Home

Emerson Process Management OXYMITTER 4000 User's Manual

1. MIIA WOLLOS 69 9 00 9 ge Es 021 vest S31OH p sare a 149 EO UT Hd 2 9 76 via TOH a A 0 76 Loc 14 EN 672 vid 216 WT 042 061 3SNV13 91 181 ISNV 08 097 NI 8L L1 SH L LI HIV AAANTINI L33SV59 dad dibus 35NV13 ONILNNOW 318VL TVAOW3H NOLLY TIYLSNI 2 318VL c ganLwwol sir HlIHV3 p L 669 3dOT3AN3 TVAON3 TVNH31NI dan 1 5679 ISNV F d NIG 43SN441A YASNAAIC OINVtdO9 HIV 33u ich H3aanNs 380Hd HOS Hlava LdN i S EL eve HLIM V WIG OL Gav TVNH3LX3 NNOO 2313 L L AN V WIG 87 96 I 1 D 972 o F B 99 o x 2 959 25 Ji Ld i E PS sduy s 13913 SN oc ANALNO some FEES MEN
2. 0 125 27 NPT 3 F gt 79 25 3 12 MAX 1 OUTLET 2 57 15 2 250 OUTLET 0 25 18 NPT INLET 215 90 122 17 8 50 0 250 IN OR 6 MM O D TUBING MAX SUPPLIED BY CUSTOMER MOUNTING t o HOLES 50 80 81 03 INSTRUMENT AIR FLOW SET 2 0 3 19 LG 69 1551 KPA GAGE POINT KNOB 4826 FOR 10 225 PSIG MAX 7 92 0 312 DRAIN 1 50 DIA TT VALVE Y THROUGH lt REF AIR SET gt 10 orien gt BOLTS 263C152G01 REPLACEMENT PARTS FLOWMETER 0 006 0 057 SCMH 0 2 2 0 SCFH 771B635H02 PRESSURE GAGE 0 103 KPA GAGE 0 15 PSIG 275431 006 COMBINATION FILTER REG 0 207 KPA GAGE 0 30 PSIG 4505C21G01 Figure 2 11 Air Set Plant Air Connection 37270008 with the Hazardous Area Oxymitter 4000 Low Gas 0 4 and High Gas 8 See Figure 2 12 for the Hazardous Area Oxymitter 4000 connections 1 FI EN Jj F REFERENCE AIR CALIBRATION GAS 26170025 gt 1 N IN If using 5 4000 SPS 4000 install it in non hazardous explosive free environment Figure 2 12 Hazardous Area Oxymitter 4000 Gas Connections 2 5 IMPS 4000 CONNECTIONS Ensure the IMPS 4000 is installed in a safe non hazardous explosive free area and verify CAUTION Do not use 100 nitrogen as a low gas
3. ROSEMOUNT pe 37270011 Figure 4 2 Defaults Hazardous Area Oxymitter 4000 with LOI Rosemount Analytical Inc A Division of Emerson Process Management Configuration with LOI 4 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 4 4 CAUTION The HART option is not protected by energy limiting barriers It must not be interfaced from within the hazardous area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case even when using the intrin sically safe version of the handheld communicator LOGIC I O This two terminal logic contact can be config ured either as a solid state relay activated alarm or as a bi directional calibration handshake sig nal to an IMPS 4000 or SPS 4000 The configu ration of this signal depends on the setting of the LOGIC I O PIN MODE via HART AMS or LOI The ten different modes available are explained in Table 4 1 a Alarm When configured as an alarm this signal alerts you to an out of spec condition The output is 5 Vdc in series with a 340 ohm resistor Hazardous Area Oxymitter 4000 For optimum performance Rosemount rec ommends connecting the output to a Potter amp Brumfield 3 2 mA DC relay P N R10S E1Y1 J1 0K Of the ten modes in 4 1 mode 1 through mode 7 are the a
4. PROBE FLANGE L1 BOTTOM VIEW GASKET 37260045 Figure 8 18 Probe Leakage Paths b The sensing cell is bolted to the end of the probe and uses a cor rugated metallicseal item 25 to separate the process gases from the ambient reference air This seal can be used only one time so always replace this seal when a cell is replaced Always apply anti seize compound on both sides of the corrugations Probe passes calibration but still appears to read low 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 boil ers cement and lime kilns catalyst regen eration recovery boilers etc this diffusion element will eventually plug It is important not to pressurize the sensing cell during calibrations by flowing excessive cal gas against a plugged diffuser Calibra tion flow rates should be set only when a new diffuser is installed As the diffuser plugs do not adjust the flow rates upward How do I detect a plugged diffuser 1 The signal s speed of response will degrade The trend in the control room will become smoother 2 When calibrating the calibration gas flow rate will be noted to be lower Never readjust this flow upwards Adjust this flow only when a new diffuser is installed Rosemou
5. 29 20 ft 6 m Cable 12 60 ft 18 m Cable 80 ft 24 m Cable 100 ft 30 m Cable 150 ft 45 m Cable 200 ft 61 m Cable Continued 1 3 00 03 oo 10 Exampde O NOTES Recommended uses High velocity particulates in flue stream installation within 11 5 ft 3 5 m of soot blowers or heavy salt cake buildup Applications Pulverized coal recovery boilers lime kiln Where possible specify ANSI DIN or JIS designation otherwise provide details of the existing mounting plate as follows Plate with studs Bolt circle diameter number and arrangement of studs stud thread and stud height above mounting plate Plate without studs Bolt circle diameter number and arrangement of holes thread and depth of stud mounting plate with accessories Startup calibration and operation can be implemented using the standard membrane keypad Remote access and additional functionality available via HART Communications Model 275 375 Handheld Communicator with Hazardous Area Oxymitter 4000 device descriptor DD required Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 15 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Table 1 2 Calibration Components Part Number Description 1A99119G01 Two disposable calibration gas bottles 0 4 and 8 Os balance nitrogen 550 liters each 1A99119G02 T
6. KoT oraon va eA yxerat Kat va SiapKwe va n npo v Tic TWV IEC227 IEC245 al KAAWSIGEIG np net KAaTGAANAES via xapou ugnA repn and 75 O ot ot Ba rip net va eiva TETOIWY EOWTEPIKwWY v nap xouv TWV Fia m Siaopadion Asrroupylac o v gonc qumi me Guokgu c Ba np ne va yiverat u vo p ow 10A TOU aywyouc om Sidpkeia kar oraonq unope enfons va nepirvapBdvet anop vworne E v p oa anoouvdeone ouoxeu c and mv np net va rrapoxrjBo v Kai va onuqv8o v oupqavouv np Turtq IEC947 onpaop va ue to
7. PIPE MOUNT WALL MOUNT CONFIGURATION SS K 37270013 Figure 2 2 Hazardous Area Oxymitter 4000 Remote Electronics Installation Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 35910003 Rosemount Analytical Inc A Division of Emerson Process Management 07 gr 092 006 69 149 gt 061 061 eo eS 7822 29 1 gt lt 60 SZO 9 0 vid E 45 O SYD NI 3ATVA MOSHO ATV ve 61 61 3 1OH 5 88 een wwol sir Sc 6 Sc 6 006 vid 216 79 NI 81 C JjanL NI L NIG Gee Gez 622 FONVIS NI ISNV sir ISNV FONVIS ga WIG Vo NIA 3gotud div 434 006606 13 6 3AISVH8V t 318V1 C SVO WO WAOWSY NOILLVTIVLSNI 318V L 5 NOLLO3NNOO 1V2IHLO313 LdN ASSY HOLO3 143d II I ASSY WAS O via 9 16 15 5 C es N Avo lt Z F z zz A 22 277 2 7
8. KEYPAD ADC Error ROSEMOUNT Eo Alarms LOI 37260022 Figure 8 6 Fault 4 A D Comm Error 8 8 Troubleshooting Hazardous Area Oxymitter 4000 d Fault 4 A D Comm Error Membrane Keypad When Fault 4 is detected the HEATER T C LED flashes four times pauses for three seconds and repeats Figure 8 6 1 Call the factory for assistance LOI When Fault 4 is detected the LOI displays the ADC Error message 1 Call the factory for assistance Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 ROSEMOUNT DIAGNOSTIC HEATER O ALARMS O2 CELL o _ CALIBRATION CALIBRATION RECOMMENDED GAGS as TEST O SUL mm 5150 POINTS HEATER TC C HEATER TC INC INC A HIGH LOW GAS GAS TEST GAS DEC DEC PROCESS O2 KEYPAD ROSEMOUNT Ed LOI TP1 TP2 e TP3 e TP4 5 TP6 e Figure 8 7 Fault 5 Open Heater RED GRN ORG 37260023 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Fault 5 Open Heater shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardou
9. a Fi a mum SNOLLIGNOO H3H1V3M 1N3IgIAV ten TVNH31X3 NOLIVOIHLLH3O OL Q3SOdX3 dl 31V INSNI 1934599 NOLLO3HIG SIHL NI 38 LSNW SS30O0ud I33 V9 MHL NI 900 Rosemount Analytical Inc A Division of Emerson Process Management Figure 2 1 Hazardous Area Oxymitter 4000 Probe Installation Installation 2 2 Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 REMOTE ELECTRONICS REMOTE ELECTRONICS WITH MEMBRANE KEYPAD AND BLIND COVER WITH LOI AND WINDOW COVER 62 0 2 44 DIA NOTE ALL DIMENSIONS ARE IN MILLIMETERS WITH INCHES IN PARENTHESES 2 21 A 164 6 p ie i 6 48 7 47 E a 246 9 9 72 2 93 5 3 68 CONFIGURATION
10. e Fuse Replacement See 1 9 12 Remove screw 18 Figure 9 3 Figure 9 4 cover lock 19 and cap tive washer 20 securing cover 1 Remove the cover See Figure 9 5 Depress and remove the J1 cell and T C connector from the J1 socket Loosen the three captive screws 10 Figure 9 3 or Figure 9 4 Slide electronic assembly 2 partially out of housing 11 See Figure 9 6 Squeeze the sides of the J8 connector and carefully remove the J8 connector heater leads from the power supply board Remove the electronic assembly 2 Figure 9 3 or Figure 9 4 from the housing 11 Turn the electronic assembly over so that you are looking at the bottom of the power supply board Figure 9 7 Gently depress the two white posts one at a time Carefully separate the power supply board from the analog board Remove the fuse and replace it with a new one Maintenance and Service Hazardous Area Oxymitter 4000 POWER SUPPLY BOARD 37270021 Figure 9 7 Fuse Location 9 Align the white posts with the post holes on the power supply board and the pin connector on the power supply board with the connector port on the back of the analog board Gently push the boards together until the white posts snap in place Ensure the as sembly is secure by gently trying to separate the boards 10 Reconnect the J8 connector to the p
11. 4 20 MA OUTPUT TWISTED PAIR HAZARDOUS AREA OXYMITTER 4000 WITH INTEGRAL ELECTRONICS TERMINATION IN CONTROL ROOM ASSET MANAGEMENT SOLUTIONS 2 CALIBRATION GAS LINES BY CUSTOMER 300 FT 90 M MAX LINE VOLTAGE 37270009 Figure 1 5 Hazardous Area Oxymitter 4000 HART Connections and AMS Application 1 6 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 STANDARD OXYMITTER 4000 PLATE LINE ba VOLTAGE INSTRUMENT AIR SUPPLY REFERENCE AIR LOGIC I O FLOWMETER PRESSURE IMPS 4000 REGULATOR MULTIPROBE 4 TO 20 mA 1 GANBEASIGN AUTOCALIBRATION OPTION T ow TE t e 2 4 2 7 i x Sos 2 71 e ee F Z N Z GAS REMOTE MOUNTED SPS 4000 SINGLE PROBE ADAPTER AF AUTOCALIBRATION OPTION PLATE CA CALIBRATION WITH REFERENCE AIR OPTION MA SS OXYMITTER 4000 LINE 3 VOLTAGE Or lt ADAPTER ein OGIC 1 0 LOGIC PLATE CA SIGNAL REFERENC OXYMITTER 4000 CALIBRATION GAS REFERENCE IMPS 4000 LINE VOLTAGE NOTE THE IMPS 4000 OR SPS 4000 MUST 4 TO 20 mA BE INSTALLED IN A NON HAZARDOUS SIGNA EXPLOSIVE FREE ENVIRONMENT CALIBRATION INSTRUMENT AIR SUPPLY LOGIC I O CALIBRATION GAS 2 RELAY OUTPUTS AND REMOTE CONTACT INPUT LINE VOLTAGE 37270014 Figure 1 6 Typical
12. 3A 7 7 E KEE DRIP LOOP REPLACE INSULATION AFTER INSTALLING HAZARDOUS AREA OXYMITTER 4000 INSULATION ia MOUNTING PLATE STACK OR DUCT METAL WALL 26310010 Figure 2 7 Installation with Drip Loop and Insulation Removal c Remote Electronics Installation 2 2 ELECTRICAL INSTALLATION FOR HAZARDOUS AREA OXYMITTER 4000 For a Hazardous Area Oxymitter 4000 with WITH INTEGRAL ELECTRONICS the remote electronics option install the probe according to the instructions in para All wiring must conform to local and national graph 2 1 b Install the remote electronics codes unit on a wall stand pipe or similar struc eem ture Figure 2 2 and Figure 2 8 WARNING Disconnect and lock out power before connecting the unit to the power supply WA 1 N IN C Install all protective equipment covers and safety ground leads after installa tion Failure to install covers and ground leads could result in serious 37260016 injury or death Figure 2 8 Remote Electronics Mounting 2 8 Installation Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 WARNING To meet the Safety Requi
