Rosemount Analytical Xi Operating Manual
CMB-MAN-910Xi, Rev C
Rosemount™ Xi Advanced Electronics for
Zirconium Oxide Flue Gas O2 Probes
Instruction Manual
July 2017
Essential Instructions
Read this page before proceeding!
Emerson designs, manufactures, and tests its products to meet many national and international standards. Because these
instruments are sophisticated technical products, you must properly install, use, and maintain them to ensure they continue to
operate within their normal specifications. The following instructions must be adhered to and integrated into your safety program
when installing, using, and maintaining Emerson's Rosemount products. Failure to follow the proper instructions may cause any one
of the following situations to occur: loss of life, personal injury, property damage, damage to this instrument, and warranty
invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson representative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
• Install your equipment as specified in the installation instructions of the appropriate instruction manual and per applicable
local and national codes. Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.
Unauthorized parts and procedures can affect the product's performance, place the safe operation of your process at risk,
and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed
by qualified persons to prevent electrical shock and personal injury.
The information contained in this document is subject to change without notice.
NOTICE
The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic License for operation with Xi Electronics. The
AMS software must be upgraded to AMS 8.0 or above.
Contact Emerson's Global Service Center (GSC) at 1-800-833-8314 to upgrade the 375 Field Communicator software to System
Software 2.0 with Graphic License.
Preface
The purpose of this manual is to provide information concerning the components,
functions, installation, and maintenance of the Xi Electronics.
Some sections may describe equipment not used in your configuration. You should become thoroughly familiar with the operation
of this module before operating it. Read this instruction manual completely.
Definitions
The following definitions apply to WARNINGS, CAUTIONS, and NOTICES found throughout
this publication.
WARNING!
Highlights an operation or maintenance procedure, condition, statement, etc. that if not strictly observed, could result in injury,
death, or long-term health hazards of personnel.
CAUTION!
Highlights an operation or maintenance procedure, practice, condition, statement, etc. that if not strictly observed, could result in
damage to or destruction of equipment or loss of effectiveness.
NOTICE
Highlights an essential operating procedure, condition, or statement.
Symbols
Earth (ground) terminal
:
Protective conduit or terminal
:
Risk of electrical shock
:
Warning: Refer to Instruction Manual
:
NOTICE
The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number
and is not related to the illustration in any technical manner.
Overview
The Xi is specifically designed to control a zirconium oxide probe for measuring oxygen,
usually the O2 remaining from a combustion process. Call the Rosemount Customer
Support Center (CSC) to get recommendations for other oxygen probes: 800 854 8257 (US
and Canada).
The Xi electronics has several main functions:
1.
Heater Control: The electronics receives a type K thermocouple input from an O2 probe and switches power on and off to
the probe's heater in order to maintain a temperature setpoint of 1357 °F (736 °C).
2. Signal Conditioning: The electronics receives the raw millivolt signal from the O2 sensing cell and then linearizes and
amplifies the signal to provide a linear 4-20 mA output signal used for recording or as in input into a DCS system for control
purposes.
3. Calibration: A bottled calibration gas of known value is typically flowed into the probe's sensor to verify that it is reading
correctly. If the signal is out of calibration, the calibration gas is used to adjust the 4-20 mA output signal. During calibration,
the Xi prompts the technician to flow two calibration gases into the probe and, with the calibration gases flowing,
automatically adjusts the O2 signal. With the addition of a Single Probe Sequencer (SPS), the Xi electronics can also switch
the calibration gases on and off.
4. Diagnostics: Multiple alarms are available for display. The alarm displays are intended to assist a technician in locating where
an instrument problem may reside.
The electronics has been verified to operate the following probes:
• Westinghouse 218 and World Class
• Rosemount Oxymitter
• Yokogawa
Technical Support Hotline
For assistance with technical problems, please call the Customer Support Center (CSC).
The CSC is staffed 24 hours a day, 7 days a week.
Phone: 1-800-433-6076, 1-440-914-1261
In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Emerson's field service throughout the U.S. and
abroad.
