Rosemount Analytical 5081FG Operating Manual

Instruction Manual

IM-106-5081, Rev 2.0
October 2008

Model 5081FG
Two-Wire In Situ
Oxygen Analyzer
(550° to 1600°C)

http://www.raihome.com

HIGHLIGHTS OF CHANGES

Effective October 31, 2008 Rev. 2.0

Page Summary

General Reformatted entire manual in accordance with Emerson Process Management style

guide. Revised all illustration formats.
Cover Updated manual revision level and release date.
1-5 Revised Figure 1-2.
1-7 Revised Specifications.
1-9 Revised Table 1-1, Product Matrix.
2-11 Corrected reference to installation drawings in the warning regarding intrinsically safe

applications.
2-14 Revised Reference Air Package illustrations.
3-3 Revised Figure 3-3.
3-5 Revised Figure 3-5 to reflect update to Diagnostics Menu.
3-7 Added Operator Adjustable Parameters discussion and Table 3-1.
3-18, 3-19 Added Current Slope and Current Constant diagnostic descriptions.
4-2, 4-3 Revised Figures 4-1 and 4-2.
4-5, 4-6, 4-7 Revised Figure 4-3, sheets 1, 2, and 3.
5-8 Added Calibration Passes discussion.
6-1 through 6-5 Revised all procedures to reflect changes to Figure 6-1.
6-2 Revised Figure 6-1 to reflect components configuration changes.
7-1 Revised Table 7-1, Replacement Parts list. Updated part numbers.
Appendix C Added new Appendix C containing installation drawings for intrinsically safe applications.

Instruction Manual

IM-106-5081, Rev 2.0
October 2008

Model 5081FG

Table of Contents

SECTION i
Introduction

SECTION 1
Description and
Specifications

SECTION 2
Installation

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

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

Technical Support Hotline: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

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

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

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

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

Handling the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Packing List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

Locating Oxygen Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Installing Oxygen Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Locating Model 5081 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Installing Model 5081 Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Oxygen Probe Signal Connections . . . . . . . . . . . . . . . . . . . . . . . .2-12

Model 5081 Transmitter 4-20 mA and Signal Connections . . . . . 2-13

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Reference Air Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Instrument Air (Reference Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Calibration Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

SECTION 3
Startup and
Operation

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

Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Establishing Proper Calibration Gas Flow Rate . . . . . . . . . . . . . . . . .3-3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Menu Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Operator Adjustable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Display Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Fault Val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Upper Range Val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

TOC-1

Model 5081FG

Instruction Manual

IM-106-5081, Rev 2.0

October 2008

Cell T Hi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Reset Max Cell T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Set O2 Filter Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Trim 4mA? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Trim 20mA? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Set Hi Bottle O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Set Lo Bottle O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Set O2 Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Set Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Show Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

T/C mV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

O2 CELL mV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Cell Impedance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Current Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Current Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Previous Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Previous Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Max Cell T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

SW Ver (SOFt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Unit Ser # (SEr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

SW Build Number (bLdn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

SW Build Date (bd). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Cal Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

In Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Accept High O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Accept Low O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

SECTION 4
HART/AMS

SECTION 5
Troubleshooting

SECTION 6
Maintenance and Service

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

Field Communicator Signal Line Connections. . . . . . . . . . . . . . . . . . . 4-2

Field Communicator PC Connections . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Off-Line and On-Line Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

HART/AMS Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Field Communicator Start Cal Check Method . . . . . . . . . . . . . . . . . . . 4-8

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

Probe Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fault Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

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

Calibration Passes, But Still Reads Incorrectly . . . . . . . . . . . . . . . . . . 5-8

Probe Passes
Calibration, O2 Still

Reads High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

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

Electronics

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Display Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Spare Board Stack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Oxygen Probe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

TOC-2

Instruction Manual

IM-106-5081, Rev 2.0
October 2008

SECTION 7
Replacement Parts

Model 5081FG

APPENDIX A
Safety Data

APPENDIX B
Return of Material

APPENDIX C
Schematics

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

Safety Data Sheet for Ceramic Fiber Products . . . . . . . . . . . . . . . . A-24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30

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

Installation Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

TOC-3

Model 5081FG

Instruction Manual

IM-106-5081, Rev 2.0

October 2008

TOC-4

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Model 5081FG

Oxygen Analyzers

READ THIS PAGE BEFORE PROCEEDING!