13. Figure 3 1 Be sure the power the 4 20 mA signal and the logic outputs are properly connected and secure To avoid a shock hazard the power terminal cover must be installed For units with remote electronics check the terminal block wiring at the probe and at the remote electronics unit Install the cover 17 Figure 9 3 Figure 9 4 over terminal block 15 and secure with captive washer 20 cover lock 19 and screw 18 HAZARDOUS AREA _ OXYMITTER 4000 da ELECTRONICS IN HOUSING 37270002 Figure 3 1 Electronics Housing Terminals and Membrane Keypad Rosemount Analytical Inc A Division of Emerson Process Management Configuration with Keypad 3 1 Instruction Manual IB 106 340C Rev 4 1 c Verify Hazardous Area Oxymitter 4000 Configuration Located on the microprocessor board the top board are two switches that configure outputs for the Hazardous Area Oxymitter 4000 Figure 3 2 SW1 determines if the 4 20 mA signal is internally or externally powered SW2 determines IN C The HART option is not protected by energy limiting barriers It must not be interfaced from within the hazardous area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case eve
14. TP1 e TP2 e_ TP3 e TP4 e TP5 e TP6 IS ACTIVE ONLY WHEN THE HEATER VOLTAGE OPTION IS SET TO MANUAL IN THE SOFTWARE AUTO TUNE NO RED YEL GRN ORG 37270001 Figure 3 2 Defaults Hazardous Area Oxymitter 4000 with Membrane Keypad Rosemount Analytical Inc A Division of Emerson Process Management Configuration with Keypad 3 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 3 2 3 4 CAUTION The HART option is not protected by energy limiting barriers It must not be interfaced from within the hazardous area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case even when using the intrin sically safe version of the handheld communicator LOGIC I O This two terminal logic contact can be config ured either as a solid state relay activated alarm or as a bi directional calibration handshake sig nal to an IMPS 4000 or SPS 4000 The configu ration of this signal depends on the setting of the LOGIC I O PIN MODE via HART AMS or LOI The ten different modes available are explained in Table 3 1 a Alarm When configured as an alarm this signal alerts you to an out of spec condition The output is 5 Vdc in series with a 340 ohm resistor Hazardous Area Oxymitter 4000 For optimum performance Rosemount rec ommends connecting the output to a Potter amp Brumfield 3 2 mA
15. zero gas It is suggested that gas for the low zero be between 0 4 and 2 0 O Do not use gases with hydro carbon concentrations of more than 40 parts per million Failure to use proper gases will result in erroneous 2 6 readings b Calibration Gas Two calibration gas concentrations are used Rosemount Analytical Inc A Division of Emerson Process Management the wiring and pneumatic connections per the IMPS 4000 Intelligent Multi probe Test Gas Sequencer Instruction Bulletin SPS 4000 CONNECTIONS Ensure the SPS 4000 is installed in a safe non hazardous explosive free area and verify the wiring and pneumatic connections per the SPS 4000 Single Probe Autocalibration Sequencer Instruction Bulletin Installation 2 15 Instruction Manual IB 106 340C Rev 4 1 July 2004 2 16 Installation Hazardous Area Oxymitter 4000 A wor Upon completing installation make sure that the Hazardous Area Oxymitter 4000 is turned on and operating prior to firing up the combustion process Damage can result from having a cold Hazardous Area Oxymitter 4000 ex posed to the process gases During outages and if possible leave all Hazardous Area Oxymitter 4000 units running to prevent condensation and premature aging from thermal cycling CAUTION If the ducts will be washed down during outage MAKE SURE to power down the Hazardous Area Oxymitter 4000 units and remove them from the wash area Rosemoun
16. 2 iz AE o oo INC INC 10 HIGH LOW GAS GAS TEST GAS TP5 amr O2 Q KEYPAD Alarms 02 T C Open ROSEMOUNT De f LOI 37260019 Figure 8 3 Fault 1 Open Thermocouple Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Fault 1 Open Thermocouple shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view The upper view also shows J1 and test points TP1 through TP6 located on the microprocessor board below the membrane keypad or the LOI module Membrane Keypad When Fault 1 is detected the HEATER T C LED flashes once pauses for three seconds and repeats 1 Check connector J1 Ensure the con nector is properly seated 2 Using a multimeter measure the volt age from TP3 to TP4 If the reading is 1 2 VDC 0 1 VDC the thermocou ple is open 3 Remove power Disconnect J1 Meas ure the resistance across the red and yellow thermocouple leads The resis tance should be approximately 1 ohm 4 If the thermocouple is open see para graph Heater Strut Replacement LOI When Fault 1 is detected the LOI displays the O2 T C Open message 1 Remove power Unscrew and remove the LOI module from the electronic assembly 2 Reconnect power to the Oxymitter
17. 1 CALIBRATION INITIATE Contact from the control room to an SPS 4000 or IMPS 4000 one per probe provides the ability to manually initiate a calibra tion at any time from the control room Rosemount Analytical Inc A Division of Emerson Process Management CALIBRATION FAILED One contact Instruction Manual IB 106 340C Rev 4 1 July 2004 Note that calibrations can also be initiated from a HART handheld com municator from Asset Management Solutions software or from the keypad on the Oxymitter 4000 IN CALIBRATION One contact per probe provides notification to the con trol room that the calibration recom mended diagnostic has initiated an automatic calibration through the SPS 4000 or IMPS 4000 If the signal is being utilized in an automatic control loop this contact should be utilized to place the control loop into manual during calibration per probe from an SPS 4000 or IMPS 4000 to the control room for notification that the calibration procedure failed Grouped with this alarm is an output from a pressure switch which indicates when the calibration gas bottles are empty 4 20 mA SIGNAL DURING CALIBRATION The 4 20 mA signal can be configured to respond normally during any calibration or it can be con figured to hold the last value upon the initiation of calibration The factory default is for the 4 20 mA signal to track operate normally throughout calibration Holding the last
18. 1 Follow the instructions in paragraph 9 4a to remove the Hazardous Area Oxymitter 4000 from the stack or duct 2 Separate the probe and the electronics housing per paragraph step 2 3 Reinstall electronics on the new probe per paragraph steps 4 and 5 4 Follow the instructions in paragraph 2 1b to install the Hazardous Area Oxymitter 4000 into the stack or duct WARNING When working on this equipment on the laboratory bench be aware that the Hazardous Area Oxymitter 4000 probe tube and flame arrestor hub can be hot up to 300 C 572 F in the region of the probe heater Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 g Heater Strut Replacement This paragraph covers heater strut replace ment Do not attempt to replace the heater strut until all other possibilities for poor per formance have been considered If heater strut replacement is needed order a re placement heater strut See 1 N IN Use heat resistant gloves and clothing when removing probe Do not attempt to work on the probe until it has cooled to room temperature The probe can be as hot as 300 572 F This can cause severe burns 1 Follow the instructions in paragraph 9 4alto remove the Hazardous Area Oxymitter 4000 from the stack duct 2 Remove oxygen sensing cell per para graph steps 1 through 5 CAUTION Do not force the
19. 2 3 2 8 2 8 2 10 2 11 2 12 HIGHLIGHTS OF CHANGES Effective April 2004 Rev 4 0 Summary Updated revision number and date Deleted certification data Added foreign language versions of Safety Instructions for the Wiring and Installation of this Apparatus Revised Warning Revised para 1 2a to include LOI and Model 375 communicator All IB references to HART Model 275 changed to read HART Model 275 375 Revised Figure 1 1 to include Oxymitter 4000 remote electronics Revised para 1 2c to include reference to remote electronics version Revised para 1 2d to include differences between units with LOI versus membrane keypad and to include new Figure 1 3 and Figure 1 4 views Revised NOTE to define LOI operating temperature range data Added Figure 1 7 to show remote electronics versions Revised para 1 7 Specifications to include LOI data update electronic noise data temperature range data Added pollution degree over volt age category and relative humidity data to specifications Added new paragraph 1 8 Hazardous Area Certifications Revised Table 1 1 Product Matrix to update Communication Options and Calibration Accessories and to include Probe to Electronics Cables Revised para 2 1a to reference remote electronics version and LOI Added temperature note Added new Figure 2 2 installation data for unit with remote electronics Added para 2 1c and Figure 2 8 to discuss mounting of remote elec
20. 61 m Termination Block Standard Remote Probe Head Termination Block Transient Protected Remote Probe Head Electronic Assembly Housing 11 4 Replacement Parts Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 SECTION 12 OPTIONAL ACCESSORIES HART HANDHELD 375 COMMUNICATOR The HART Handheld 375 Communicator is an interface device that provides a common communication link to HART compatible instruments such as the Oxymitter 4000 HART Communica tions Protocol permits all the information available from the Oxymitter 4000 s electronics to be transmitted over standard 4 20 mA signal wires By attaching the HART handheld commu nicator at a termination point along the 4 20 mA signal line a technician can diagnose problems and configure and calibrate the Hazardous Area Oxymitter 4000 as if he or she were stand ing in front of the instrument For more information call Rosemount Analytical at 1 800 433 6076 37260059 ASSET MANAGEMENT SOLUTIONS AMS Asset Management Solutions AMS software works in con junction with the HART Communication Protocol and offers the capability to communicate with all HART plant devices from a single computer terminal For more information call Rosemount Analytical at 1 800 433 6076 BY PASS PACKAGES The specially designed Rosemount Analytical By Pass Package for oxygen
21. ETUKIVOUVEC EVUTIGpXOUV k ro and va apaipouvtal u vo rav Exet n and m ouokseur Kal vo and EL IKEUM VO TEXVIK Onou vai TO UT PXEI an K TW and kak pata no ne va apapo vra u vo and EL IKEUH VO TEXMK tav n Exel apaipeBei and m ouokeurj T roug enipdvetec UNopouv va napaueivouv Ceat c we Kal 45 9 Onou KaA para e vat ue o uBoNo avagepbeltat aug o nyles xp onc mc ovoKeuric 10 ta nou xonotponoro vrai og aut npoi v and va amp np tura 61010 1 IEC417 Kal 1503864 Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 CERAMIC FIBER PRODUCTS MATERIAL SAFETY DATA SHEET JULY 1 1996 SECTION I IDENTIFICATION PRODUCT NAME Ceramic Fiber Heaters Molded Insulation Modules and Ceramic Fiber Radiant Heater Panels CHEMICAL FAMILY Vitreous Aluminosilicate Fibers with Si
22. HHH ET c0 ee S 55 poc 1 5 1Sna uaasnNs 091 004 6 SLL 66 3dO T3AN3 TVAOW3H re g Wid WIG SASSHLNAYVd NI S3HONI HLIM Sd31dINWITIIA AAV SNOISN3WIG 1 AUNSS Hd LON ANY SNS 1 SIP 8 NIG ISNV OL GAYNLOVANNVW SSDNV1S 30 1V14 SSSHL SALON Figure 2 3 Hazardous Area Oxymitter 4000 Probe with Abrasive Shield Installation 2 4 Instruction Manual q13IHS 3AISVYHSV HLIM c 0007 H3LLINAXO SNOGHVZVH 31V1d 5NILNnOIN gt Y 5 5 O m O sr gt JONVIS qT3IHS 3AISVH8V I m d NO 39VdS ATIVNOA S31OH dqaavasHi 8 JOovduns ACISLNO OL AlV ld dO ONILIOd 913154 S3 1OH 3dlAOHd OL qasn a8 AVN SHadNHOO Q3HOJIVHSSOuO 687 4 067 002 061 L6L Qv3uHL c X 9LIN Ge X OZIN LL SC9 O iu c6 v ve e 5 4 Gel 001 92 6 626 00 6 62c Sir Nid ISNV NW SNOISNAWIG Q1AIHS SAISVYEV HLIM 0007 HALLINAXO SNOCYVZVH SNOISNAWIC ALV ld ONILNNOW IA 318V1 Hazardous Area Oxymitter 4000 0007 YALLINAXO SNOCYVZVH ALV Id INILNNON 98 9 NO d39vdS ATIVNOA SLAN QNV SHAHSYMAIOT SGNLS v Vid Sc 9