Phone: 1-800-654-RSMT (1-800-654-7768)
Emerson may also be reached via the Internet through email and the World Wide Web:
Email: GAS.CSC@emerson.com
World Wide Web: www.Emerson.com/RosemountGasAnalysis
Warranty
Rosemount warrants that the equipment manufactured and sold by it will, upon shipment,
be free of defects in workmanship or material. Should any failure to conform to this
warranty become apparent during a period of one year after the date of shipment,
Rosemount shall, upon prompt written notice from the purchaser, correct such
nonconformity by repair or replacement, F.O.B. factory of the defective part or parts.
Correction in the manner provided above shall constitute a fulfillment of all liabilities of
Rosemount with respect to the quality of the equipment.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR
IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE).
The remedy(ies) provided above shall be purchase'rs sole remedy(ies) for any failure of Rosemount to comply with the warranty
provisions, whether claims by the purchaser are based in contract or in tort (including negligence).
Rosemount does not warrant equipment against normal deterioration due to environment. Factors such as corrosive gases and
solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the
warranty period.
Equipment supplied by Rosemount but not manufactured by it will be subject to the same warranty as is extended to Rosemount by
the original manufacturer.
At the time of installation, it is important that the required services are supplied to the system and that the electronic controller is
set up at least to the point where it is controlling the sensor heater. This will ensure that, should there be a delay between
installation and full commissioning, the sensor being supplied with ac power and reference air will not be subjected to component
deterioration.
Contents
Contents
Chapter 1 Description and specifications ........................................................................................1
1.1 Component checklist ...................................................................................................................1
1.2 System overview ..........................................................................................................................2
1.2.1 Scope ............................................................................................................................2
1.2.2 System configurations .................................................................................................. 3
1.2.3 Automatic calibration ....................................................................................................4
1.2.4 Communication options ............................................................................................... 4
1.2.4.1 Data communications ....................................................................................... 4
1.2.4.2 Optional OxyBalance display and averaging system ...........................................5
1.3 Specifications .............................................................................................................................. 6
Chapter 2 Install .............................................................................................................................9
2.1 System considerations ...............................................................................................................10
2.2 Mechanical installation .............................................................................................................. 10
2.2.1 Mount .........................................................................................................................10
2.3 Electrical installation ..................................................................................................................12
2.3.1 Optional flame safety interlock ................................................................................... 15
2.3.2 Traditional architecture cable connections ..................................................................16
Chapter 3 Configure .....................................................................................................................19
3.1 Verify installation .......................................................................................................................19
3.1.1 Xi configuration .......................................................................................................... 19
3.2 Set test gas values ......................................................................................................................20
3.2.1 Setting test gas values using Field Communicator .......................................................20
3.3 Alarm relay output configuration ...............................................................................................20
3.3.1 Configuring alarm relays with the Xi keypad/display ....................................................21
3.3.2 Configuring autocalibration with the Field Communicator ..........................................21
3.4 Analog output configuration ..................................................................................................... 22
3.4.1 Configuring the analog output with the Xi keypad/display .......................................... 22
3.4.2 Configuring alarm relays with the Field Communicator ...............................................22
3.5 Autocalibration setup ................................................................................................................ 22
3.6 Optional advanced features inside the Xi ................................................................................... 23
3.6.1 Extended process temperature range to 1472 °F (800 °C) ............................................23
3.6.2 Stoichiometer ............................................................................................................. 24
3.6.3 Programmable reference ............................................................................................ 24
Chapter 4 Startup and operation .................................................................................................. 25
4.1 Overview ................................................................................................................................... 25
4.2 Startup ...................................................................................................................................... 25
4.2.1 Operation via Xi ...........................................................................................................26
4.2.2 Error conditions ...........................................................................................................26
4.2.3 Xi Controls .................................................................................................................. 26
4.2.4 Password protection ................................................................................................... 30
4.3 System parameter descriptions ................................................................................................. 31
4.4 Probe parameter descriptions ....................................................................................................34
4.5 Operation via HART/AMS ........................................................................................................... 39
4.5.1 Field communicator signal line connections ................................................................39
4.5.2 Field Communicator menu trees .................................................................................40
Instruction Manual i
Contents
4.6 Offline and online operations .....................................................................................................42
4.7 Calibration - general .................................................................................................................. 43
