents the time to take a step change in oxygen to reach 90% of

N Y O2 Cell Ref % O2 sensor reference gas percentage. It allows using a sensor reference gas other than air.
N Y O2 Temp SP degC O2 sensor temperature set point. It allows measurement of oxygen with an elevated sensor

N Y Features -- Advanced software features.

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.

N Y Alarm Relay 2 -- Alarm Relay 2 mode. (no alarm; unit alarm; low O2 alarm; low O2/unit alarm

N Y Low O2 Alm % Low O2 alarm threshold.
N Y Hi Temp Alm % High temperature alarm threshold.
N Y AO Tracks -- Analog output track O2 sensor measurement during a calibration. (No, Yes).
N Y Auto Cal -- Enable/disable automatic calibration.

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

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

Y Y Gas Time sec Test Gas application time. This is the length of time test gases are applied to the O2 probe

Y Y Purge Time sec Test Gas purge time. This is the length of time before the output will be returned to the process

N Y Cal Interval hr Automatic calibration interval. The number 9999 disables the automatic timed calibration.
N Y Next Cal Time hr Time remaining until the next automatic periodic calibration. The number 9999 disables the next

Y Y T EE Val -- Transmitter board nonvolatile memory diagnostic.
NYIO
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 IO board.
Y Y Alarms -- Current Alarms (See section 5, Troubleshooting, ”Alarm Indications”.)

NAME

EE Val -- I/O board nonvolatile memory diagnostic.

UNITS PARAMETER DESCRIPTION

previous successful calibration. There are ten calibration results. Index 1 is the most recent and
Index 10 is the least recent sensor resistance measured.

the final value at the filter output.

temperature. (0=736 degC set point; 1=834 degC set point)

(0=Stoichiometer; 1=Programmable Reference; 2=Elevated Temperature)

(no alarm; unit alarm; low O2 alarm; low O2/unit alarm;
Cal recommended; Cal recommended/unit alarm; low O2/Cal recommended;
low O2/unit alarm/Cal recommended)

Cal recommended; Cal recommended/unit alarm; low O2/Cal recommended;
low O2/unit alarm/Cal recommended; Heater relay)

No = Set to Manual calibration mode.
Yes = Set to Automatic calibration mode.

of a calibration.

of a calibration.

during low or high Test Gas phase of a calibration.

reading after a calibration.

automatic timed calibration.

X-STREAM O2 Transmitter

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X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

OPERATION VIA
HART/AMS

Field Communicator
Signal Line Connections
(No Xi)

The 375 Field Communicator is a handheld communications interface device.
It provides a common communications link to all microproce ssor-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 Field Communicator, details the specific functions of all the keys.

The 375 Field Communicator accomplishes its task using a frequency shift
keying (FSK) technique. With the use of FSK, high-frequency digital commu­nication signals are superimposed on the X-STREAM unit's 4 -20 mA current
loop. The 375 Field Communicator does not disturb the 4-20 mA signal, since
no net energy is added to the loop.

NOTES

The 375 Field Communicator must be upgraded to System Software 2.0 with
Graphic License for operation with the Hazardous Area X-STREAM O
Transmitter. The AMS software must be upgraded to AMS 8.0 or above for
operation with the Hazardous Area X-STREAM O

Contact Emerson Process Management’s Global Service Center (GSC) at
1-800-833-8314 to upgrade the 375 Field Communi cator software to System
Software 2.0 with Graphic License.

To interface with the X-STREAM, the 375 Field Communicator requires a ter­mination point along the 4-20 mA current loop and a minimum load resist ance
of 250 ohms between the communicator and the power supply.

The 375 Field Communicator can connect to th e X-STREAM unit's analog
output signal line at any wiring termination in the 4-20 mA current loop . Ther e
are two methods of connecting the 375 Field Communicator to the signal line.
For applications in which the signal line has a load resistance of 250 ohms or
more, refer to method 1 shown in Figure 4-3. For applications in which the sig­nal line load resistance is less than 250 ohms, refer to method 2 shown in
Figure 4-5.

Transmitter.

2

2

4-10

Method 1, For Load Resistance

Refer to Figure 4-3 and the following instructions to connect the 375 Field
Communicator to a signal line with a load resistance of 250 ohms or more.