23. Maintenance and Service 6 Follow the instructions in paragraph 2 1b to install the Hazardous Area Oxymitter 4000 into the stack or duct CAUTION Opening the electronic housing will cause the loss of ALL hazardous per mits Opening the electronics housing in hazardous areas may cause an explosion resulting in loss of property severe personal injury or death It may be required to get a hot work permit from your company safety offi cer before opening the electronic housing c Electronic Assembly Replacement Remove and replace the electronic assem bly according to the following procedure 1 Remove screw 18 Figure 9 3 or Figure 9 4 cover lock 19 and cap tive washer 20 securing cover 1 Remove the cover 2 See Figure 9 5 Depress and remove the J1 cell and T C connector from the J1 socket MOUNTING SCREW ROSEMOUNT HEATERT C DIAGNOSTIC HEATER ALARMS O2 CELL c CALIBRATION CALIBRATION RECOMMENDED J1 O2 CELL mv TP2 e HEATER T C TP3 e HEATER T C TP4 e TEST POINTS O2 CELL mV TP1 e INC INC 4 CAL TEST GAS TP5 e PROCESS TP6 e 96 O2 DEC DEC 37270018 Figure 9 5 Electronic Assembly Rosemo
24. pound on the stud threads to ease future removal of the Hazardous Area Oxymitter 4000 7 Insert probe through the opening in the mounting plate and bolt the unit to the plate NOTE To maintain CE compliance ensure a good connection exists between the mounting plate studs or earthing screws on electronics housing and earth Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 8 Ensure the Hazardous Area Oxymitter 4000 is properly earthed by way of both internal and external points CAUTION Uninsulated stacks or ducts may cause ambient temperatures around the electronics to exceed 85 C 185 F which may cause overheating damage to the electronics 9 If duct work insulation is removed for Hazardous Area Oxymitter 4000 probe mounting make sure the insulation is replaced afterward See NOTE For probe temperatures that will exceed 85 C 185 F we recommend the remote mounted electronics option 10 Ensure the probe installation does not obscure the warnings on the housing covers GAS FLOW DIRECTION VEE DEFLECTOR APEX ts CERAMIC DIFFUSION ELEMENT FILTER SETSCREW VEE DEFLECTOR 27540009 Figure 2 6 Orienting the Optional Vee Deflector Installation 2 7 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 VOLTAGE UI Pd 4 20 mA SIGNAL
25. tronics version Revised para 2 2 to apply to a unit with integral electronics only Added warning Added new Figure 2 9 wiring for unit with integral electronics Added new para 2 3 to apply to a unit with remote electronics only Added new Figure 2 10 sheets 1 and 2 to identify different wiring views as applicable to discrete system configurations Revised Figure 2 11 to list Sl units first followed by U S standards Added note Revised Section 3 heading to apply to equipment configuration instruc tions for instruments with a membrane keypad Revised para 3 1c to correct mA signal level values Revise para 3 1e to define new voltage selection parameters Revised Figure 3 2 to update default parameter settings HIGHLIGHTS OF CHANGES Continued Page 3 5 4 1 through 4 5 5 1 through 5 4 6 1 through 6 6 8 1 8 2 and 8 3 8 4 8 5 through 8 19 8 20 9 0 9 3 9 7 through 9 20 9 8 9 9 9 12 11 1 through 11 4 Page Cover 2 12 and 2 13 Effective April 2004 Rev 4 0 Summary Revised para 3 3a to correct mA signal level values Moved power up and remaining procedures to Section 5 Startup and Operation Added new Section 4 to discuss system configuration instructions for instruments with an LOI Added new Section 5 to cover equipment Startup and Operation for instruments with a membrane keypad Added new Section 6 to cover equipment Startup and Operation for instruments with an LOI
26. 20 cover lock 19 and screw 18 Installation 2 9 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 CALIBRATION LOGIC HANDSHAKE LOGIC I O 4 20 mA 4 20 mA GROUND 90 250 VAC 50 60 HZ LINE 1 NEUTRAL LINE VOLTAGE INPUT INTEGRAL ELECTRONICS WITHOUT SPS 4000 CALIBRATION 4 20 mA HANDSHAKE SIGNAL LOGIC I O ZZ LINE VOLTAGE TERMINAL BLOCK GROUND LUGS TER EE K R INTEGRAL ELECTRONICS gt WITH REMOTE SPS 4000 Je 2 1 4 20 4 20 GROUND INES 90 250 VAC 50 60 HZ LINE 1 BIAS WALL MOUNTED LINE VOLTAGE INPUT GROUND SPS 4000 CALIBRATION HANDSHAKE LINE 1 90 250 VAC 50 60 HZ NEUTRAL LINE VOLTAGE INPUT INTEGRAL ELECTRONICS 7 WITH REOMTE IMPS 4000 N LINE 1 NEUTRAL 90 250 VAC 50 60 HZ GROUND LINE VOLTAGE INPUT 4 20mA 4 20mA GROUND CALIBRATION HANDSHAKE REFER TO IMPS 4000 INSTRUCTION MANUAL divos Figure 2 9 Electrical Installation Hazardous Area Oxymitter 4000 with Integral Electronics 2 10 Installation Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 2 3 ELECTRICAL INSTALLATION FOR HAZARDOUS AREA OXYMITTER 4000 WITH REMOTE ELECTRONICS All wiring must conform to local and national codes WNA i N IN C Disconnect and lock out p
27. 4000 3 Perform the diagnostic steps 1 through 4 shown for the membrane keypad Troubleshooting 8 5 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 b Fault 2 Shorted Thermocouple shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view The upper view also shows J1 and test points TP1 through TP6 ROSEMOUNT HEATERT C O DIAGNOSTIC HEATER O ALARMS O2 CELL S CALIBRATION o CALIBRATION RECOMMENDED O located on the microprocessor board below O2CELLmV TP1 the membrane keypad or the LOI module TEST O2 CELLmv TP2 PCM SENEC Membrane Keypad When Fault 2 is detected the HEATER LED flashes twice pauses for three seconds Ee CAL O repeats GAS GAS sme lore TEST GAS TP5 1 Using a multimeter measure the volt PROCESS age from TP3 to TP4 If the reading iu is 0 0 5 mV then a shorted thermo couple is likely 2 Remove power and disconnect J1 KEYPAD 3 Measure the resistance from TP3 to TP4 The reading should be ap proximately 20K ohms 4 If so the short is not on the PC board The thermocouple wiring or the ther mocouple is shorted See pa
28. A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Fault 15 Last Calibration Failed igure 8 17 shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view Membrane Keypad When Fault 15 is detected the CALIBRATION LED flashes three times pauses for three seconds and repeats 1 The last calibration failed alarm acti vates when the slope and constant values calculated are out of range and the unit reverts to using the previous calibration values 2 he cell should be replaced See para graph Cell Replacement for cell replacement instructions LOI When Fault 15 is detected the LOI displays the Calib Failed message Refer to the comments in paragraphs 1 and 2 above Troubleshooting 8 19 Instruction Manual IB 106 340C Rev 4 1 July 2004 8 6 HAZARDOUS AREA OXYMITTER 4000 PASSES CALIBRATION BUT STILL READS INCORRECTLY There are a few fault conditions where no alarm indication is present and the probe passes cali bration but the reading may still be incorrect a Probe passes calibration but still ap pears to read high 1 There may be a leak that is permitting ambient air to mix with the process gases Since many combustion proc esses are slightly negative in pressure ambient air can be sucked into the cell area biasing the reading upwa
29. Added new Figure 8 1 to show mV readings of an sensor cell at nor mal operating temperature Revised para 8 3 and 8 5 to include reference to LOI error indications Corrected mA signal level values in notes for Table 8 1 Added Table 8 2 to identify to LOI fault alarm messages Revised Figure 8 3 through Figure 8 17 and related text to include LOI fault alarm messages and corrective actions Added new para 8 6 to troubleshoot cell faults that do not show an alarm indication Moved calibration record sheet to front of section for easy access Added new procedural step para 9 2b 2 b for use with LOI Revised heading of para 9 2b 3 to Manual Calibration with Membrane Keypad Added new para 9 4 heading to identify equipment repair procedures All component replacement procedures revised reformatted accordingly Revised Figure 9 3 to show LOI and glass window cover Added new Figure 9 4 to show remote electronics components Revised Figure 9 7 Updated replacement parts lists Effective July 2004 Rev 4 1 Summary Updated revision number and date Added new Figure 2 10 sheets 1 and 2 to identify corrections to wiring color codes Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 TABLE OF CONTENTS CONFIGURATION OF HAZARDOUS AREA OXYMITTER 4000 WITH MEMBRANE KEYPAD A 2 JP AND OF DD A WITH MEMBRANE KEYPAD Rosemount Analytical Inc A Division of Emerson Pro
30. Heater Open Cell Temp Very HI Status Group 1 High Case Temp Cell Temp Low Cell Temp High Cell Open Status Group 2 High Cell Imp CK ER EEPROM Cal Error Slope Cal Recommended Cal Error Const Status Group 3 Last Cal Failed Operate Model AO Saturated AO1 Out Rnge lim AO Fixed Max Case Temp Loop test method PERFORM C2 O2 Cal method O2 Cal CAL Optrak TG Refer to para 7 7 for the complete O2 CalState calibration method using the HART Communicator CalState CRI TimeRemain Present O2 Cal slope Cal const LAST CALCONSTANTS Cell Imp Reset CaIConstants RESET CALCONSTANTS method D A trim method 37270003 Figure 7 3 HART AMS Menu Tree Sheet 1 of 3 Rosemount Analytical Inc A Division of Emerson Process Management HART AMS 7 5 Instruction Manual IB 106 340C Rev 4 1 July 2004 CONTINUED FROM SHEET 1 Tag ASSIGN PV amp SV SELECT O2 RANGE BASIC SETUP DEVICE INFORMATION S W VERSION INFO SENSORS SIGNAL CONDITION OUTPUT CONDITION DEVICE SETUP PV PV AO PV LRV PV URV DETAILED SETUP CONTINUED ON SHEET 3 O2 CALIBRATION O2 ALARMS Hazardous Area Oxymitter 4000 Oxygen Cold Junct Cell Cell TC Dev id Descriptor Message Date Final asmbly num Snsr s n Ver Chk sum Bld num Bld date O2 O2 CELLTEMP COLDJUNCTEMP O2 CELL MV O2 CELLTCMV COLD JUNC MV LIMITS DISPLAYED PV
31. Jordingsforbindelsene alltid holdes 1 god stand Kabler fra spenningsforsyning skal oppfylle kravene spesifisert 1 IEC227 eller IEC245 Alle ledningsforbindelser skal v re konstruert for en omgivelsestemperatur h yere en 750C Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnaes For sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom en strombryter minimum 10 som vil bryte spenningsforsyningen til alle elektriske kretser ved en feilsituasjon Strombryteren kan ogsa inneholde en mekanisk operert bryter for isolere instrumentet fra spenningsforsyningen Dersom det ikke er en mekanisk operert bryter installert ma det veere en annen mate a isolere utstyret fra spenningsforsyningen og denne m ten ma v re tydelig merket Kretsbrytere eller kontakter skal oppfylle kravene 1 en annerkjent standard av typen IEC947 eller tilsvarende Der hvor utstyr eller deksler er merket med symbol for farlig spenning er det sannsynlig at disse er tilstede bak dekslet Disse dekslene ma bare fjzernes spenningsforsyning er frakoblet utstyret og da bare av trenet servicepersonell Der hvor utstyr eller deksler er merket med symbol for meget varm overflate er det sannsynlig at disse er tilstede bak dekslet Disse dekslene ma bare fjeernes nar spenningsforsyning er frakoblet utstyret og da bare av trenet servicepersonell Noen overf
32. The factory default is for the 4 20 mA signal to track operate normally throughout calibration Holding the last value may be useful if several probes are being averaged for the purpose of automatic control Unless several probes are being averaged always place control loops that are using the O signal into the manual mode prior to starting the calibration Configuration with Keypad 3 5 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 3 6 Configuration with Keypad Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 SECTION 4 CONFIGURATION OF HAZARDOUS AREA OXYMITTER 4000 WITH LOI WARNING b Verify Terminal Block Wiring Install all protective equipment covers 1 Remove screw 18 Figure 9 3 and safety ground leads before Figure 9 4 cover lock 19 and cap equipment startup Failure to install tive washer 20 that secure cover 17 covers and ground leads could result on left side of housing 11 Remove in serious injury or death the cover to expose the terminal block 15 ERE 2 Check the terminal block wiring Figure 3 1 Be sure the power the a Verify Mechanical Installation 4 20 mA signal and the logic outputs Ensure the Hazardous Area Oxymitter 4000 are properly connected and secure is installed correctl