4.8 O2 calibration
4.8.1 O2 calibration with Xi .................................................................................................. 44
4.8.2 O2 calibration with Xi and Field Communicator ........................................................... 45
4.9 D/A trim .....................................................................................................................................46
4.9.1 D/A trim with Xi ...........................................................................................................46
............................................................................................................................ 43
Chapter 5 Troubleshooting .......................................................................................................... 47
5.1 Overview of operating principles ............................................................................................... 47
5.2 General ......................................................................................................................................48
5.2.1 Grounding ...................................................................................................................48
5.2.2 Electrical noise ............................................................................................................ 48
5.2.3 Electrostatic discharge ................................................................................................49
5.3 Alarm indications .......................................................................................................................49
5.4 Identifying and correcting fault indications ................................................................................50
5.5 Calibration passes, but still reads incorrectly ..............................................................................51
5.5.1 Probe passes calibration, O2 still reads high .................................................................52
5.5.1.1 External reference air leak ................................................................................52
5.5.1.2 Internal reference air leak ................................................................................ 52
5.5.2 Probe passes calibration, O2 still reads low .................................................................. 53
5.5.3 How do I detect a plugged diffuser? ............................................................................ 53
5.5.4 Can I calibrate a badly plugged diffuser? ......................................................................53
Chapter 6 Maintenance and service ..............................................................................................55
6.1 Overview ................................................................................................................................... 55
6.2 Maintenance intervals ................................................................................................................55
6.3 Calibration .................................................................................................................................56
6.3.1 Automatic calibration ................................................................................................. 56
6.3.2 Manual calibration ...................................................................................................... 56
6.4 Replacement parts .....................................................................................................................56
6.5 Xi components replacement ......................................................................................................56
6.5.1 I/O board replacement ................................................................................................58
6.5.2 AC relay board replacement ........................................................................................62
6.5.3 Power supply board replacement ................................................................................63
6.5.4 Xi front panel replacement ..........................................................................................65
6.5.4.1 Replacing front panel assembly without CPU board .........................................65
6.5.4.2 Replacing front panel assembly with CPU board .............................................. 66
6.5.5 DR board replacement ................................................................................................ 67
Chapter 7 Replacement parts ....................................................................................................... 71
7.1 Xi electronics ............................................................................................................................. 71
7.2 Calibration components ............................................................................................................ 72
Chapter 8 Optional accessories .................................................................................................... 73
8.1 HART handheld 375/475 Field Communicator ...........................................................................73
8.2 Asset Management Solutions (AMS) .......................................................................................... 74
8.3 By-Pass Packages ....................................................................................................................... 74
8.4 SPS 4001B Single Probe Autocalibration Sequencer ...................................................................75
8.5 IMPS 4000 Intelligent Multiprobe Test Gas Sequencer ............................................................... 76
8.6 O2 calibration gas
8.7 OxyBalance Display and Averaging System ................................................................................ 78
...................................................................................................................... 77
ii 910Xi
Contents
Appendices and reference
Appendix A XPS information ...........................................................................................................79
A.1 XPS equipment description ........................................................................................................79
A.1.1 Remote XPS for 44 V probes - 6A00358G01 ................................................................ 79
A.1.2 Remote XPS for 115 V probes - 6A00358G03 .............................................................. 80
A.1.3 Integral XPS 6A00365G01 with Xi (for 44 V probes) .................................................... 81
A.1.4 Other XPS uses ............................................................................................................81
A.2 Specifications ............................................................................................................................ 88
A.3 Recommended spare parts ........................................................................................................ 88
Appendix B Service support ............................................................................................................ 89
Instruction Manual iii
Contents
iv 910Xi
Description and specifications
1 Description and specifications
1.1 Component checklist
A typical Rosemount O2 Combustion Flue Gas Transmitter should contain all the items
shown in Figure 1-1. A complete Oxygen Analyzer system will include some or all of the
equipment shown. However, this manual describes item H only.
Use the product matrix (Table 1-1) at the end of this section to compare your order number
against your unit. The first part of the matrix defines the model. The last part defines your
options and features. Ensure the features and options specified by your order number are
on or included with the unit.
Instruction Manual 1
Description and specifications
Typical system packageFigure 1-1:
A. Quick Start Guide
Weld plate
B.