ESSENTIAL INSTRUCTIONS

Emerson Process Management designs, manufactures and tests its products
to meet many national and international standards. Because these
instruments are sophisticated technical products, you MUST properly
install, use, and maintain them to ensure they continue to operate within
their normal specifications. The following instructions MUST be adhered to
and integrated into your safety program when installing, using, and
maintaining Emerson’s Rosemount 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 the proper installation,

operation, and maintenance of the product.

• Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes. Connect all products to the proper electrical and

pressure sources.

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

• When replacement parts are required, ensure that qualified people use
replacement parts specified by 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.

prior to installing, operating, and servicing the

marked on and

to install,

http://www.raihome.com

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

If a Model 275/375 Universal HART® Communicator is used with this unit, the software
within the Model 275/375 may require modification. If a software modification is required,
please contact your local Emerson Process Management Service Group or National
Response Center at 1-800-433-6076 or 1-888-433-6829.

Model 5081FG

Instruction Manual

IM-106-5081, Rev. 2.0

October 2008

ii

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Section i Introduction

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page i-iv

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page i-iv

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page i-iv

Model 5081FG

http://www.raihome.com

Instruction Manual

IM-106-5081, Rev. 2.0

Model 5081FG

October 2008

PREFACE The purpose of this manual is to provide information concerning the

components, functions, installation and maintenance of the Model 5081FG
Two-Wire In Situ Oxygen Analyzer (550° to 1600°C).

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.

SYMBOLS

Technical Support Hotline:

NOTE

Highlights an essential operating procedure, condition, or statement.

:

EARTH (GROUND) TERMINAL

:

PROTECTIVE CONDUCT OR TERMINAL

:

RISK OF ELECTRICAL SHOCK

:

WARNING: REFER TO INSTRUCTION MANUAL

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a
manual illustration number. It is not a part number, and is not related to the
illustration in any technical manner.

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 Watch. 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 reached via the Internet through:

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

iv

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Model 5081FG

Section 1 Description and Specifications

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

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-7

COMPONENT CHECKLIST

A typical Rosemount Analytical Two-Wire In Situ Oxygen Analyzer should
contain the items shown in Figure 1-1. Record the part number, serial number,
and order number for each component of your system in the table located on
the first page of this manual.

Also, use the product matrix in Table 1-1 at the end of this section to compare
your order number against your unit. The first part of the matrix defines the
model. The last part defines the various options and features of the Model
5081FG Analyzer. Ensure the features and options specified by your order
number are on or included with the unit.

http://www.raihome.com

Model 5081FG

Figure 1-1. Typical System Package

Instruction Manual

IM-106-5081, Rev. 2.0

October 2008

1. Instruction Manual

2. Model 5081 Transmitter

3. Oxygen Probe

4. Adapter Plate with Mounting Hardware and Gasket (Optional)

5. Infrared Remote Control (IRC)

6. Reference Air Set (Optional)

7. Field Communicator Package (Optional)

8. Pipe Mounting Kit (Optional)

1-2

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Model 5081FG

SYSTEM OVERVIEW

Scope This Instruction Bulletin is designed to supply details needed to install, start

up, operate, and maintain the Rosemount Analytical Two-Wire In Situ Oxygen
Analyzer. The analyzer consists of an oxygen probe and Model 5081
transmitter. The signal conditioning electronics of the Model 5081 transmitter
outputs a 4-20 mA signal representing an O
control (IRC) allows access to setup, calibration, and diagnostics. This same
information, plus additional details, can be accessed with the HART field
communicator or Asset Management Solutions (AMS) software.

value. An infrared remote

2

System Description The Rosemount Analytical Two-Wire In Situ Oxygen Analyzer is designed to

measure the net concentration of oxygen in an industrial process; i.e., the
oxygen remaining after all fuels have been oxidized. The oxygen probe is
permanently positioned within an exhaust duct or stack and performs its task
without the use of a sampling system. The Model 5081 transmitter is mounted
remotely and conditions the oxygen probe outputs.