$ 250 Ohms

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Figure 4-3. Signal Line Connections, ≥ 250 Ohms Load Resistance

X-STREAM O2 Transmitter

Hazardous Area

Signals are not intrinsically safe. In an explosive atmosphere do not make connections to
the 375 Field Communicator’s serial port, 4-20 mA signal line, or NiCad recharger jack.

Using the supplied lead set, connect the 375 Field Communicator in parallel
with the X-STREAM. Use any wiring termination points in the analog output
4-20 mA signal line.

The 375 Field Communicator may also be connected directly to the
transmitter electronics board. Refer to Figure 4-4 for connecting the 375 Field
Communicator at the H1 and H2 terminals on the O
board. The AM+ and AM- test points shown in Figure 4-4 are provided to
monitor the 4-20 mA signal without breaking into th e loo p.

transmitter electronics

2

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X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Figure 4-4. 375 Field Communicator Connection at the O

Transmitter

2

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Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Method 2, For Load Resistan ce < 250 ohms

Refer to Figure 4-5 and the following steps to connect the 375 Field Commu­nicator to a signal line with < 250 ohms load resista nce.

Signals are not intrinsically safe. In an explosive atmosphere do not make connections to
the 375 Field Communicator’s serial port, 4-20 mA signal line, or NiCad recharger jack.

1. At a convenient point, break the analog output 4-20 mA signal line and
install the optional 250 ohm load resistor.

2. Plug the load resistor into the loop conne ctors (located on the rear panel
of the 375 Field Communicator).

Figure 4-5. Signal Line Connections, < 250 Ohms Load Resistance

X-STREAM O2 Transmitter

Hazardous Area

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X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Field Communicator
Signal Line Connections
(with Xi)

Figure 4-6. 375 Field Communicator Connection at the Xi Enhanced Interface

Whenever the Hazardous Area X-STREAM O2 Transmitter includes the Xi
Enhanced Interface option, be sure to connect the 375 Field Communicator
only to the 4 to 20 mA signal loop wiring between the Xi Enhanced Interface
and the control room or data acquisition system as shown in Figure 4-6.
When working at the Xi, the 375 Field Communicator can be connected
directly to test points TP21 and TP22 on the Xi Enhanced Interface I/O Board.
The AM+ and AM- test points are provided to monitor the 4-20 mA signal
without breaking into the loop.

4-14

Do not use the H1 and H2 terminals or connect the HART in the probe (transmitter-to-Xi)
4-20 mA signal loop if your system includes the Xi Enhanced Interface. Xi communication
with the transmitter will be disrupted if a 375 Field Communicator is connected to the H1
and H2 terminals or to the transmitter-to-Xi signal loop.

The Xi Enhanced Interface communicates with the transmitter via HART
communications riding on the 4 to 20 mA signal comi ng fro m the tra ns m itte r.
Xi communication with the transmitter will be disrupted if a 375 Field
Communicator is connected to the signal loop between the transmitter and
the Xi Enhanced Interface.

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

Field Communicator
Menu Trees

OFF-LINE AND ON-LINE
OPERATIONS

When the 375 Field Communicator is connected as shown in Figure 4-3,
Figure 4-4, or Figure 4-5, refer to Figure 4-7 for the 375 Field Communicator
Transmitter menu tree.

If the Xi Enhanced Interface is used, connect the 375 Field Communicator in
the Xi (Xi-to-DCS) 4-20 mA signal loop or to the Xi Enhanced Interface
terminals as shown in Figure 4-6 and refer to Figure 4-8 for the 375 Field
Communicator Xi menu tree.

The 375 Field Communicator can be operated both off-line and on-line.
Off-line operations are those in which the communicator is not connected to

the X-STREAM. Off-line operations can include interfacing the 375 Field
Communicator with a PC (refer to applicable HART documentation regarding
HART/PC applications.)

In the on-line mode, the 375 Field Communicator is connected to the 4-20 mA
analog output signal line. The communicator is connected in parallel to the
X-STREAM or in parallel to the 250 ohm load resistor.

4-15

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X-STREAM O2 Transmitter

Figure 4-7. 375 Field Communicator Transmitter Menu Tree (Sheet 1 of 2)

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

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IM-106-910C, Rev. 1.0
November 2009

Figure 4-7. 375 Field Communicator Transmitter Menu Tree (Sheet 2 of 2)

X-STREAM O2 Transmitter

Hazardous Area

4-17

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X-STREAM O2 Transmitter

Figure 4-8. 375 Field Communicator Xi Menu Tree (Sheet 1 of 2)

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

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Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Figure 4-8. 375 Field Communicator Xi Menu Tree (Sheet 2 of 2)

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X-STREAM O2 Transmitter

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X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

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 ne ar the end
of their life.