33. a diagnostic alarm LED will be flashing The diagnos tic alarm will remain active until the purge cycle is over If the three pattern flash occurs without a diagnostic alarm the calibration gases could be the same or the calibration gas was not turned on A flashing CAL LED indicates the calibration is done See TROUBLE SHOOTING for an explana tion of the 2 pattern and 3 pattern flashes Remove the second calibra tion gas and cap off the cali bration gas port 8 Push the CAL key the CAL LED will be on solid as the unit purges Default purge time is three minutes When the purge is complete the CAL LED will turn off and the Hazardous Area Oxymitter 4000 output unlocks from its held value and begins to read the process Os If the calibration was valid the DIAGNOSTIC ALARMS LEDs will indicate normal operation If either new calibration value slope or constant is not within parameters the DIAGNOSTIC ALARMS LED will indicate an alarm See Section TROUBLESHOOTING for alarm codes If the calibration was lid the Hazardous Area Oxymitter 4000 will return to normal opera tion as it was before a calibration was initiated and the parameters Will not be updated e Place control loop in automatic Rosemount Analytical Inc A Division of Emerson Process Management 9 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 CALIBRATION HAZARDOUS AREA OXYMITTER 4000 WITH LOI R
34. analog signal proportional to the oxygen level The HART output is Superimposed on the 4 20 mA out put signal This information can be accessed through the following 1 Rosemount Model 275 375 Handheld Communicator The handheld communicator requires Device Description DD software specific to the Hazardous Area Oxymitter 4000 The DD software will be supplied with many Model 2 5 375 units but can also be programmed into existing units at most Fisher Rosemount service offices see HART AMS for additional information IN Personal Computer PC The use of a personal com puter requires AMS software available from Fisher Rosemount 3 Selected Distributed Control Systems The use of distrib uted control systems requires input output 1 hardware and AMS software which permit HART communica tions Description and Specifications 1 5 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 d Optional IMPS 4000 The Pro f System Considerations rammable Logic Controller PLC the IMPS 47 provides Prior to installing your Hazardous Area Oxymitter 4000 make sure you have all the indications using flashing LEDs ee ee components necessary to make the system and LCD display messages Refer to the IMPS 4000 Intelligent Multi installation Ensure all the components are probe Test Gas Sequencer manual Ms T colon to make the system unctional for more information
35. itis tight Secure the cover using cap tive washer 20 cover lock 19 and screw 18 CAUTION Opening the electronic housing will cause the loss of ALL hazardous per mits Opening the electronics housing in a hazardous area may cause an explosion resulting in loss of property severe personal injury or death It may be required to get a hot work permit from your company safety officer be fore opening the electronic housing d Terminal Block Replacement See Figure 9 3 or Figure 9 4 1 Remove the left side cover 17 from the housing 11 2 Loosen the three captive screws 16 in the terminal block 15 Carefully lift the terminal block out of the housing 3 Carefully align the new terminal block on the pins so that it sits flat in the housing The round end of the terminal block should be on the opposite side of the housing conduit ports and should not be able to rotate 4 Tighten the three mounting screws and ensure the terminal block is secure in the housing Maintenance and Service 9 11 Instruction Manual IB 106 340C Rev 4 1 July 2004 WARNING Opening the electronic housing will cause the loss of ALL hazardous per mits Opening the electronics housing in a hazardous area may cause an explosion resulting in loss of property severe personal injury or death It may be required to get a hot work permit from your company safety officer be fore opening the electronic housing
36. sion hub with two pin spanner wrenches Torque to 14 N m 10 ft lbs Secure with hub retaining 8 setscrew m On systems equipped with abra sive shield install dust seal gas 9 kets with joints 180 apart n Reinstall vee deflector orienting apex toward gas flow Apply anti 10 seize compound to setscrews and tighten with hex wrench o Reinstall probe on stack flange j Contact and Thermocouple Assembly Replacement See Figure 9 11 1 Remove the cell per paragraph steps 1 through 5 2 Remove the heater strut assembly per paragraph steps 3 through 8 SS Hazardous Area Oxymitter 4000 Squeeze the tabs on the spring clips and pull the contact and thermocouple assembly out of the heater strut Retain the spring clips and spring replace if damaged While very carefully handling the new contact and thermocouple assembly lay the old assembly next to the new one Transfer the pencil marks to the new rod Throw away the old contact and thermocouple assembly Carefully guide the new contact and thermocouple assembly through the spring spring clips held open by squeezing the tabs tube supports and heater support of the heater strut assembly until the spring clip reaches the pencil mark Install the cell per the instructions in paragraph steps 7 through 12 Slide the heater strut assembly into the probe per the instructions in paragraph steps 9 through 14 On systems equipped
37. the LOI displays the Board Temp Hi message Refer to the comments in paragraphs 1 through 4 above Troubleshooting 8 11 Instruction Manual IB 106 340C Rev 4 1 July 2004 ROSEMOUNT HEATER DIAGNOSTIC HEATER ALARMS O2 CELL CALIBRATION CALIBRATION RECOMMENDED O uit O2CELLmV 1 TEST O2 CELL mv TP2 e e C POINTS HEATER TP3 e HEATER 4 E er gt DO INC INC ES CAL HIGH LOW GAS GAS TEST GAS TP5 e DEC DEC PROCESS TP6 O2 KEYPAD Alarms 02 Temp Low ROSEMOUNT Ble oy LOI 37260026 Figure 8 10 Fault 8 Low Heater Temp 8 12 Troubleshooting Hazardous Area Oxymitter 4000 h Fault 8 Low Heater Temp igure 8 10 shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view Membrane Keypad When Fault 8 is detected the HEATER LED flashes four times pauses for three seconds and repeats 1 The low heater temperature alarm is active when the thermocouple reading has dropped below 28 6 mV If the thermocouple reading continues to ramp downward for one minute and does not return to the temperature set point of approximately 29 3 mV then an
38. 340C Rev 4 1 July 2004 RL lt 2500 ANALOG OUTPUT DEVICE 250 OHM LOAD RESISTOR NOTE NOTE THE SIGNAL LOOP MUST BE BROKEN TO INSERT THE OPTIONAL 250 OHM LOAD RESISTOR 23230002 Figure 7 2 Signal Line Connections lt 250 Ohms Load Resistance HART COMMUNICATOR PC CONNECTIONS There is an option to interface the HART Com municator with a personal computer Load the designated AMS software into the PC Then link the HART Communicator to the PC using the interface PC adapter that connects to the serial port on the communicator rear panel Refer to the proper HART Communicator docu mentation in regard to the PC interface option OFF LINE AND ON LINE OPERATIONS The HART Communicator can be operated both off line and on line a Off line operations are those in which the communicator is not connected to the Haz ardous Area Oxymitter 4000 Off line op erations can include interfacing the HART Communicator with a PC refer to applica ble HART documentation regarding HART PC applications Rosemount Analytical Inc A Division of Emerson Process Management b If the HART Communicator is turned on while connected to the 4 20 mA analog output signal line an undefined status indication appears while the communicator warms up Wait until In the on line mode the communicator is connected to the 4 20 mA analog output signal line The communicator is connected in parallel to the Haz
39. Area Oxymitter 4000 f Rosemount Analytical Inc A Division of Emerson Process Management Fault 6 High High Heater Temp shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view Membrane Keypad When Fault 6 is detected the HEATER LED flashes twice pauses for three seconds and repeats 1 The high high heater temp alarm will activate when the thermocouple pro duces a voltage of 37 1 mV 900 C 1652 F 2 The triac and the temperature control may be at fault 3 Remove power Allow Hazardous Area Oxymitter 4000 to cool for five minutes Restore power 4 f the condition repeats replace the electronic assembly per paragraph Electronic Assembly Replacement LOI When Fault 6 is detected the LOI displays the Very Hi O2 Temp message 1 The very high temperature alarm will activate when the thermocouple produces a voltage of 37 1 mV 900 C 1652 F 2 The triac and the temperature control may be at fault 3 Remove power Allow the Oxymitter 4000 to cool for five minutes Restore power 4 If the condition repeats replace the electronic assembly per paragraph Electronic Assembly Replace ment Hazardous Area Oxymitter 4000 ROSEMOUNT HEATERT C DIAGNOSTIC HEATER o SW2 ALARMS O2 CELL o L CALIBRATION o CALIBRATION R
40. DC relay P N R10S E1Y1 J1 0K Of the ten modes in Table 3 1 modes 0 through 7 are the alarm modes The factory default is mode 5 for Hazardous Area Oxy mitter 4000 units without an IMPS 4000 or SPS 4000 In this mode the output will sig nal when a unit alarm or a CALIBRATION RECOMMENDED indication occurs Calibration Handshake Signal If using an optional IMPS 4000 or SPS 4000 the logic I O must be configured for calibration handshaking Of the ten modes in only modes 8 and 9 are con figured for calibration handshaking For a Hazardous Area Oxymitter 4000 with an IMPS 4000 or an SPS 4000 the factory sets the default to mode 8 In this mode the logic I O will be used to communicate between the Hazardous Area Oxymitter 4000 and the sequencer and to signal the sequencer when a CALIBRATION REC OMMENDED indication occurs Table 3 1 Logic I O Configuration as set at HART AMS or LOI The unit is configured for a High AC Impedance CALIBRATION RECOMMENDED The unit is configured for both a Unit Alarm and a High AC Imped ance CALIBRATION RECOMMENDED The unit is configured for both a Low and High AC Imped ance CALIBRATION RECOMMENDED The unit is configured for a Unit Alarm a Low O gt and a High AC Im pedance CALIBRATION RECOMMENDED The unit is configured for a calibration handshake with IMPS 4000 or SPS 4000 CALIBRATION RECOMMENDED will initiate the calibra tion cycle The unit is configured for a cal
41. DUCT PIPE SLEEVE NOT METAL WALL BY ROSEMOUNT JOINT MUST LENGTH BY CUSTOMER BE AIRTIGHT MASONRY WELD OR BOLT MOUNTING PLATE TO METAL WALL 11 E NOTE DIMENSIONS MILLIMETERS WITH INCHES IN PARENTHESES gein Figure 2 5 Hazardous Area Oxymitter 4000 Mounting Plate Installation 2 6 Installation Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 4 f using the optional ceramic diffusion element the vee deflector must be cor rectly oriented Before inserting the Hazardous Area Oxymitter 4000 check the direction of flow of the gas in the duct Orient the vee deflector so the apex points upstream toward the flow Figure 2 6 This may be done by loosening the setscrews and rotating the vee deflector to the desired posi tion Retighten the setscrews 5 n vertical installations ensure the system cable drops vertically from the Hazardous Area Oxymitter 4000 and the conduit is routed below the level of the electronics housing This drip loop minimizes the possibility that moisture x the electronics See 2 7 6 If the system has an abrasive shield check the dust seal gaskets The joints in the two gaskets must be staggered 180 degrees Make sure the gaskets are in the hub grooves as the Hazard ous Area Oxymitter 4000 slides into the 15 degree forcing cone in the abrasive shield NOTE If process temperatures will exceed 200 C 392 F use anti seize com