C. Traditional architecture cable
D. O2 probe
E. Reference Air Set (not used if SPS 4001B or IMPS 4000 is used)
F. HART® 375/475 Field Communicator package (optional)
G. Optional SPS 4001B or IMPS 4000 Autocalibration Sequencer
H. Xi Advanced Electronics
1.2 System overview
1.2.1 Scope
This Instruction Manual supplies details needed to install, start up, operate, and maintain
the Xi Electronics. Signal conditioning electronics output a 4-20 mA signal representing
the O2 value. This information, plus additional details, can be accessed with the HART
Model 375/475 Field Communicator or Asset Management Solutions (AMS) software..
2 910Xi
1.2.2 System configurations
Traditional architecture, HART ,and Xi communications
Some customers prefer not to mount electronics onto the probe, so a traditional
architecture version is offered. This probe sends raw millivolt signals via a 7-conductor
cable to the Xi electronics, Figure 1-2, which does all heater control and signal conditioning
in addition to its display/keypad functions. The Xi Advanced Electronics is offered to
support direct replacement probes with either 120 volt or 44 volt heaters.
Direct replacement probe with traditional architecture electronicsFigure 1-2:
Description and specifications
Figure 1-3:
O2 probe with Xi Electronics and autocalibration sequencer
Instruction Manual 3
Description and specifications
1.2.3 Automatic calibration
Calibrations consist of introducing bottled gases of known value into the probe so the
electronics can make automatic adjustments to the O2 readings to match the bottled gas
value. 0.4% O2 and 8% O2 (balance nitrogen) gases are recommended. Never use nitrogen
or instrument air as calibration gases.
Flowmeters (for calibration gases) and regulators and flowmeters (for reference air) are
available as loose components, mounted into an optional manual calibration switching
panel or as a fully automated calibration system, Figure 1-3, where calibration solenoids are
switched from the Xi Electronics. See IM-106-340AC, SPS 4000B Single Probe
Autocalibration Sequencer or IM-106-400IMPS, IMPS 4000 Intelligent Multiprobe Test Gas
Sequencer, for additional details.
1.2.4 Communication options
Data communications
An operator can configure and troubleshoot the O2 probe system in one of two ways:
1. Using the Xi Advanced Electronics; the Xi carries the following optional advanced
features:
• Fully automatic calibration
• Flame safety interface
• High temperature operation [above 1292 °F (700 °C) standard temperature]
• Stoichiometer feature provides the ability to indicate O2 efficiency when the
combustion process goes into reducing conditions (0% O2).
• Programming reference provides advanced accuracy when measuring at or near
O2 level (20.95% O2).
2. Using the HART interface, the Xi's 4-20 mA output line transmits an analog signal
proportional to the oxygen level. The HART output is superimposed on the 4-20 mA
output line. This information can be accessed through the following:
• Rosemount 375/475 Field Communicator - The handheld communicator
requires Device Description (DD) software specific to the Xi. The DD software will
be supplied with many 375/475 units, but can also be programmed into existing
units at most Emerson service offices. See Chapter 4 for additional information.
• Personal computer (PC) - The use of a personal computer requires AMS software
available from Emerson.
• Delta V and Ovation Distributed Control System (DCS) with AMS-inside
capability.
NOTICE
The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic
License for operation with the Xi. The AMS software must be upgraded to AMS 8.0 or
above.
Contact Emerson's Global Service Center (GSC) at 1-800-833-814 to upgrade the 375
Field Communicator software to System Software 2.0 with Graphic License.
4 910Xi
Description and specifications
3. The Xi can also transmit HART information wirelessly via a wireless THUM Adapter,
Figure 1-4. The THUM Adapter threads into the Xi conduit ports and converts the
4-20 mA O2 signal to a wireless protocol. All other HART information is also
transmitted.
In addition to the wireless THUM Adapter, a hard-wire connection of the 4-20 mA
signal to the DCS may be used at the same time. More detailed information
regarding the application of the THUM Adapter is available in Product Data Sheet
00813-0100-4075. Note that the THUM Adapter may also be used with the
Oxymitter, mounted integral to the probe, or to the Oxymitter remote electronics.
Wireless THUM AdapterFigure 1-4:
Optional OxyBalance display and averaging system
Receives up to eight 4-20 mA signals from individual Xi units. Trends individual outputs
and calculates four programmable averages as additional 4-20 mA outputs. OxyBalance
graphic displays are shown in Figure 1-5. See IM-106-4050, OxyBalance Oxygen Display and
Averaging System, for additional details.