CALIBRATION RECOMMENDED alarm provides notice of when a calibration

A
is required. This strategy ensures that the O
eliminates many unnecessary calibrations based on calendar days or weeks
since previous calibration.

The Hazardous Area X-STREAM O
manually through the handheld 375 Field Communicator or the Xi. Fully
automatic calibration can be performed automatically using the Xi Enhanced
Interface and the SPS 4001B Single Probe Autocalibration Sequencer or the
IMPS 4000 Intelligent Multiprobe Sequencer.

Transmitter(s) can be calibrated

2

reading is always accurate and

2

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.

X-STREAM O
methods. The methods available to you for use depend on the configuration
of your system. The paragraphs that follow describe how to perform a calibra­tion for three basic system configurations shown in Figure 4-9.

Included in the calibration procedures are instructions for setting up the cali­bration parameters. Setup of the calibration para meters should be performed
before the first O
needed to change the calibration parameters or to reset the parameters fol­lowing the replacement of primary system components.

calibration can be performed using three basic calibration

2

calibration. Thereafter, perform calibration setup only as

2

Before calibrating verify that the calibration gas parameters ar e correct. Refer
to Section 3: Configuration of Hazardous Area X-STREAM O2 Transmitter.

Figure 4-9. Calibration Methods - Simplified

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November 2009

X-STREAM O2 Transmitter

Hazardous Area

O2 Calibration without Xi For systems with configuration 1, shown in Figure 4-9, use the following

procedure to perform a calibration using the 375 Field Communicator. If
necessary, use the menu tree in Figure 4-7 for reference.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the
menu item and press the right arrow key or use the number keypad to select
the menu item number. To return to a preceding menu press the left arrow
key.

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

6. From the O
access the O

CALIBRATION screen.

2

CALIBRATION screen, select menu item 1, O2 CAL, to

2

calibration procedure.

2

Failure to remove the Hazardous Area X-STREAM from automatic control loops prior to
performing this procedure may result in a dangerous operating condition.

7. In the first O2 CAL screen, a "Loop should be removed from automatic
control" warning appears. Remove the Hazardous Area X-STREAM O
Transmitter from any automatic control loops to avoid a potentially dan­gerous operating condition and press OK.

8. Follow the handheld 375 Field Communicator display prompts to per­form the O

cal procedure.

2

O2 Calibration with Xi For systems with configuration 2, shown in Figure 4-9, use the following pro-

cedure to perform a calibration using the Xi Enhanced Interface. If necessary,
use the Xi menu tree in Figure 4-2 for reference.

NOTE

To select a menu item, either 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.

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 gas flow
times.

2

4-21

Hazardous Area
X-STREAM O2 Transmitter

4. Return to the SYSTEM menu and select the last menu item,
CALIBRATION, to access the CALIBRATION menu.

5. From the O
calibration procedure.

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

6. In the first Start Cal screen, a "Loop should be removed from automatic
control" warning appears. Remove the Hazardous Area X-STREAM O
Transmitter from any automa tic control loops to avoid a potentially dan­gerous operating condition and press OK.

7. Follow the Xi Enhanced Interface display prompts to perform the O
procedure.

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

CALIBRAT ION options, select Start Cal to start the O2

2

cal

2

2

O2 Calibration with Xi
and Field Communicator

For systems with configuration 3, shown in Figure 4-9, use the following pro­cedure to perform a calibration of the system using the 375 Field Communica­tor. If necessary use the menu tree in Fig ure 4-8 for reference.

NOTE

To select a menu item, either use the up and down arrow keys to scroll to the
menu item and press the right arrow key or use the number keypad to select
the menu item number. To return to a preceding menu, press the left arrow
key.

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

6. From the O
access the O

CALIBRATION screen.

2

CALIBRA TION screen, select menu item 1, O2 CAL, to

2

calibration procedure.

2

4-22

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

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

7. In the first O2 CAL screen, a "Loop should be removed from automatic
control" warning appears. Remove the Hazardous Area X-STREAM O
Transmitter from any automatic control loops to avoid a potentially dan­gerous operating condition and press OK.