42. Open Heater fault will be displayed Power down the electronics Remove the electronic assembly per paragraph Electronic Assembly Replace ment Using a multimeter measure the resistance across the terminals of heater connector J8 If the heater is good the reading will be approximately 70 ohms If the heater is open see paragraph Heater Strut Replacement LOI When Fault 8 is detected the LOI displays the O2 Temp Low message Refer to the comments and procedures in paragraphs 1 through 4 above Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 ROSEMOUNT HEATERT C O DIAGNOSTIC HEATER Sw2 ALARMS 92 CALIBRATION o s CALIBRATION RECOMMENDED O O2CELL mV 1 TEST O2 CELLmv TP2 e POINTS HEATER TP3 e HEATER Sen er gt i ui oa o HIGH LOW GAS GAS TEST GAS 5 Oss 1 2 2 KEYPAD Alarms 02 Temp Hi ROSEMOUNT LOI 37260027 Figure 8 11 Fault 9 High Heater Temp Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Fault 9 High Heater Temp igure 8 11 shows the electronic assembly for a Hazardous Area Oxymitt
43. Remote Contact 9 3 Replacement Parts 11 1 S Semi Automatic Calibration 9 3 Signal 4 20 mA 12 1 Specifications 1 12 SPS 4000 1 2 1 3 1 9 12 2 13 2 Index Hazardous Area Oxymitter 4000 T Temperature 1 6 Temperature Limits 1 12 Terminal Block 3 1 Test Points 3 2 4 2 5 2 6 7 Thermocouple 8 5 8 6 Troubleshooting 8 1 V Vee Dellector 2 7 W Wiring 3 1 4 1 Z Zirconia Disc 1 1 Rosemount Analytical Inc A Division of Emerson Process Management 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 OF FITNESS FOR PURPOSE The remedy ies provided above shall be purchaser s 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 includin
44. away from the probe Note that the contact pad inside of the probe will sometimes fuse to the oxygen sensing cell If the cell is fused to the contact pad push the cell assembly back into the probe against spring pressure and quickly twist the cell as sembly The cell and contact pad should separate If the contact pad stays fused to the cell a new con tact thermocouple assembly must be 9 16 Maintenance and Service 10 11 Hazardous Area Oxymitter 4000 installed Disconnect the orange cell wire at the probe electronics end of the strut by cutting the wire Withdraw the cell with the wire still attached Remove entire electronics per para graph steps 2 and 3 If the contact and thermocouple assembly is damaged replace the assembly or the contact pad Refer to paragraph 9 4j to replace the contact and thermocouple assembly Instruc tions for replacing the contact pad are in the cell replacement kit Remove and discard the corrugated seal Clean the mating faces of the probe tube and cell Remove burrs and raised surfaces with a block of wood and crocus cloth Clean the threads on the probe flange and flame arrestor hub Apply a light coating of anti seize compound to both sides of the new corrugated seal Assemble the cell and flange assembly and corrugated seal to the probe tube Make sure the calibration tube lines up with the calibration gas passage in each component Apply a small amount of anti seize
45. be kept separate to prevent contamination Product which has been in service at elevated temperatures greater than 1800 F 982 C may undergo partial conversion to cristobalite a form of crystalline silica This reaction occurs at the furnace lining hot face As a consequence this material becomes more friable special caution must be taken to minimize generation of air borne dust The amount of cristobalite present will depend on the temperature and length in service IARC has recently reviewed the animal human and other relevant experimental data on silica in order to criti cally evaluate and classify the cancer causing potential Based on its review IARC classified crystalline silica as a group 2A carcinogen probable human carcinogen The OSHA permissible exposure limit PEL for cristobalite is 0 05 mg m respirable dust The ACGIH threshold limit value TLV for cristobalite is 0 05 mg m respirable dust ACGIH 1991 92 Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded The minimum respiratory pro tection recommended for given airborne fiber or cristobalite concentrations are CONCENTRATION 0 1 fiber cc or 0 0 05 mg m cristobalite the OSHA PEL Up to 5 fibers cc or up to 10 times the OSHA PEL for cristobalite Up to 25 fibers cc or 50 times the OSHA PEL for cristobalite 2 5 mg m Greater than 25 fibers cc or 50 times the OSHA PEL for cristobalite 2 5 mg m Optional di
46. compound to the screw threads and use the screws to secure the assembly Torque to 4 N m 35 in Ibs Apply anti seize compound to the probe threads flame arrestor hub and setscrews Reinstall the flame arrestor on the probe Using pin spanner wrenches torque to 14 N m 10 ft Ibs Secure the flame arrestor with the locking setscrew Torque to 2 8 25 in Ibs If applicable reinstall the vee deflector orienting apex toward gas flow Secure with the setscrew and anti seize compound Torque to 2 8 N m 25 in Ibs On systems equipped with an abrasive shield install the dust seal gaskets with joints 180 apart Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 12 If previously removed install the entire electronics per paragraph steps 4 and 5 13 Follow the instructions in paragraph 2 1b to install the Hazardous Area Oxymitter 4000 into the stack or duct If there is an abrasive shield in the stack make sure the dust seal gaskets are in place as they enter the 15 reducing cone Ceramic Diffusion Element Replacement NOTE This procedure applies to the ceramic diffuser element only 1 General The diffusion element protects the cell from particles in process gases The element does not normally need to be replaced because the vee deflector protects it from particulate erosion In severe environments the filter may be broken or subject to excess
47. ductwork Materials OL G PN MEL Wetted or welded parts 316L stainless steel SS Non wetted parts 304 SS low copper aluminum Electronics Enclosure Low copper aluminum CADP p Manual semi automatic or automatic Calibration Gas Mixtures Recommended 0 4 Balance N gt 8 O gt Balance Calibration Gas Flow o scfh 2 5 I m Reference Air 0 5 scfh 0 25 I hr clean dry instrument quality air 20 95 regulated to 5 psi 34 kPa E leCIr lll6S NEMA 4X IP66 with fitting and pipe on reference exhaust port to clear dry atmosphere Line Voltage 90 250 VAC 48 62 Hz 3 4 in 14 NPT conduit port Pollution Degree 2 Over Voltage Category II Relative Humildity 5 to 95 non condensing Signals Analog Output HART 4 20 mA isolated from power supply 950 ohms maximum load BOOG VOo u UN DT Two terminal logic contact configurable as either an alarm output or as a bi directional calibration handshake signal to IMPS 4000 or SPS 4000 Self powered 5 V in series with 340 ohms Conduit port 3 4 in 14 NPT for analog output and logic I O signal lines 1 12 Description and Specifications Rosemount An
48. last cal basis MEMBRANE KEYPAD increase as the oxygen concentration decreases 1 N IN C 37260003 Figure 1 3 Membrane Keypad The HART option is not protected by energy limiting barriers It must not be interfaced from within the hazardous area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case even when using the in trinsically safe version of the handheld communicator 3 4 Membrane keypad and HART communication are standard To use the HART capability you must have either to lt a HART Model 275 375 Communi cator b Asset Management Solutions AMS software for the PC An optional Local Operator Interface 37260004 Figure 1 4 allows continual O display and full interface capability Figure 1 4 Local Operator Interface LOI 1 4 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 5 Field replaceable cell heater thermo couple diffuser and PC boards 6 The Hazardous Area Oxymitter 4000 is constructed of rugged 316L stainless steel for all wetted parts 7 The electronics is adaptable for line voltages from 90 250 VAC therefore no configuration is necessary 8 The Hazardous Area Oxymitter 4000 membrane keypad is available in five languages English French German Italian and Spanish 9 An operator can ca
49. probe housing when installing or removing from the inte gral electrical barrier feedthrough Figure 9 3 Damage to the aluminum probe housing can occur 3 Remove four screws 22 Figure 9 3 and washers 21 from the probe tube assembly 23 Remove the probe tube assembly from the housing 11 4 Once the probe and housing are sepa rated spring tension releases and the heater strut assembly 32 moves up Remove strut pressure clamp 35 5 Disconnect the heater and signal wire connectors from the mating connectors on the heater strut assembly 32 Maintenance and Service 9 13 Instruction Manual IB 106 340C Rev 4 1 July 2004 CERAMIC DIFFUSER ASSEMBLY 9 14 V DEFLECTOR CELL FLANGE HEATER CERAMIC SUPPORT ROD Hazardous Area Oxymitter 4000 WIRE LOOP 27540007 Figure 9 8 Heater Strut Assembly Remove tube clamps 33 Carefully pull the CAL and REF gas silicon tubes 34 from the CAL and REF gas ports Remove gas port fittings 29 from the CAL REF and VENT ports See Figure 9 8 Grasp the wire loop and carefully slide the heater strut assembly 32 out of the probe tube When replacing the strut orient the probe so that the small calibration gas tube lays at the 6 o clock position of the probe tube Align the slot on the heater plate with the calibration gas line in the probe tube Slide the strut into the probe tube It will turn t
50. to a comfort able working temperature Replace a Bolt the Hazardous Area Oxymitter 4000 to the stack and install the insulation b Connect all signal and power leads at the probe Refer to INSTALLATION for detailed wiring instructions c Install left side cover 17 9 3 or Figure 9 4 and ensure it is tight Secure the cover using cap tive washer 20 cover lock 19 and screw 18 d Connect the calibration gas and instrument air lines to probe e Turn on the calibration gases at the cylinders and turn on instrument air Maintenance and Service 9 7 Instruction Manual IB 106 340C Rev 4 1 July 2004 Note The Electronic Assembly item 2 consists of items 3 through 10 Integral Electrical Barrier Feedthrough 20 Note Not all parts shown gt N gt Flame Hazardous Area Oxymitter 4000 Blind Cover Window Cover Electronic Assembly Screw Membrane Keypad LOI Module Microprocessor Board Analog Board Fuse Cap Fuse Power Supply Board Captive Screw Housing Screw Lock Washer Cable Clamp Terminal Block Captive Screw Blind Cover O Ring Screw Cover Lock Captive Washer Washer Screw Probe Tube Assembly Gasket Corrugated Seal Cell and Flange Assembly Retainer Screw Flame Arrester with Snubber Diffuser Arre
51. to bustible gases the Hazardous Area 25 Os 0 to 40 is also configur Oxymitter 4000 may self ignite able only through HART AMS 3 The 4 20 mA signal at fault or power up 3 5 mA or 21 6 mA CAUTION Remove power from the Hazardous Area Oxymitter 4000 before changing defaults If defaults are changed under power damage to the electronics 3 package may occur d SW1 The two settings are internally or externally powering the 4 20 mA signal The factory 4 setting is for the 4 20 mA signal to be inter nally powered e SW2 The factory sets this switch as follows If necessary the O range can be con figured from 0 to 40 To select values within this range set SW2 position 1 to HART and then enter the range via HART AMS or the LOI Do not change SW2 position 1 to LOCAL unless you want to operate in the range specified by SW2 position 2 Position 3 determines the output at startup or at an alarm The settings are 3 5 MA or 21 6 mA The factory setting is 3 5 mA At startup the current at the analog output is 3 5 mA or 21 6 mA Position 4 can be used to set the heater for 115 or 220 Vac operation This switch is functional only when the software is set for manual voltage selection Auto Tune No Otherwise the internal electronics auto detect the input line voltage and sets the heater voltage accordingly Auto Tune Yes 4 2 Configuration with LOI Rosemount Analytica