Instruction Manual 5
Description and specifications
OxyBalance displaysFigure 1-5:
1.3 Specifications
SpecificationsTable 1-1:
Measurement specifications
Net O2 range 0 to 50% O2 user scalable
-2 to 50% O2 user scalable with stoichiometer
Lowest detectable limit 0.01% O
Signal stability ±0.03% O
Accuracy in reducing conditions ±10% of reading or 0.1% O
System responses in reducing conditions Going from oxidizing to reducing -T90 in 120 seconds
Going from reducing to oxidizing -T90 in 30 seconds
Ambient temperature effect on Xi 4-20 mA signal Less than 0.0025% O2 per degree Celsius
Environmental specifications
Xi Advanced Electronics Type 4X/IP66 polycarbonate material
Ambient temperature limits -4 to 122 °F (-20 to 50 °C)
-4 to 158 °F (-20 to 70 °C) as measured by electronics
Xi LCD display: ambient temperature limits -4 to 131 °F (-20 to 55 °C)
2
2
2
6 910Xi
Description and specifications
Specifications (continued)Table 1-1:
General purpose certifications
Installation specifications
Mounting Panel, wall, or pipe
Reference air 0.5 scfh (0.25 l/min), clean, dry, instrument-quality air
(20.95% O2), regulated to 5 psi (34 kPa)
Calibration Semi-automatic or automatic
Cal gases 0.4% O2 and 8% O2, balance N
Traditional architecture cable 200 ft (61 m) maximum length
Transmitter electrical power 12 - 24 Vdc (loop-powered from control room or Xi)
Electrical power for Xi 100 - 240 Vac ±10%, 50/60 Hz
Power consumption of Xi 12 VA maximum or 776 VA maximum with traditional arch-
tecture, 120 V probes
450 VA maximum with traditional architecture, 44 V
probes
Alarm relay outputs Two provided - 2 Amperes, 30 Vdc, Form-C
Optional loss of flame input Internally powered input to remove heater power actuated
via dry contact output from user's flame scanner
Emerson has satisfied all obligations from the European legislation to harmonize the product requirements in Europe.
All static performance characteristics are with operating
variables constant. Specifications subject to change without notice.
2
Product matrix, Xi advanced electronicsTable 1-2:
Xi Xi Advanced Electronics
Code Remote type
01 Single channel
(1)
02 Single channel, accepting a loss-of-flame input to remove heater power with flame
status relay
03 Dual channel
(1)
(1)
04 Single channel traditional architecture for 120 V probes
05 Single channel traditional architecture for 44 V probes
Code Mounting
00 No hardware
01 Panel mount kit with gasket
02 2 in. pipe/wall mount kit
Instruction Manual 7
Description and specifications
Code Cable
00 No cable
10 20 ft (6 m) cable
11 40 ft (12 m) cable
12 60 ft (18 m cable)
13 80 ft (24 m cable)
14 100 ft (30 m) cable
15 150 ft (45 m) cable
16 200 ft (60 m) cable
Code Stoichiometer function
00 None
01 Single channel (stoichiometer cell also required in probe)
02 Dual channel (stoichiometer cell also required in probe)
Code Programmable reference function
00 None
01 Single channel
02 Dual channel
Product matrix, Xi advanced electronics (continued)Table 1-2:
Code 800 deg C process function
00 None
01 Single channel
02 Dual channel
1. Requires XPS transmitter, P/N 6A00358G03
8 910Xi
2 Install
WARNING!
Before installing this equipment, read the Essential Instructions at the front of this Instruction
Manual. Failure to follow safety instructions could result in serious injury or death.
WARNING!
ELECTRICAL HAZARD
Install all protective equipment covers and safety ground leads after installation. Failure to
install covers and ground leads could result in serious injury or death.
WARNING!
HAZARDOUS AREAS
The Xi Advanced Electronics can be installed in general purpose areas only. Do not install the Xi
in hazardous areas or in the vicinity of flammable liquids.
Install
WARNING!
ELECTRICAL HAZARD
If external loop power is used, the power supply must be a safety extra low voltage (SELV)
type.
NOTICE
All unused ports on the probe housing and Xi enclosure should be plugged with a suitable
filling.