8. Follow the handheld 375 Field Communicator display prompts to per­form the O

cal procedure.

2

Hazardous Area

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 two paragraphs that follow describe how to perform a D/A trim for two of

the three basic system configurations shown in Figure 4-10. Only the signal to
the DCS needs to be trimmed.

Figure 4-10. D/A Trim Methods - Simplified

2

D/A T rim without Xi For systems with configuration 1, shown in Figure 4-10 , use the handheld 375

Field Communicator to access the D/A trim procedure according to the
instructions that follow. Refer to the 375 Field Communicator Transmitter
Menu Tree in Figure 4-7.

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.

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X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

D/A Trim with Xi For systems with configuration 2, shown in Figure 4-10, use the handheld 375

Field Communicator to access the D/A trim procedure according to the
instructions that follow. Refer to the 375 Field Communicator Xi Menu Tree in
Figure 4-8.

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.

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Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O

Section 5 Troubleshooting

Overview of Operating Principles . . . . . . . . . . . . . . . . . . . page 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 5-2

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-2

Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 5-3

Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-3

Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5-3

Identifying and Correcting Fault Indications . . . . . . . . . . page 5-4

Calibration Passes, but Still Reads Incorrectly . . . . . . . .page 5-5

Probe Passes Calibration, O2 Still Reads High . . . . . . . .page 5-5

Probe Passes Calibration, O2 Still Reads Low . . . . . . . .page 5-7

How do I detect a plugged diffuser? . . . . . . . . . . . . . . . . . page 5-7

Can I calibrate a badly plugged diffuser? . . . . . . . . . . . .page 5-7

Hazardous Area

Transmitter

2

OVERVIEW OF
OPERATING
PRINCIPLES

When the Zirconium Oxide sensing cell is heated to its setpoint [736°C
(1357°F)], the cell will generate a voltage that represents the difference
between the process O

instrument air).

O

2

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 logrithmically as the O

% and the reference O2% inside the probe (20.95%

2

concentration decreases.

2

http://www.raihome.com

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Figure 5-1. O

Sensor mV Reading vs. %O2 at 736°C (1357°F) (Reference Air, 20.95% O2)

2

O2 % 100201510987654
EMF (mV) -34 1.0 7.25 16.1 18.4 21.1 23.8 27.2 31.2 36.0

O2 % 3 2 1 0.8 0.6 0.5 0.4 0.2 0.1 0.01
EMF (mV) 42.3 51.1 66.1 71.0 77.5 81.5 86.3 101.4 116.6 166.8

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.

GENERAL Consider the following equipment conditions, features, and requirements

when troubleshooting a problem with the X-STREAM O

Transmitter.

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.

5-2

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

Electrical Noise The Hazardous Area X-STREAM O

Transmitter has been designed to

2

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 gen erated
in the immediate circuitry of a faulty system. Ensure all cable shields are
connected to earth.

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.

ALARM INDICATIONS The first indication of a problem at the Hazardous Area X-STREAM O

mitter usually comes from the operators running the process. Critical alarms
that render the O
put signal representing O

4-20 mA Signal
Alarm Level

0 mA Transmitter unpowered, or completely failed

3.5 mA Critical Alarm - transmitter reading unusable (factory default)

3.8 mA
4 to 20 mA Normal Operation

20.5 mA Reading Over Range (Example - range is 0-10%. Current reading is 12%)
>21 mA

measurement unusable will force the 4-20 mA analog out-

2

Transmitter Condition

Reading Under Range
(Example - user sets range to 2-10%. Current reading is 1.9%)

Critical Alarm - transmitter reading is unusable (user can choose this alarm
level instead of the factory default level of 3.5 to 3.6 mA)

to go to a default condition, as follows:

2

Trans-

2

NOTE

Make sure that the Control System is configured to interpret these signal
levels correctly!

Once an alarm condition is identified, the Hazardous Area X-STREAM O

2

Transmitter electronics offers a number of diagnostics to interpret the specific
alarm.

Alarm indications are available via the Xi Enhanced Interface or the 375 Field
Communicator and Rosemount Analytical's Asset Management soft ware.
When the error is corrected and/or power is cycled, the diagnostic alarms will
clear or the next error on the priority list will appear.

5-3

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

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 will disappear when
the alarm condition no longer exists. If an alarm is not recoverable, the alarm
indication will continue to be displayed after the cause of the alarm condition
is corrected. Loop power to the transmitter must be cycled to clear a
non-recoverable alarm.