52. value may be useful if several probes are being averaged for the purpose of automatic control Unless several probes are being averaged always place control loops that are using the signal into the manual mode prior to starting the calibration Configuration with LOI 4 5 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 4 6 Configuration with LOI Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 SECTION 5 STARTUP AND OPERATION OF HAZARDOUS AREA OXYMITTER 4000 WITH MEMBRANE KEYPAD 5 1 POWER UP b Operating Display The ramp cycle turns into a cycle where the a Startup Displa diagnostic LEDs light sequence from the When power is applied to the probe the cell top to the bottom one at a time After the heater turns on It takes approximately one bottom LED turns on the sequence starts half hour for the cell to heat to operating again at the top with the HEATER T C LED temperature This condition is indicated by Figure 5 1 the top four LEDs DIAGNOSTIC ALARMS on the membrane keypad Figure 5 1 c Error Starting with the CALIBRATION LED the LEDs light in ascending order until all four If there is an error condition at startup one LEDs are on At this point all four turn off of the io Becton B nostics LEDs will be blinking and the cycle starts again This r
53. ven upp till 45 minuter efter avst ngning av str mmen 9 Nar utrustning eller h lje markerats med vidstaende symbol b r instruktionsmanualen studeras f r information 10 Samtliga grafiska symboler som f rekommer 1 denna produkt finns angivna 1 en eller flera av f ljande f reskrifter EN61010 1 IEC417 amp ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management P 13 Instruction Manual IB 106 340C Rev 4 1 July 2004 P 14 Hazardous Area Oxymitter 4000 NPOZOXH Odnyles yia ryv xai ykar graar cuoxcu c obny t s aopaAelas epapp lovrar cibik AzG p An Evpwnaixis Koiv rnrac Oa rp rgi va va cEaoqadiotei n pe yia T on Xwpec mou Sev civat p An Tnq Eupurraikra va Tic 5 KT G h ouvd ceic yeiwonc np ne va yfvovrai onpeia yeiwone Kat EEWTEPIK nou UT PXOUV mv mv aopakslac kat ot
54. 0 10 2 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 SECTION 11 REPLACEMENT PARTS Table 11 1 Replacement Parts for Probe Figure and Index No Part Number Description Dust Seal No Dust Seal 9 4 33 3D39746G01 3D39745G01 18 ANSI Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3D39746G02 3D39745G02 3 ANSI Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3D39746G03 3D39745G03 6 ANSI Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3D39746G04 3D39745G04 18 JIS Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3D39746G05 3D39745G05 3 JIS Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3039746606 3039745606 6 JIS Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3039746607 3039745607 18 DIN Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3039746608 3039745608 3 DIN Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3D39746G09 3D39745G09 6 DIN Flame Arrestor with Ceramic Diffuser Probe 9 4 33 3D39746G10 3D39745G10 18 ANSI Flame Arrestor with Snubber Diffuser Probe 9 4 33 3D397466G11 3039745611 3 ANSI Flame Arrestor with Snubber Diffuser Probe 9 4 33 3D39746G12 3D39745G12 6 ANSI Flame Arrestor with Snubber Diffuser Probe 9 4 33 3D39746G13 3D39745G13 18 JIS Flame Arrestor with Snubber Diffuser Probe 9 4 33 3D39746G14 3D39745G14 3 JIS Flame Arrestor with Snubber Diffuser Probe 9 4 33 3D
55. 245 voorschriften 4 Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen hoger dan 75 5 Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd 15 6 de veilige werking van dit toestel te verzekeren moet de voeding door een stroomonderbreker gevoerd worden min 10 welke alle draden van de voeding moet onderbreken De stroomonderbreker mag een mechanische schakelaar bevatten Zoniet moet een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook duidelijk zo zijn aangegeven Stroomonderbrekers of schakelaars moeten onderworpen zijn aan een erkende standaard zoals IEC947 7 Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning aanwezig Deze deksels mogen enkel verwijderd worden nadat de voedingsspanning werd afgelegd en enkel door getraind onderhoudspersoneel 8 Waar toestellen of deksels aangegeven staan met het symbool 15 er gevaar voor hete oppervlakken Deze deksels mogen enkel verwijderd worden door getraind onderhoudspersoneel nadat de voedingsspanning verwijderd werd Sommige oppper vlakken kunnen 45 minuten later nog steeds heet aanvoelen 9 Waar toestellen of deksels aangegeven staan met het symbool gelieve het handboek te raadplegen 10 Alle grafische symbolen gebruikt in dit produkt zijn afkomstig uit een of meer van devolgende standaards EN61010 1 IEC417
56. 28 5 5 NI SIHONI HLIM SHALANNT TIN NI SNOISNAWIG 3 LON AZIS GALS 000v HALLINAXO SNOCYVZVH SNOISN3NWIG ONILNNOW 318V1 ANIILNO ALV Id ONILNNOW 27540003 Figure 2 4 Hazardous Area Oxymitter 4000 Mounting Plate Dimensions 2 5 Installation Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 i July 2004 Hazardous Area Oxymitter 4000 INSTALLATION FOR METAL WALL STACK OR DUCT INSTALLATION FOR MASONRY CONSTRUCTION WALL STACK CONSTRUCTION ABRASIVE SHIELD MOUNTING 13 0 50 BOLT MOUNTING PLATE TO OUTSIDE WALL SURFACE FIELD WELD 95 3 75 114 4 50 PIPE TO OD REF MIN DIA HOLE MOUNTING PLATE ind IN WALL MTG HOLES MTG HOLES EIT ZD SHOWN ROTATED SHOWN ROTATED IK 45 OUT OF 45 OUT OF PIPE 4 00 IN SCHED 40 TRUE POSITION S STACK OR DUCT TRUE POSITION PIPE SLEEVE NOT B METAL WALL BY ROSEMOUNT LENGTH BY CUSTOMER JOINT MUST BE AIRTIGHT MASONRY WELD OR BOLT MOUNTING STACK WALL PLATE TO METAL WALL OF STACK OR DUCT OUTSIDE WALL JOINT MUST BE AIRTIGHT SURFACE NOTE ALL MASONRY STACK WORK AND JOINTS EXCEPT ADAPTOR PLATE NOT FURNISHED BY ROSEMOUNT PROBE MOUNTING BOLT MOUNTING PLATE TO OUTSIDE Be A WALL SURFACE MOUNTING PLATE 102 4 0 82 5 3 25 5 MIN DIA HOLE IN WALL E PIPE 3 5 IN SCHED 40 STACK OR
57. 39746G15 3D39745G15 6 JIS Flame Arrestor with Snubber Diffuser Probe 9 4 33 3D39746G16 3D39745G16 18 DIN Flame Arrestor with Snubber Diffuser Probe 9 4 33 3D39746G17 3D39745G17 3 DIN Flame Arrestor with Snubber Diffuser Probe 9 4 33 3D39746G18 3D39745G18 6 DIN Flame Arrestor with Snubber Diffuser Probe 9 3 32 3D39744G01 18 Heater Strut Assy 9 3 32 3D39744G02 3 Heater Strut Assy 9 3 32 3D39744G03 6 Heater Strut Assy 11 1 4847B61G20 DIN 3 Cell Replacement Kit 11 1 4847B61G21 DIN 6 Cell Replacement Kit 11 1 4847B61G25 DIN 18 Cell Replacement Kit 11 1 4847B61G26 ANSI 18 Cell Replacement Kit 11 1 4847B61G27 ANSI 3 Cell Replacement Kit 11 1 4847B61G28 ANSI 6 Cell Replacement Kit 11 1 4847B61G29 JIS 18 Cell Replacement Kit 11 1 4847B61G30 JIS 3 Cell Replacement Kit 11 1 4847B61G31 JIS 6 Cell Replacement Kit 4849B94G01 ANSI High Sulfur HCI Resistant Cell Only 11 1 4849B94G02 ANSI 18 Cell Replacement Kit High Sulfur HCI Resistant 11 1 4849B94G03 ANSI 3 Cell Replacement Kit High Sulfur HCI Resistant 11 1 4849B94G04 ANSI 6 Cell Replacement Kit High Sulfur HCl Resistant Includes pad and wire Rosemount Analytical Inc A Division of Emerson Process Management Replacement Parts 11 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Table 11 1 Replacement Parts for Probe Continued Figure and Index No Part Number 4849B94G07 4849B94G08 4849B94G09 4849B94G10 4
58. 4000 or SPS 4000 The default condition for a Hazardous Area Oxymitter 4000 without an IMPS 4000 or SPS 4000 The default condition for a Hazardous Area Oxymitter 4000 with an IMPS 4000 or SPS 4000 Configuration with LOI Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 4 3 RECOMMENDED CONFIGURATION a 4 20 mA Signal Upon Critical Alarm Rosemount recommends that the factory default be utilized The 4 20 mA signal will go to the 3 5 mA level upon any critical alarm which will cause the Os reading to be unusable Customer can also select 21 6 mA as the failure setting if normal opera tions cause readings to go below the zero O gt 3 5 mA level If the O2 measurement is being utilized as part of an automatic control loop the loop should be placed into manual upon this failure event or other appropriate action should be taken Calibration Rosemount recommends utilizing an auto calibration system actuated by the calibra tion recommended diagnostic New cells may operate for more than a year but older cells may require recalibration every few weeks as they near the end of their life This strategy ensures that the O reading is always accurate and eliminates many unnecessary calibrations based on calendar days or weeks since previous calibration When utilizing the SPS 4000 or IMPS 4000 consider wiring some or all associated alarm contacts
59. 6 C setpoint temperature REESE and this will indicate this condition Figure 6 5 LOI Module Connectors 6 6 Startup and Operation with LOI Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 68 OXYMITTER 4000 TEST POINTS Refer to Figure 6 6 System test points are located on the board below the LOI module Test points 1 through 6 allow you to monitor with a multimeter the heater thermocouple the cell millivolt and the process TP1 and TP2 monitor the oxygen millivolt output which equates to the percentage of oxygen present July 2004 b TP3 and TP4 monitor the heater thermo couple c TP5 and TP6 monitor the process gas or the calibration gas parameter MODEL 751 REMOTE POWERED LOOP LCD DISPLAY OPTIONAL Refer to Remote Powered Loop LCD manual for calibration and operation 37260037 Figure 6 6 Test Points Rosemount Analytical Inc A Division of Emerson Process Management Startup and Operation with LOI 6 7 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 6 8 Startup and Operation with LOI Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 Instruction Manu
60. 7 9 3 1A 9 3 2 9 3 4 9 3 4 9 3 4 9 3 4 9 3 4 9 3 4A 9 3 11 9 3 15 9 3 15 9 3 17A 9 3 31 5 10145601 08732 0007 0002 3039861601 4849 72 01 4849B72H02 4849B72H03 4849B72H04 4849B72H05 6A00115G01 4850B86G01 08732 0002 0001 08732 0002 0002 120039078 120039076 3D39861G01 4849 72 01 4849B72H02 4849B72H03 4849B72H04 4849B72H05 6A00115G01 5 10146604 08732 0002 0001 08732 0002 0002 120039078 6A00091G02 120039076 4849B92G20 4849B92G21 6A00122G01 6A00122G02 6A00122G03 6A00122G04 6A00122G05 6A00122G06 6A00122G07 3D39866G01 3D39866G02 4850B86G01 Cover Blind Cover with Window Electronic Assembly Membrane Keypad English Membrane Keypad German Membrane Keypad French Membrane Keypad Spanish Membrane Keypad ltalian LOI Module Local Operator Interface Housing Termination Block Standard Termination Block Transient Protected O Ring O Ring Membrane Keypad English Membrane Keypad German Membrane Keypad French Membrane Keypad Spanish Membrane Keypad Italian LOI Module Local Operator Interface Housing Termination Block Standard Termination Block Transient Protected O Ring Junction Box O Ring Connecting Cable Signal Connecting Cable Heater Cable Assembly 20 ft 6 m Cable Assembly 40 ft 12 m Cable Assembly 60 ft 18 Cable Assembly 80 ft 24 Cable Assembly 100 ft 30 m Cable Assembly 150 ft 46 m Cable Assembly 200 ft
61. 849B94G13 4849B94G15 4849B94G16 3D39003G16 3039003617 3039003618 3039003619 3039003620 3039003621 3039003622 3039003623 3039003624 et I lI lI lI ll I M LI mk s 2 LI ll 4513C61G03 4513C61G04 4513C61G05 Includes pad and wire IN KIT CELL AND 7 FLANGE ASSEMBLY 11 2 Replacement Parts PROBE TUBE NOT INCLUDED Description JIS High Sulfur HCl Resistant Cell Only JIS 18 Cell Replacement Kit High Sulfur HCI Resistant JIS 3 Cell Replacement Kit High Sulfur HCl Resistant JIS 6 Cell Replacement Kit High Sulfur HCl Resistant DIN High Sulfur HCI Resistant Cell Only DIN 3 Cell Replacement Kit High Sulfur HCI Resistant DIN 6 Cell Replacement Kit High Sulfur HCl Resistant ANSI 18 Abrasive Shield Assy ANSI 3 Abrasive Shield Assy ANSI 6 Abrasive Shield Assy DIN 18 Abrasive Shield Assy DIN 3 Abrasive Shield Assy DIN 6 Abrasive Shield Assy JIS 18 Abrasive Shield Assy JIS 3 Abrasive Shield Assy JIS 6 Abrasive Shield Assy 18 Contact and Thermocouple Replacement Assy 3 Contact and Thermocouple Replacement Assy 6 Contact and Thermocouple Replacement Assy ANSI GASKET WIRE AND 222 PAD ASSEMBLY ANTI SEIZE COMPOUND 22 GA WIRE PASSAGE CALIBRATION GAS CONNECTOR SSAG SET SCREWS M6 1 x 6 mm SOCKET HEAD TEFLON CAP SCREWS TUBING 27540010 Figure 11 1 Cell Replacement Kit Rosemo