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

EMF = KT 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

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

NOTE

The probe uses a Type B thermocouple to measure the cell temperature.

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
Rosemount Analytical Two-Wire In Situ Oxygen Analyzer to provide
exceptional sensitivity at low oxygen concentrations.

1-3

Instruction Manual

IM-106-5081, Rev. 2.0

Model 5081FG

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

October 2008

System Configuration The equipment discussed in this manual consists of two major components:

the oxygen probe and the Model 5081 tModel 5081 transmitterransmitter.
Oxygen probes are available in three length options, providing in situ penetra-

tion appropriate to the size of the stack or duct. The options on length are 20
in. (508 mm), 26 in. (660 mm), or 38 in. (965 mm).

The Model 5081 transmitter is a two-wire transmitter providing an isolated out­put, 4-20 mA, that is proportional to the measured oxygen concentration. A
customer-supplied 24 VDC power source is required to simultaneously pro­vide power to the electronics and a 4-20 mA signal loop. The transmitter
accepts millivolt signals generated by the probe and produces the outputs to
be used by other remotely connected devices. The output is an isolated 4-20
mA linearized current.

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

concentration decreases.

2. High process temperatures eliminate the need for external cell heating
and increase cell accuracy.

3. HART communication is standard. To use the HART capability, you
must have either:

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

4. Easy probe replacement due to the light-weight, compact probe design.

5. Remote location of the Model 5081 transmitter removes the electronics
from high temperature or corrosive environments.

6. Power is supplied to the electronics through the 4-20 mA line for intrinsic
safety (IS) purposes.

7. Infrared remote control (IRC) allows interfacing without exposing the
electronics.

1-4

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Model 5081FG

8. An operator can operate and diagnostically troubleshoot the Two-Wire
In Situ Oxygen Analyzer in one of two ways:

a. Infrared Remote Control. The IRC allows access to fault indication

menus on the Model 5081 transmitter LCD display. Calibration can
be performed from the IRC keypad.

b. Optional HART Interface (Figure 1-2). The Two-Wire In Situ Oxygen

Analyzer's 4-20 mA output line transmits an analog signal
proportional to the oxygen level. The HART output is superimposed
on the 4-20 mA output line. This information can be accessed
through the following:

• Field Communicator - The field communicator requires Device
Description (DD) software specific to the Two-Wire In Situ
Oxygen Analyzer. The DD software will be supplied with many
field communicators but can also be programmed into existing
units at most Fisher-Rosemount Analytical service offices. See
Section 4: HART/AMS, for additional HART information.

• Personal Computer (PC) - The use of a personal computer
requires AMS software available from Fisher-Rosemount.

9. Selected Distributed Control Systems - The use of distributed control
systems requires input/output (I/O) hardware and AMS Security codes
are provided to (by infrared remote control) prevent unintended changes
to analyzers adjacent to the one being accessed.

10. A calibration check procedure is provided to determine if the Rosemount
Analytical Two-Wire In Situ Oxygen Analyzer is correctly measuring the
net oxygen concentration in the industrial process.

Figure 1-2. Two-Wire In Situ Oxygen Analyzer HART Connections and AMS Application

1-5

Instruction Manual

IM-106-5081, Rev. 2.0

Model 5081FG

October 2008

Handling the Analyzer The probe was specially packaged to prevent breakage due to handling. Do

not remove the padding material from the probe until immediately before
installation.

It is important that printed circuit boards and integrated circuits are handled only when
adequate antistatic precautions have been taken to prevent possible equipment damage.

The oxygen probe is designed for industrial applications. Treat each component of the
system with care to avoid physical damage. Some probe components are made from
ceramics, which are susceptible to shock when mishandled.