For a Hazardous Area X-STREAM O

Transmitter without an optional Xi

2

Enhanced Interface, alarm messages are accessed via the HART/AMS
communication menu. A listing of the alarm/fault messages and the related
fault status descriptions are shown in Table 5-1.

For a Hazardous Area X-STREAM O

Transmitter with the optional Xi

2

Enhanced Interface, alarm messages are displayed on the Xi interface
display window when the alarm status display is accessed via the Xi interface
menu. A listing of the alarm/fault messages and the related fault status
descriptions are shown in Table 5-2.

The following are five general fault symptoms:

1. The system does not respond to changes in the oxygen concentration.

2. The system responds to oxygen changes but does not give the correct
indication.

3. The system does not give an acceptable indication of the value of the
oxygen test gas being applied during calibration.

4. The probe takes longer than normal to return to flue gas value after the
calibration gas is turned off.

5. The probe heater temperature is unstable.

Fault conditions that give no fault indication and that allow the probe to pass
calibration are listed and discussed after Tables 5-1 and 5-2.

Table 5-1. Diagnostic/Unit Alarm Fault Definitions - Transmitter without Xi Enhanced Interface

Message Status Self Clearing

NV Mem Fail A checksum error was detected in the nonvolatile memory configuration data when the unit was

turned on.

Factory Mode On transmitter board, SW1, position 1 is set to "ON". This setting should only be used in the

factory.
Board Temp Hi The transmitter electronic board temperature reading is above 126°C. No
O2 Sensor Open 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.
O2 TC Open The O

O2 Temp Low The heater temperature is below the minimum temperature. The predefined low temperature

O2 Temp High The heater temperature is above the predefined temperature threshold of 750°C. Yes
O2 T/C Shorted The O2 sensor heater temperature thermocouple voltage is shorted. Yes
O2 T/C Reversed The O

CPU Voltage Low The transmitter CPU voltage is less than 2.7 V indicating the CPU voltage is too low. Yes
CPU Voltage High The transmitter CPU voltage is more than 3.3 V indicating the CPU voltage is too high. Yes
Htr Voltage Low T he heater voltage for the O2 cell heater is below 35 volts. Yes
Htr Voltage High The heater voltage for the O

cell heater thermocouple voltage is reading more than the hardware configured threshold

2

voltage. This indicates the thermocouple wires may be disconnected or the thermocouple junction

may be open.

threshold is the 726°C.

sensor heater temperature thermocouple voltage is reading a negative voltage indicating

2

the thermocouple wire connections may be reversed.

cell heater is above 264 volts. Yes

2

No

No

Yes

Yes

Yes

Yes

5-4

Instruction Manual

Hazardous Area

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O2 Transmitter

Table 5-2. Diagnostic/Unit Alarm Fault Definitions - Transmitter with Xi Enhanced Interface

Message Status Self Clearing

NV Mem Fail A checksum error was detected in the nonvolatile memory configuration data when the unit was

turned on.
Factory Mode On Xi box IO board, SW4, position 1 is set on "ON". On transmitter electronics board, SW1,

position 1 is set to "ON". This setting should only be used in the factory.
Board Temp Hi The transmitter electronic board temperature reading is above 126°C or the

O2 Htr Ramp Rate The O2 sensor heater ramp rate is greater than max allowed ramp rate indicating a run away

O2 Sensor Open The cell impedance voltage is reading less than -1.1 VDC indicating the O2 sensor wires may be

O2 TC Open The O2 cell heater thermocouple voltage is reading more than the hardware configured threshold

O2 Temp Low The heater temperature is below the minimum temperature. The predefined low temperature

O2 Temp High The heater temperature is above the defined temperature threshold. The high temperature

O2 T/C Shorted The O
O2 T/C Reversed The O2 sensor heater temperature thermocouple voltage is reading a negative voltage indicating

O2 Htr Failure T he O

No Flame The Flame Status Relay Input is set to the OFF state indicating it is not safe to operate the O2

Xmtr Disconnect Communication failures detected between transmitter and the IO board indicating the transmitter

Cal Recommended Probe calibration is recommended. The cell impedance is above 100 ohms and has shifted 50

Cal Failed A calibration error occurred during the last calibration. The measured slope or constant is outside