Instruction Manual 9
Install
2.1 System considerations
A typical system installation for an Xi or O2 probe is shown in Figure 2-1.
Typical system installationFigure 2-1:
2.2 Mechanical installation
2.2.1 Mount
The Xi Advanced Electronics is available in a panel mounting, wall mounting, or pipe
mounting configuration.
Refer to Figure 2-2 or Figure 2-3 for the panel, wall, or pipe mounting details.
Procedure
Ensure all components are available to install the Xi.
1.
2. Select a mounting location near or removed from the O2 probe.
Consider the temperature limitations of the Xi (see Section 1.3) when selecting the
mounting location.
3. Mount the Xi at a height convenient for viewing and operating the interface.
Approximately 5 ft (1.5 m) is recommended.
10 910Xi
Install
4. The keypad window on the Xi may have interior and exterior protective membranes.
Remove the protective membranes prior to use of the Xi enclosure.
NOTICE
Failure to remove the protective membranes may cause the display to appear distorted.
The membrane may be difficult or impossible to remove after extended use at elevated
temperatures.
Xi Advanced Electronics - panel mounting detailsFigure 2-2:
Instruction Manual 11
Install
Xi Advanced Electronics - wall/surface and pipe mounting detailsFigure 2-3:
2.3 Electrical installation
All wiring must conform to local and national codes. Multiple wiring diagrams are shown in
this section. Always refer to the diagrams that apply to your transmitter configuration and
disregard all other wiring diagrams.
12 910Xi
Install
WARNING!
ELECTRIC SHOCK
Disconnect and lock out power before connecting the power supply. Failure to lock out power
could result in serious injury or death.
WARNING!
ELECTRIC SHOCK
Install all protective covers and safety ground leads after installation. Failure to install covers
and ground leads could result in serious injury or death.
WARNING!
ELECTRIC SHOCK
To meet the safety requirements of IEC 1010 (EC requirement) and ensure safe operation of this
equipment, connection to the main electrical power supply must be made through a circuit
breaker (min 10 A) which will disconnect all current-carrying conductors during a fault
situation. This circuit breaker should also include a mechanically operated isolating switch. If it
does not, locate another external means of disconnecting the power supply close by. Circuit
breakers or switches must comply with a recognized standard such as IEC 947.
NOTICE
Line, voltage, signal, and relay wiring must be rated for at least 105 °C (221 °F).
NOTICE
If a metal conduit is used with the Xi, the conduit should be reliably bonded to protective earth.
The grounding plate inside the Xi is not bounded to PE and does not provide adequate
grounding.
1. Remove cover screws from the front cover of the Xi. Swing down the front cover of
the interface box.
2. Pull out the I/O board on the right-hand side of the card rack inside the Xi. If your
system is configured to operate two transmitter probes, there are two I/O interface
boards.
3. See Figure 2-4. Connect the 4-20 mA signal wires at J4 of the I/O board. Attach the
supplied ferrite clamp over the 4-20 mA OUT wires that extend past the shield.
NOTICE
Installation of the ferrite clamp over the 4-20 mA OUT wires is required for compliance
with the European EMC directive.
Instruction Manual 13
Install
Signal connections at I/O boardFigure 2-4:
Alarm indicator relay terminalsFigure 2-5:
4. Terminate the shield of the 4-20 mA signal wires at the designated ground terminal
of the Xi. Do not allow bare shield wires to contact the circuit boards. Insulate the
shield wires prior to termination.
Connect the signal wires from the SPS or IMPS (if used) to the applicable terminals of
5.
J3. Refer to the SPS or IMPS instruction manual for wiring details.
6. Connect the signal wires for the flame status input (if used) to the applicable
terminals of J2. The flame status sensing device is supplied by the customer. Refer to
the applicable OEM documents for signal wiring details.
7. Connect the customer's alarm indicator devices to the alarm indicator relay
terminals. See Figure 2-5 for the alarm indicator relay terminals.
8. Reinstall the I/O board in the card rack of the Xi.
14 910Xi
Install
Power connections - Xi Advanced ElectronicsFigure 2-6:
9. If your system is configured for two channel operation, repeat steps 2 through 7 to
connect the other signal wires.
10.
Remove the connector from the power supply board located on the left-hand side of
the card rack inside the Xi.