System Considerations Prior to installing your Rosemount Analytical Two-Wire In Situ Oxygen

Analyzer, make sure you have all the components necessary to make the
system installation. Ensure all the components are properly integrated to
make the system functional.

After verifying that you have all the components, select mounting locations
and determine how each component will be placed in terms of available line
voltage, ambient temperatures, environmental considerations, convenience,
and serviceability. Figure 1-1 shows a typical system package. A typical
system installation is shown in Figure 1-3.

Figure 1-3. Typical System
Installation

1-6

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Model 5081FG

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

If the calibration gas bottles will be permanently connected, a check valve is
required next to the calibration fittings on the integral electronics.

This check valve is to prevent breathing of the calibration gas line and
subsequent flue gas condensation and corrosion. The check valve is in
addition to the stop valve in the calibration gas kit.

NOTE:

The electronics is rated NEMA 4X (IP65) and is capable of operation at
temperatures up to 65°C (149°F).

Retain the packaging in which the Rosemount Analytical Two-Wire In Situ
Oxygen Analyzer arrived from the factory in case any components are to be
shipped to another site. This packaging has been designed to protect the
product.

SPECIFICATIONS

Transmitter

Range 0 to 25% O

Net O

2

System Accuracy ±1.5% of reading or 0.05% O2, whichever is greater
System Response in Flue Gas Initial – less than 3 seconds,

Probe Lengths 20 in. (508 mm)

Process Temperature Limits: 550° to 1400°C (1022° to 2552°F)

Ambient Temperature Limits: -40° to 149°C (-40° to 300°F)
Mounting and Mounting Position Vertical or horizontal
Materials of Construction
(Process Wetted Parts):

Inner Probe
Outer Protection Tube

Probe Junction Box
Speed of Installation/Withdrawal 1 in. (25,4 mm) per minute
Hazardous Area Certification Intrinsically safe per EN50 014 (1977), clause 1.3
Reference Air Requirement 100 m per minute (2,119 scfh) of clean, dry

Calibration Check Gas Fittings 1/4 in. tube fittings
Cabling Two twisted pairs, shielded

T90 – less than 8 seconds

26 in. (660 mm)
38 in. (965 mm)

Operation to 1600°C (2912°F) with reduced cell life

Zirconia
Alumina [1600°C (2912°F) limit]
Inconel 600 [1000°C (1832°F) limit]
Cast aluminum

instrument air; 1/4 in. tube fittings

Continued on Next Page

2

(1)

1-7

Model 5081FG

Instruction Manual

IM-106-5081, Rev. 2.0

October 2008

Electronics

Electronics Enclosure IP65 (NEMA 4X), weatherproof, and

Materials of Construction Low copper aluminum
Ambient Temperature Limits -20° to 65°C (-4° to 149°F)
Relative Humidity 95% with covers sealed
Power Supply and Load Requirements See Figure 1-4
Inputs (from O2 Probe) Two wires - O2 signal

Output One 4-20 mA signal with superimposed digital HART

Hazardous Area Certification ATEX EEx ia IIC T4 or T5

Power Transient Protection IEC 801-4
Shipping Weight 10 lbs (4,5 kg)

Infrared Remote Control

Power Requirements Three AAA Batteries
Hazardous Area Certification ATEX EEx ia IIC Class 1, Div 1, Group A, B, C, D

(1)

Thermocouple and O2 probe cell are both unpowered, developing a millivolt emf, and are
considered a "simple apparatus" by certifying agencies.