62. After verifying that you have all the compo nents select mounting locations and deter mine how each component will be placed in terms of available line voltage ambient temperatures environmental considera tions convenience and serviceability 10 The optional Rosemount 751 remote mounted LCD display panel is loop driven by the 4 20 mA output signal representing the percentage e Handling the Hazardous Area Figure 1 5 shows a typical system wiring Oxymitter 4000 A typical system installation with integral electronics is illustrated in Figure 1 61 A CAUTION typical system installation with remote elec It is important that printed circuit tronics is illustrated in boards and integrated circuits are handled only when adequate antistatic precautions have been taken to pre vent possible equipment damage WARNING The HART option is not protected by energy limiting barriers It must not be The Hazardous Area Oxymitter 4000 is interfaced from within the hazardous 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 area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case even when using the in trinsically safe version of the handheld communicator HART 9 MODEL 275 375 HAND HELD INTERFACE
63. CELL mV TEST 02 CELL mv POINTS HEATER T C HEATER INC LOW GAS DEC CAL O HIGH GAS DEC TEST GAS PROCESS 02 37260044 Figure 8 2 Diagnostic LEDs Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 8 4 ALARM CONTACTS Ifautocalibration is not utilized a common bi directional logic contact is provided for any of the diagnostic alarms listed in The assignment of alarms which can actuate this contact can be modified to one of seven additional groupings mode 0 through mode 7 listed in The logic contact is self powered 5 VDC with a 340 ohm series resistance An inter posing relay will be required if this contact is to be utilized to annunciate a higher voltage device such as a light or horn An inter posing relay may also be required for cer tain DCS input cards A Potter amp Brumfield R10S E1Y1 J1 0K 3 2 mA DC or an equal interposing relay will be mounted where the contact wires terminate in the control relay room b If autocalibration systems are utilized the bi directional logic contact is utilized as a hand shake signal between the autocali bration system SPS 4000 or IMPS 4000 and is unavailable for alarming purposes The following additional contacts are pro vided through the autocalibration systems 1 SPS 4000 and IMPS 4000 1 4 pr
64. ECOMMENDED O O2CELL mV TPI TEST O2 CELL mv 2 POINTS HEATER T C TP3 TP4 CAL TEST GAS PROCESS O2 KEYPAD Alarms Board Temp 1 ROSEMOUNT Ble LOI 37260025 Figure 8 9 Fault 7 High Case Temp Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Fault 7 High Case Temp shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view Membrane Keypad When Fault 7 is detected The HEATER LED flashes three times pauses for three seconds and repeats 1 If the case temperature exceeds 85 C 185 F the temperature control will shut off and the 4 20 mA signal output will go to the default value 2 This signifies that the environment where the Hazardous Area Oxymitter 4000 is installed exceeds the ambient temperature requirements or that heat due to convection is causing case tem perature to rise above the limit 3 Placing a spool piece between the stack flange and the Hazardous Area Oxymitter 4000 flange may eliminate this problem 4 f a spool piece does not solve the problem relocation is the only solution LOI When Fault 7 is detected
65. EXPLOSION DATA FLASH POINT None FLAMMABILITY LIMITS EXTINGUISHING MEDIA Use extinguishing agent suitable for type of surrounding fire UNUSUAL FIRE AND EXPLOSION HAZARDS SPECIAL FIRE FIGHTING PROCEDURES N A P 16 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 SECTION V HEALTH HAZARD DATA THRESHOLD LIMIT VALUE See Section EFFECTS OF OVER EXPOSURE EYE Avoid contact with eyes Slightly to moderately irritating Abrasive action may cause damage to outer surface of eye INHALATION May cause respiratory tract irritation Repeated or prolonged breathing of particles of respirable size may cause inflammation of the lung leading to chest pain difficult breathing coughing and possible fibrotic change in the lung Pneumoconiosis Pre existing medical conditions may be aggravated by exposure specifically bron chial hyper reactivity and chronic bronchial or lung disease INGESTION May cause gastrointestinal disturbances Symptoms may include irritation and nausea vomiting and diarrhea SKIN Slightly to moderate irritating May cause irritation and inflammation due to mechanical reaction to sharp bro ken ends of fibers EXPOSURE TO USED CERAMIC FIBER PRODUCT Product which has been in service at elevated temperatures greater than 1800 F 982 C may undergo partial conversion to cristobalite a fo
66. Instruction Manual IB 106 340C Rev 4 1 July 2004 OXYMITTER 4000 HAZARDOUS AREA OXYGEN TRANSMITTER ROSEMOUNT Analytical EMERSON http www processanalytic com ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING Rosemount Analytical 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 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 prior to installing operating and servicing the product If you do not understand any of the instructions contact your Rosemount Analytical repre sentative 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 th
67. Manual IB 106 340C Rev 4 1 July 2004 TROUBLESHOOTING OVERVIEW While the Hazardous Area Oxymitter 4000 electronics provides a significant number of diagnostic alarms to assist in troubleshooting b potential problems it s good to place these alarms in perspective with respect to the instrument s operating principles c a EMF mV o 30 20 45 When the Zirconium Oxide sensing cell is heated to its setpoint 736 1357 F the cell will generate a voltage that represents 200 O Sensor Performance at 736 the difference between the process 02 and the reference O2 inside the probe 20 95 O gt ambient air Test points Figure 8 1 are provided to read the raw millivolt value generated by the ther mocouple that controls both the cell temperature and the raw cell signal The cell temperature at test points 3 and 4 should always be stable at approximately 29 to 30 millivolts which represents the 736 setpoint temperature 150 100 50 0 0 01 0 1 Concentration O KGENSEEENEM 10 100 37260043 ae 10 725 63 4 1 272 12_ Ou a _2_ _1_ 08 06 05 04 02 04 0 01 Figure 8 1 O Sensor mV Reading vs O at 736 C Reference Air 20 9 Rosemount Analytical Inc A Division of Emerson
68. ND 90 250 VAC 50 60 HZ LINE 1 LINE VOLTAGE INPUT ISSUE 37270023 Figure 2 10 Electrical Installation Hazardous Area Oxymitter 4000 with Remote Electronics Sheet 1 of 2 2 12 Installation Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 TYPE K IN OXYGEN THERMOCOUPLE SIGNAL SIGNAL ZE Ei HEATER POWER BELOW COVER TERMINAL BLOCK GRN YEL or GRN REMOTE ELECTRONICS GROUND LUGS CALIBRATION HANDSHAKE LOGIC I O LINE VOLTAGE INTERCONNECTING CABLE WIRING DIAGRAM TO ELECTRONICS TERMINAL BLOCK GROUND LUGS GENERAL PURPOSE OXYMITTER i HAZARDOUS AREA OXYMITTER FROM PROBE 4 20 MA 4 20 mA GROUND CALIBRATION HANDSHAKE LINE 1 NEUTRAL 90 250 VAC 50 60 HZ NEUTRAL LINE VOLTAGE INPUT ween oasa sot yf LINE VOLTAGE INPUT GROUND 37270024 Figure 2 10 Electrical Installation Hazardous Area Oxymitter 4000 with Remote Electronics Sheet 2 of 2 Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 13 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Remove cover 17 Figure 9 4 from the junction box 24 Connect the electronics end of the interconnecting cable 30 to
69. Oxymitter 4000 for reference air use Since the unit can be equipped with an in place calibration fea ture provisions can be made to perma nently connect calibration gas bottles to the Hazardous Area Oxymitter 4000 If the calibration gas bottles will be perma nently connected a check valve is required next to the calibration fittings on the integral electronics 1 5 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 and solenoid valves in the IMPS 4000 or SPS 4000 NOTE The integral electronics is rated NEMA 4X IP66 and is capable of operation at temperatures up to 85 C 185 F The optional LOI is also rated for operation at temperatures up to 85 185 F The infrared keypad function ality will degrade at temperatures above 70 C 158 F Retain the original packaging for the Hazardous Area Oxymitter 4000 in case the components are to be shipped to another site This packag ing is designed to protect the product IMPS 4000 OPTIONAL If using an IMPS 4000 with a Hazardous Area Oxymitter 4000 the IMPS 4000 sequencer must be installed in a non hazardous explosive free environment For further IMPS 4000 information refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin Rosemount Analytical Inc A Division of Emerson
70. Pressing INC or DEC a second time will increase or decrease the calibra tion gas parameter If the keys have been inactive for one minute the HART O RANGE SET BY HART AMS INTERNALLY FROM 40 POWERED DEFAULT LOCAL O RANGE SET BY POS 2 0 TO 10 0 TO 25 O O RANGE 3 5 mA 21 6 mA WHEN ALARM EXISTS OR ON POWER UP OUTPUT CURRENT GOES TO THIS VALUE 4 20 mA REQUIRES Instruction Manual IB 106 340C Rev 4 1 July 2004 output reverts to the process gas When a calibration has been initiated the value at TP5 and TP6 is the O seen by the cell Oxygen levels as seen on the multimeter are 8 0 O5 8 0 VDC 0 4 O2 0 4 VDC 2 HART AMS 3 Model 751 The loop driven LCD display O md HART LOCAL 10 0 e 0 25 3 5 mA 21 6 mA 220V 115 V DEFAULT POSITION EXTERNAL POWER HEATERT C O SW DIAGNOSTIC HEATER 4 ALARMS O2CELL CALIBRATION CALIBRATION RECOMMENDED O2CELL mV p TEST O2 CELL mV W POINTS HEATER T C HEATERTC INC INC T HIGH LOW GAS GAS TEST GAS 4 DEG DEC PROCESS O2 EX FACTORY THE 115 V OPTION SWITCH SW2 POSITION 4
71. Process Management Figure 1 8 Instruction Manual IB 106 340C Rev 4 1 July 2004 SPS 4000 OPTIONAL If using an SPS 4000 with a Hazardous Area Oxymitter 4000 the SPS 4000 sequencer must be installed in a non hazardous explosive free environment For further SPS 4000 information refer to the SPS 4000 Single Probe Autocalibration Sequencer Instruction Bulletin MODEL 751 REMOTE POWDERED LOOP LCD DISPLAY The display provides a simple economical means to obtain accurate reliable and remote indication of important process vari ables This display operates on the 4 20 mA line from the Hazardous Area Oxymitter 4000 Refer to Model 751 remote powered loop LCD manual for calibration and wiring 22220059 Model 751 Remote Powered Loop LCD Display Description and Specifications 1 9 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 1 6 PROBE OPTIONS a Flame Arrestor Ceramic Diffusion Assembly The flame arrestor ceramic diffusion as sembly includes a set of baffles between the cell and the stack gases This keeps 816 C 1500 F cell temperatures from igniting unburned fuel in the stack The ceramic diffusion assembly is also available with a dust seal for use with the abrasive shield assembly 36220006 Figure 1 10 Flame Arrestor Snubber Diffusion Assembly b Flame Arrestor Snubber Diffusion Assembly The flame arrest