11. See Figure 2-6. Connect the line, or L1, wire to the L1 terminal and the neutral, or L2,
wire to the N terminal.
12. Reinstall the power supply connector in the power supply board.
13. Close and fasten the Xi cover.
2.3.1 Optional flame safety interlock
A flame safety interlock by Emerson is available for the heater power disconnect whenever
there is a loss of the process flame or a heater runaway condition (heater overtemperature) in the O2 probe. A simplified wiring diagram for the flame safety interlock is
shown in Figure 2-7. The input is internally powered by the Xi and is actuated via a dry
contact output from the user's flame scanner. A closed contact indicates a flame is
present. An open contact indicates a loss of flame.
Instruction Manual 15
Install
Flame safety interlock - wiring diagramFigure 2-7:
2.3.2 Traditional architecture cable connections
A traditional architecture configuration is used to provide for remote location of the
transmitter electronics. All electronics are housed inside the Xi. A multi-conductor power/
signal cable connects between the probe and the Xi. Use the following procedure to
connect the traditional architecture probe to the Xi.
NOTICE
The traditional architecture cable is provided at the specified length and is ready for
installation. The cable glands must be properly terminated to maintain EMC/EMI noise
protection.
Procedure
Run the 7-conductor cable between the traditional architecture probe and the
1.
installation site for Xi. Use new cable conduit or trough as needed.
16 910Xi
Traditional architecture cable gland assemblyFigure 2-8:
2. Install the cable and lead wires to the probe per manufacturer's instructions.
3.
Install the cable at the probe housing and at the Xi enclosure according to the
following procedure:
a. Unscrew the locking nut from the gland assembly (Figure 2-8) and slide the
locking nut back along the cable.
b. Pull the gland body away from the plastic insert.
Install
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 left front cable port from
inside 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 and environmental seal.
4. At the Xi, connect the cable leads to the connectors on the transmitter I/O board as
indicated in Figure 2-9.
Instruction Manual 17
Install
Transmitter board connections at Xi -traditional architectureFigure 2-9:
18 910Xi
3 Configure
3.1 Verify installation
WARNING!
ELECTRIC SHOCK
Install all protective equipment covers and safety ground leads before equipment startup.
Failure to install covers and ground leads could result in serious injury or death.
WARNING!
ELECTRIC SHOCK
If external loop power is used, the power supply must be a safety extra low voltage (SELV)
type.
Configure
3.1.1 Xi configuration
Refer to Figure 3-1 for the configuration of jumpers JP1 through JP8. The jumper
configuration for your I/O board depends on the system design and system components
used in your installation.
The setting of switch SW4 and the configuration of jumpers JP1 through JP8 must be
verified on the I/O board in the Xi. All four dip switches on switch SW4 must be set to the
Off position, as shown.
I/O board jumper configurationFigure 3-1:
Instruction Manual 19
Configure
3.2 Set test gas values
Use a Field Communicator or the Xi to set test gas values for calibration.
An Xi shipped from the factory has test gas values for low and high set to 0.4% and 8%
respectively. This same process must be performed any time a replacement transmitter
board, I/O board, or DR board is installed.
Setting test gas values using Xi display/keypad
Procedure
1. Press the MENU button once.
2. From the main menu, select PROBE 1.
3. From PROBE 1, select DETAILED SETUP.
4. From the DETAILED SETUP menu, select CAL SETUP.
5. From CAL SETUP, select Cal Gas 1. Enter the percent O2 used for the low O2 test gas.
6. From CAL SETUP, select Cal Gas 2. Enter the percent O2 used for the high O2 test gas.
7. Press the Left arrow key several times to return to the main menu.
8. Repeat steps 2 through 6 for PROBE 2 if configured for dual channel.
3.2.1 Setting test gas values using Field Communicator
1. Use the Field Communicator software to access the HART menu.
2.
From the DEVICE SETUP menu, select DETAILED SETUP.
3. From the DETAILED SETUP menu, select CAL SETUP.
4. From CAL SETUP, select Cal Gas 1. Enter the percent O2 used for the low O2 test gas.
5. From CAL SETUP, select Cal Gas 2. Enter the percent O2 used for the high O2 test gas.
3.3 Alarm relay output configuration
The Xi has two dry contact Form-C alarm relay output signals that can be configured in
eight different modes through the Xi keypad display or the 375/475 Field Communicator.