(2)

Dependent on ambient temperature limits.

corrosion-resistant

Two wires - type B thermocouple

signal

NEC Class 1 Div 1 Group B,C,D

(2)

Figure 1-4. Power Supply and
Load Requirements

1-8

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Table 1-1. Product Matrix

5081FG High Temperature Oxygen Flue Gas Analyzer

High Temperature Analyzer - Instruction Manual

Code Sensing Probe Type

1 20 in. (508 mm) probe, 1/4 in. tube fittings
2 26 in. (660 mm) probe, 1/4 in. tube fittings
3 38 in. (965 mm) probe, 1/4 in. tube fittings

Code Probe Outer Tube Material - Maximum Operating Temperature

1 Alumina - 2912°F (1600°C) maximum - 1.25 NPT mounting
2 Inconel Alloy - 1832°F (1000°C) maximum - 1.25 NPT mounting

Code Mounting Adapter- Stack Side

0 No adapter plate required uses 1.25 NPT

("0" must also be chosen under "Mounting Adapter" below)
1 New flanged installation - Square weld plate with studs (matches "Mounting Adapter" below)
2 Model 450 mounting ("4" must also be chosen under "Mounting Adapter" below)
3 Competitor's Mount ("5" must also be chosen under "Mounting Adapter" below)

Code Mounting Adapter - Probe Side

0 No adapter plate
1 ANSI 2 in. 150 lb flange to 1.25 NPT adapter

(6 in. dia. flange, 4.75 in. BC with 4 x 0.75 in. dia. holes)
2 DIN to 1.25 NPT adapter (184 mm flange, 145 mm BC with 4 x 18 mm dia. holes)
3 JIS to 1.25 NPT adapter (155 mm flange, 130 mm BC with 4 x 13 mm dia. holes)
4 Model 450 to 1.25 NPT adapter
5 Competitor's mounting flange

Code Electronics & Housing - Intrinsically Safe, NEMA 4X, IP65

1 5081 Electronics (Hart-compatible) - ATEX EEx ia IIC T5
2 5081 Electronics (Hart-compatible) - CSA pending
3 5081 Electronics (Hart-compatible) - FM Class 1, Div. 1, Groups B,C,D

Code Housing Mounting

1 Surface or wall mounting
2 1/2 to 2 in. pipe mounting

Code Communications

1 No remote control
2 Infrared Remote Control (IRC)

(LCD display through cover window

Code Calibration Accessories

1 No hardware
2 Calibration and reference air flowmeters and

reference air pressure regulator

Code Armored Cable Length

00 No cable

11 20 ft (6 m)
12 40 ft (12 m)
13 60 ft (18 m)
14 80 ft (24 m)
15 100 ft (30 m)
16 150 ft (45 m)
17 200 ft (61 m)
18 300 ft (91 m)
19 400 ft (122 m)
20 500 ft (152 m)

5081FG 2 1 0 0 1 1 1 2 11 Example

Model 5081FG

1-9

Model 5081FG

Instruction Manual

IM-106-5081, Rev. 2.0

October 2008

1-10

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Section 2 Installation

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2

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

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-11

Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-14

Before installing this equipment, read the "Safety instructions for the wiring and installation
of this apparatus" in Appendix A. Failure to follow safety instructions could result in serious
injury or death.

Model 5081FG

http://www.raihome.com

Instruction Manual

IM-106-5081, Rev. 2.0

Model 5081FG

October 2008

PRE-INSTALLATION

Inspect Carefully inspect the shipping container for any evidence of damage. If the

container is damaged, notify the carrier immediately.

Packing List Confirm that all items shown on the packing list are present. Notify

Rosemount Analytical immediately if items are missing.

Before installing this equipment, read the "Safety instructions for the wiring and installation
of this apparatus" in Appendix A. Failure to follow safety instructions could result in serious
injury or death.

MECHANICAL INSTALLATION

Avoid installation locations near steam soot blowers.

Locating Oxygen Probe 1. The location of the oxygen probe in the stack or flue is important for

maximum accuracy in the oxygen analyzing process. The probe must
be positioned so the gas it measures is representative of the process.
Longer ducts may require several analyzers since the O
to stratification. A point too near the wall of the duct, or the in-side radius
of a bend, may not provide a representative sample because of the very
low flow conditions. The sensing point should be selected so the
process gas temperature falls within a range of 550° to 1400°C (1022°
to 2552°F). Figure 2-1 provides mechanical installation references.