Cell Imp High The O2 sensor impedance/cell resistance value measurement is greater than 2000 Ohms

CPU Voltage Low The transmitter CPU voltage is less than 2.7 V indicating the CPU voltage is too low. Yes
CPU Voltage High The transmitter CPU voltage is more than 3.3 V indicating the CPU voltage is too high. Yes
Htr Voltage Low The heater voltage for the O
Htr Voltage High The heater voltage for the O2 cell heater is above 264 volts. Yes
Low O2 The O

Xi unit IO board temperature reading is above 86°C.

heater condition.

disconnected or the O2 sensor junction may be open.

voltage. This indicates the thermocouple wires may be disconnected or the thermocouple junction

may be open.

threshold is the 726°C.

threshold is the defined by the "High Temp Alm SP" parameter. The default value is 750°C.

sensor heater temperature thermocouple voltage is shorted. Yes

2

the thermocouple wire connections may be reversed.

sensor heater temperature is not responding to the controller and can't reach final

2

temperature set by the device, indicating the O

heater and the heater should be turned off.

has been disconnected from the IO board.

ohms since the last calibration; the accuracy of the O

the acceptable range. (Slope: 34.5 to 57.5 mv/decade) (Constant: ±20 mv)

indicates the cell may be beyond its useful life.

cell heater is below 35 volts. Yes

2

reading is below the "Low O2 Alm SP". Yes

2

heater may have failed.

2

reading may be compromised.

2

No

No

No

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

CALIBRATION PASSES,
BUT STILL READS
INCORRECTLY

Probe Passes
Calibration, O

Still

2

Reads High

There are a few fault conditions where no alarm indication is present and the
probe passes calibration, but the O

reading may still be incorrect:

2

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 than 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
"Probe Passes Calibration, But O

Still Appears To Read Low".

2

No or improper reference air supplied.
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 O

reading upward.

2

5-5

Hazardous Area
X-STREAM O2 Transmitter

1. Make sure that the calibration gas line is capped tightly between
calibrations. If autocal is used, make sure the check valve is seating
properly.

2. A leak in the Oxycore viton o-ring seal can allow ambient air to migrate
down the annular space between the sensor core and probe tube, and
then into the cell. Always inspect the viton o-ring when removing and
reinstalling the Oxycore sensor core.

Figure 5-2. Probe Leakage Paths

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

5-6

Internal Reference Air Leak - There may be a leak inside the Oxycore
sensor core itself, permitting the reference air (20.95% O
process gases at the cell. To confirm this leak condition, pressurize the inside
(reference side) of the probe by plugging the reference air exhaust port with
your finger for 1 minute. (the conduit ports where the signal and power wires
pass may also need to be sealed.) The O

reading increases during this test, there is a leak inside the probe.

the O

2

1. Acid condensation inside the probe can degrade the cal gas hose
(25, Figure 6-5) that carries the cal gas to the cell. Inspect this hose.
See Figure 5-2. Dislodging or improper installation of the cal gas or
reference air hose can cause a leakage path.

2. The sensing cell (4, Figure 6-1) is fastened to the end of the probe tube
and uses a corrugated washer (3, Figure 6-1) to separate the process
gases from the ambient reference air. The corrugated washer may be
damaged by corrosion. Discard used washer.

reading should decrease slightly. If

2

) to mix with the

2

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

Hazardous Area

X-STREAM O2 Transmitter

NOTE

Always install a new corrugated washer whenever the sensing cell is r emoved
from the probe.

Bad Reference Side Cell Electrode - A bad reference side cell electrode can
cause an elevated O2 reading.This fault is usually indicated by a frequent
"Calibration Recommended" alarm and increasing cell impedance readings. A
high cell impedance can be calibrated out, but if the impedance continue s to
increase rapidly, the sensing cell must be replaced.

Probe Passes
Calibration, O

Still

2

Reads Low

How do I detect a
plugged diffuser?

Can I calibrate a badly
plugged diffuser?

The diffusion element at the end of the probe is a passive filter. It plugs very
slowly, since 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.

NOTE

It is important not to pressurize the sensing cell during calibrations by flowing
excessive cal gas against a plugged diffuser. Calibration flow rates should be
set only when a new diffuser is installed. As the diffuser plugs, do not adjust
the flow rates upward.

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 no rmal process
value after the cal gas is removed. As the diffuser plugs, this recovery time will
get longer and longer. Use the Calibration Record provided to record and
trackCalibration Response times.