A list of possible configurations is shown in Table 3-1. Each alarm relay can be configured
separately.
If the Xi is configured with the optional flame safety interlock, Alarm 2 is configured with
Heater Relay and prewired to the AC relay board. In this condition, the relay configuration
cannot be changed to any other setting. If the Xi is not configured with the optional flame
safety interlock, Heater Relay is not valid and cannot be chosen for Alarm 2.
20 910Xi
Configure
Alarm relay output configurationsTable 3-1:
Mode Configuration
No alarm
Unit alarm The output is configured for a unit alarm.
Low O2 alarm The output is configured for a low O2 alarm.
Low O2/unit alm The output is configured for a unit alarm and a low O2 alarm.
Cal recommended The output is configured for a calibration recommended display.
Cal rec/unit alm
Low O2/cal rec The output is configured for a low O2 alarm and a calibration recom-
Low O2/unit/cal rec The output is configured for a low O2 alarm, a unit alarm, and a cali-
Heater relay The output is configured for flame safety interlock.
(1) The default configuration for Alarm 2
(2) The default configuration for Alarm 1
(1)
(2)
The output is not configured for any alarm condition.
The output is configured for a unit alarm and a calibration recommended display.
mended display.
bration recommended display.
3.3.1 Configuring alarm relays with the Xi keypad/display
1. Press the MENU button once.
2. From the main menu, select PROBE 1.
3. From PROBE 1, select DETAILED SETUP.
4. From the DETAILED SETUP menu, select ALARM RELAY.
5. From ALARM RELAY, select as follows:
• Alm Relay1 - Alarm 1 mode
• Alm Relay2 - Alarm 2 mode
• Low O2 Alm SP - Low O2 alarm setpoint
• High Temp Alm SP - High temperature alarm setpoint
6. Press the Left arrow key several times to return to the main menu.
7. Repeat steps 2 through 6 for PROBE 2 if configured for dual channel.
3.3.2 Configuring autocalibration with the Field Communicator
1. Use the 375/475 Field Communicator software to access the HART menu.
2.
From the DEVICE SETUP menu, select DETAILED SETUP.
3. From the DETAILED SETUP menu, select CAL SETUP.
4. From CAL SETUP, select Auto Cal.
5. Press the Right arrow key to change the state from NO to YES.
Instruction Manual 21
Configure
3.4 Analog output configuration
The analog output signal from the Xi can be configured for the 4-20 mA range and fault
condition.
An Xi shipped from the output has the analog outputs set to 4 to 20 mA range with a
3.5 mA alarm level. This same process must be performed any time a replacement
transmitter board or I/O board is installed.
3.4.1 Configuring the analog output with the Xi keypad/ display
1. Press the MENU button once.
2. From the main menu, select PROBE 1.
3. From PROBE 1, select DETAILED SETUP.
4. From the DETAILED SETUP menu, select ANALOG OUTPUT.
5. From ANALOG OUTPUT, select the following parameters:
• O2 LRV - O2 value at the lower analog output value (0 mA or 4 mA)
• O2 URV - O2 value at the upper analog output value (20 mA)
• AO Range - Range of the analog output (0-20 mA or 4-20 mA)
• Signal Alarm Level - O2 alarm level (3.5 mA or 21.1 mA)
3.4.2 Configuring alarm relays with the Field Communicator
1. Use the 375/475 Field Communicator software to access the HART menu.
2. From the DEVICE SETUP menu, select DETAILED SETUP.
3. From the DETAILED SETUP menu, select ALARM RELAY.
4. From ALARM RELAY, select as follows:
• Alm Relay1 - Alarm 1 mode
• Alm Relay2 - Alarm 2 mode
• Low O2 Alm SP - Low O2 alarm setpoint
• High Temp Alm SP - High temperature alarm setpoint
5. From CAL SETUP, select Cal Gas 2. Enter the percent O2 used for the high O2 test gas.
3.5 Autocalibration setup
If autocalibration is desired, the Xi must be used with either an SPS 4001B or IMPS 4000.
The Xi must be properly configured before autocalibration can take place. Refer to the
applicable SPS 4001B or IMPS 4000 instruction manual for details on performing
autocalibration. Refer to Chapter 4 for details on manual calibration procedures.
22 910Xi
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