2. Check the flue or stack for holes and air leakage. The presence of this
condition will substantially affect the accuracy of the oxygen reading.
Therefore, either make the necessary repairs or install the probe
upstream of any leakage.

3. Ensure the area is clear of internal and external obstructions that will
interfere with installation and maintenance access to the probe. Allow
adequate clearance for probe removal (Figure 2-1).

can vary due

2

2-2

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Figure 2-1. Probe Installation Details

Model 5081FG

2-3

Model 5081FG

Installing Oxygen Probe

Instruction Manual

IM-106-5081, Rev. 2.0

October 2008

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

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

NOTE

Leave the probe inner protective cover in place until installation. This is
required to protect the ceramic cell during movement.

2. If using an optional adapter plate (Figure 2-2) or an optional mounting
flange (Figure 2-3), weld or bolt the component onto the duct. The
through hole in the stack or duct wall and refractory material must be
2 in. (50,8 mm) diameter, minimum.

3. If the optional adapter plates are not used, a 2 in. NPT, schedule 40,
pipe nipple (Figure 2-4) should be welded to the stack or duct wall.
When a 2 in. NPT to 1.25 NPT adapter is threaded to the welded pipe
nipple, the adapter provides the pipe threads needed for the probe's
process fitting.

4. Where high particulate or slag is in the flue gas stream, it may be
desirable to inset the probe in the refractory as shown in Figure 2-5. Use
pipe couplings and nipples to adjust the probe insertion depth.

5. Use high temperature material (alumina wool) to seal around the probe
during insertion. This prevents hot gases from escaping or cold air from
entering the stack or duct.

6. Initially insert the probe to a depth of 3 in. (76,2 mm) or 1/2 the depth of
the stack or duct refractory, whichever is greater.

2-4

After initial insertion, do not insert the probe at a rate exceeding 1 in. per minute (25.4 mm
per minute) or damage to the probe may result due to thermal shock.

7. After initial insertion, insert the probe at a rate of 1 in. (25,4 mm) per
minute until the probe is fully inserted.

8. Install anti-seize compound on the pipe threads and screw the probe
into the process flange or adapter.

9. If insulation was removed to access the duct work for probe mounting,
make sure the insulation is replaced. See Figure 2-4.

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

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Figure 2-2. Optional Adapter Plate

Model 5081FG

Figure 2-3. Optional Probe Mounting Flange

2-5

Model 5081FG

Figure 2-4. Horizontal Probe Installation

Instruction Manual

IM-106-5081, Rev. 2.0

October 2008

2-6

Instruction Manual

IM-106-5081, Rev. 2.0
October 2008

Figure 2-5. Adjusting Probe Insertion Depth

Model 5081FG

Locating Model 5081 Transmitter

1. Ensure the Model 5081 transmitter is easily accessible for maintenance
and service and for using the infrared remote control (if applicable).

Do not allow the temperature of the Model 5081 transmitter exceed 65°C (149°F) or
damage to the unit may result.

2. The ambient temperature of the transmitter housing must not exceed
65°C (149°F). Locate the electronics in an area where temperature
extremes, vibration, and electromagnetic and radio frequency
interference are minimal.

3. Locate the Model 5081 transmitter within 150 ft (45,7 m) of the oxygen
probe due to wiring and signal considerations.

2-7

Model 5081FG

Instruction Manual

IM-106-5081, Rev. 2.0

October 2008

Installing Model 5081 Transmitter

Figure 2-6. Flat Surface Mounting Dimensions

1. Ensure all components are available to install the Model 5081
transmitter.

2. Choose a method or location to mount the transmitter.
a. Flat Surface Mounting. The transmitter may be mounted on a flat

b. Pipe Mounting. An optional pipe mounting bracket is available for

surface using the threaded mounting holes located on the bottom of
the transmitter housing. Refer to Figure 2-6 for installation
references.

this type of installation. Refer to Figure 2-7 for installation references.

2-8