It may not be possible to immediately replace a plugged diffuser while the
process is on line.

One 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 process gases are now mixing in 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.

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

5-7

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

Calibration Record

For

Rosemount Analytical In Situ O

Probe Serial Number: ______________________________________________________________________
Probe Tag Number: _________________________________________________ ______________________
Probe Location: __________________________________________________________________________
Date Placed Into Service: __________________________________________________________________

Probe

2

Date Slope Constant Impedance Response

initial

Response

final

Notes: Response

Response

5-8

When the second calibration gas is turned off, note the number of seconds required for the O2 value to begin migrating

initial

back to the process value.
When the second calibration gas is turned off, note the number of seconds required for the O2 value to settle out at the

final

process value.

Instruction Manual

IM-106-910C, Rev. 1.0
November 2009

X-STREAM O

Hazardous Area

Transmitter

2

Section 6 Maintenance and Service

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

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-2

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-2

Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-2

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6-2

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-3

Removal and Installation of Probe . . . . . . . . . . . . . . . . . . page 6-3

X-STREAM O2 Transmitter Probe Repair . . . . . . . . . . . . . page 6-5

Sensor Core or Diffuser Replacement . . . . . . . . . . . . . . .page 6-5

Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6-8

Replace Contact Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6-8

Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6-12

Replace Contact & Thermocouple Assembly . . . . . . . . . page 6-13

Replacing Gas/Air Hoses, O-rings and Spacers . . . . . . . page 6-14

Electronics Board Replacement . . . . . . . . . . . . . . . . . . . . page 6-14

Blind Cover(s) Replacement . . . . . . . . . . . . . . . . . . . . . . . page 6-15

Xi Components Replacement . . . . . . . . . . . . . . . . . . . . . . page 6-18

I/O Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-19

AC Relay Board Replacement . . . . . . . . . . . . . . . . . . . . . . page 6-24

Power Supply Board Replacement . . . . . . . . . . . . . . . . . . page 6-26

Power Supply Board Wiring . . . . . . . . . . . . . . . . . . . . . . . page 6-27

Xi Front Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . page 6-27

DR Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6-30

OVERVIEW This section identifies the calibration methods available and provides the

procedures to maintain and service the Hazardous Area X-STREAM O
Transmitter.

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.

http://www.raihome.com

2

Hazardous Area
X-STREAM O2 Transmitter

Instruction Manual

IM-106-910C, Rev. 1.0

November 2009

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 SO
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 O

A calibration check is generally recommended on a quarterly basis (every 3
months) by flowing bottled gas to the probe. (Make sure that the oper ations
personnel are notified when doing this, and also make sure that the O
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
Section 4: Startup and Operation.

The Xi enhanced electronics offers a "calibration recommended" diagnostic
that will indicate 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 will cause a slower speed of response to changing O
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 dif fuser is badly plugged. (Never increase the flo w
rate back up, however, as this can cause a shifted calibration. Adjust the
calibration flow rate only when a new diffuser is installed). Always r ecord the
response time back to the process after the calibration gases are re moved, as
noted on the calibration record at the end of this section. Diffuser pluggage
can be tracked through this record.

resulting from sulfur

2

are very low (below 1% O2).

2

control

2

2

A visual inspection of the probe sensor core should be conducted during plant
outages, paying particula r attention to condensed component s. Condensation
can be reduced or eliminated by insulating the probe installation, including the
probe mount, flange, and dual blue housings.

CALIBRATION The Hazardous Area X-STREAM O

through the handheld 375 Field Communicator, or automatically through the
SPS 4001B Single Probe Autocalibration Sequencer or the IMPS 4000
Intelligent Multiprobe Test Gas Sequencer and the Xi Enhanced Interface.

Transmitter can be calibrated manually

2

Automatic Calibration Contact from the Xi Enhanced Interface to an SPS 4001B (one per probe) or

IMPS 4000 (up to four probes) provides the ability to manually initiate a
calibration at any time from the control room. The Xi Enhanced Inter face must
be used with the SPS 4001B or IMPS 4000 in order to perform an auto /
semi-auto calibration. Refer to the SPS 4001B or IMPS 4000 Instruction
Manual for further details on how to configure and perform an automatic
calibration.

Manual Calibration Refer to the "Calibration - General" in Section 4: Startup and Operation to

perform a manual calibration.

6-2