72. Process Management Troubleshooting 8 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 8 2 d When flowing calibration gasses the raw cell millivolt value at test points 1 and 2 should represent the levels on the chart in Figure 8 1 Note that the raw cell millivolt value increases logarithmically as the O concentration decreases WARNING Install all protective equipment covers and safety ground leads after trouble shooting Failure to install covers and ground leads could result in serious injury or death GENERAL The troubleshooting section describes how to identify and isolate faults that may develop in the Hazardous Area Oxymitter 4000 When troubleshooting reference the following a Grounding It is essential that adequate grounding pre cautions are taken when installing the sys tem 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 b Electrical Noise The Hazardous Area Oxymitter 4000 has been designed to operate in the type of environment normally found in a boiler room or control room Noise suppression circuits are employed on all field terminations and main inputs When fault finding evaluate the electrical noise being generated in the immediate circuitry of a faulty system Ensure all cable shields are connected to e
73. REPAIR Each of the following procedures details how to remove and replace a specific component of the Hazardous Area Oxymitter 4000 vA 81 IN C It is recommended that the Hazardous Area Oxymitter 4000 be removed from the stack for all service activities The unit should be allowed to cool and be taken to a clean work area Failure to comply may cause severe burns 1 N IN C Disconnect and lock out power before working on any electrical components There is voltage up to 115 VAC a Removal and Replacement of Hazardous Area Oxymitter 4000 Probe 1 Remove a Turn off power to the system b Shut off the calibration gases at the cylinders and the instrument air c Disconnect the calibration gas and instrument air lines from the Hazardous Area Oxymitter 4000 d While facing the Hazardous Area Oxymitter 4000 and looking at the Rosemount label remove screw 18 Figure 9 3 or Figure 9 4 cover lock 19 and captive Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 washer 20 securing cover 17 on left side of housing 11 Remove the cover to expose the terminal block 15 e Remove all signal and power wiring to the probe f Remove insulation to access the mounting bolts g Unbolt the Hazardous Area Oxymitter 4000 from the stack and take it to a clean work area h Allow the unit to cool
74. RIAL IS RELEASED OR SPILLED Where possible use vacuum suction with HEPA filters to clean up spilled material Use dust suppressant where sweeping if necessary Avoid clean up procedure which may result in water pollution Observe Special Protection Information Section WASTE DISPOSAL METHODS The transportation treatment and disposal of this waste material must be conducted in compliance with all ap plicable Federal State and Local regulations SECTION VIII SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded NIOSH MSHA approved breathing equipment may be required for non routine and emergency use See Section IX for suit able equipment Pending the results of long term health effects studies engineering control of airborne fibers to the lowest lev els attainable 15 advised VENTILATION Ventilation should be used whenever possible to control or reduce airborne concentrations of fiber and dust Carbon monoxide carbon dioxide oxides of nitrogen reactive hydrocarbons and a small amount of formalde hyde may accompany binder burn off during first heat Use adequate ventilation or other precautions to elimi nate vapors resulting from binder burn off Exposure to burn off fumes may cause respiratory tract irritation bronchial hyper reactivity and asthmatic response SKIN PROTECTION Wear gloves hats and full body clothing to prevent
75. SS 02 DEC MEMBRANE KEY MEMBRANE KEYS 22220023 Figure 5 2 Calibration Keys Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 4 CAL LED The CAL LED is on steady or flashing during calibration Further information is available in MAINTENANCE AND SERVICE 5 Keys a INC and DEC The INC and DEC keys are used to set the values of the calibration gases Attach a multimeter across 5 and TP6 The calibration and process gases can now be monitored Pressing the INC or DEC once will cause the output to switch from the proc ess gas to the calibration gas Pressing INC or DEC a second time will increase or decrease the calibration gas parameter If the keys have been inactive for one minute the output reverts to the process gas When a calibration has been initiated the value at TP5 and TP6 is the seen by the cell ROSEMOUNT HEATER T C HEATERT C DIAGNOSTIC HEATER HEATER ALARMS O2 CELL o CALIBRATION c O CELL CALIBRATION RECOMMENDED CALIBRATION O2 CELL mv HEATER T C HEATER T C TEST POINTS O2 CELL mV INC INC CAL EN Tea Leo TEST GAS TP5 e DEC ipa O2 Instruction Manual IB 106 340C Rev 4 1 July 2004 Oxygen levels as seen on the multimeter are 8 0 O 8 0 vo
76. System Installation Oxymitter 4000 with Integral Electronics Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 7 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 a STANDARD Y fos ADAPTER PLATE FLOWMETER ELECTRONICS N 2 j mS ashy gt gt REFERENCE AIR IA PRESSURE REGULATOR IMPS 4000 LOGIC I O CALIBRATION MULTIPROBE GAS AUTOCALIBRATION 4 TO 20 mA OPTION SIGNAL LINE VOLTAGE ADAPTER PLATE OXYMITTER 4000 CALIBRATION GAS REMOTE MOUNTED SPS 4000 REFERENCE AIR SINGLE PROBE AUTOCALIBRATION OPTION WITH REFERENCE AIR OPTION REMOTE ELECTRONICS LINE VOLTAGE LOGIC I O gt 4 020 SIGNAL OXYMITTER 4000 ADAPTER LINE VOLTAGE Qe PLATE IMPS 4000 4 CALIBRATION GAS ELECTRONICS REFERENCE AIR a INSTRUMENT AIR SUPPLY A REFERENCE AIR vats THE IMPS 4000 OR SPS 4000 MUST SPS 4000 BE INSTALLED IN A NON HAZARDOUS CALIBRATION GAS 1 EXPLOSIVE FREE ENVIRONMENT CALIBRATION GAS 2 LINE 4 20 mA SIGNAL RELAY VOLTAGE OUTPUTS AND REMOTE CONTACT INPUT 37270006 Figure 1 7 Typical System Installation Oxymitter 4000 with Remote Electronics 1 8 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 1 3 A source of instrument air is optional at 1 4 the Hazardous Area
77. URV PV LRV PV 96 rnge PV AO mA PV AO Alrm typ ANALOG LOOP TEST OUTPUT D A TRIM Poll addr HART OUTPUT sss ALARM OUTPUT Logic I O Pin State Logic I O Pin Mode CONSTANT HighTG LowTG OPtrak TG TGtime PurgeTime Cal Mode Cal Intrvl h Next CalTime h LoAlarmSP OP locks OP tracks Manual Auto Figure 7 3 HART AMS Menu Tree Sheet 2 of 3 7 6 5 Loop test method D A trim method No Alarm Unit Alarm Low O2 Alarm Low O2 Unit Alarm Cal Rec Cal Rec Unit Alarm Low O2 Cal Rec Low O2 Unit Cal Rec Cal Rec Handshake Handshake 35910004 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 Manufacturer Descriptor Message Date Final asmbly num Snsr s n Fld dev rev Hardware rev Software rev Universal rev DEVICE CONTINUED FROM INFORMATION SHEET 2 Optrak TG Tgtime LowTG HighTG Cal slope Cal const Celllmp Imp Delta CAL INFO REVIEW DEVICE SETUP PV PV AO PV LRV PV URV Slope URV LRV OUTPUTS LoAlarmSP CONFIG Pin Mode Poll addr Num req preams 26170030 Figure 7 3 HART AMS Menu Tree Sheet 3 of 3 Rosemount Analytical Inc A Division of Emerson Process Management HART AMS 7 7 Instruction Manual IB 106 340C Rev 4 1 July 2004 7 8 HART COMMUNICATOR CAL METHOD
78. Use the following procedure to perform a calibration using the HART Communicator If necessary use the menu tree in Figure 7 3 sheet 1 of 3 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 a From the PERFORM O CAL screen select menu item 1 O CAL to access the calibration procedure 1 N IN Failure to remove the Hazardous Area Oxymitter 4000 from automatic control loops prior to performing this proce dure may result in a dangerous oper ating condition b In the first O CAL screen a Loop should be removed from automatic control warning appears Remove the Hazardous Area Oxymitter 4000 from any automatic control loops to avoid a potentially dangerous op erating condition and press OK The next several screens indicate the cali bration status At each of the following status prompts select menu item 2 NEXT CAL STEP COMPLETE CAL RECOMMENDED APPLY GAS 1 GAS 1 FLOW d Atthis point select menu item 4 EXIT to leave the O CAL procedure From the PERFORM O CAL screen view menu item 3 CALSTATE to monitor the calibration status as it updates Or access HART AMS Hazardous Area Oxymitter 4000 the CALIBRATE screen and select menu item 2 CAL STATUS to
79. a ambiente at 75 C 5 dimens es internas dos bucins dos cabos devem ser adequadas a uma boa fixa o dos cabos 6 assegurar um funcionamento seguro deste equipamento a liga o ao cabo de alimenta o el ctrica deve ser feita atrav s de um disjuntor min 10 que desligar todos os condutores de circuitos durante uma avaria O disjuntor poder tamb m conter um interruptor de isolamento accionado manualmente Caso contrario devera ser instalado qualquer outro meio para desligar o equipamento da energia el ctrica devendo ser assinalado convenientemente Os disjuntores ou interruptores devem obedecer a uma norma reconhecida tipo IEC947 7 Sempre que equipamento ou as tampas contiverem simbolo provavel a exist ncia de tens es perigosas Estas tampas s devem ser retiradas quando energia el ctrica tiver sido desligada e por Pessoal da Assist ncia devidamente treinado 8 Sempre que o equipamento ou as tampas contiverem simbolo ha perigo de exist ncia de superficies quentes Estas tampas s devem ser retiradas por Pessoal da Assist ncia devidamente treinado depois de a energia el ctrica ter sido desligada Algumas superficies permanecem quentes at 45 minutos depois 9 Sempre que equipamento ou as tampas contiverem simbolo Manual de Funcionamento deve ser consultado para obten o das necess rias instru es 10 Todos os s mbolos gr ficos utilizados neste p
80. acuuming should be used to clean the work area If dry vacuuming 15 used the vacuum must be equipped with HEPA filter Air blowing or dry sweeping should not be used Dust suppressing components can be used to clean up light dust Product packaging may contain product residue Do not reuse except to reship or return Ceramic Fiber products to the factory Rosemount Analytical Inc A Division of Emerson Process Management P 21 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS Edited from selected paragraphs of the Compressed Gas Association s Handbook of Compressed Gases published in 1981 Compressed Gas Association 1235 Jefferson Davis Highway Arlington Virginia 22202 Used by Permission l Never drop cylinders or permit them to strike each other violently 2 Cylinders may be stored in the open but in such cases should be protected against extremes of weather and to prevent rusting from the dampness of the ground Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent 3 The valve protection cap should be left on each cylinder until it has been secured against a wall or bench or placed in a cylinder stand and is ready to be used 4 Avoid dragging rolling or sliding cylinders even for short distance they should be moved by using a suitable hand truck 5 N
81. agnostic LEDs will display the operating cycle All other LEDs should be off See Figure 5 3 1 DIAGNOSTIC ALARM LEDS If there is an error in the system one of these LEDs will flash various blink codes see Section 8 TROUBLESHOOT ING In the case of multiple errors only one will be displayed based on a priority system Correct the problem and cycle power The operating display will return or the next error will be dis played The alarms are HEATER T C HEATER CELL CALIBRATION 2 CALIBRATION RECOMMENDED LED Turns on when the system determines that a calibration is recom mended Further information is avail able in MAINTENANCE AND SERVICE 5 2 Startup and Operation with Keypad Hazardous Area Oxymitter 4000 3 TEST POINTS Test points 1 through 6 allow you to monitor with a multimeter the heater thermocouple the cell millivolt value and the process a TP1 and TP2 monitor the oxygen cell millivolt output which equates to the percentage of oxygen present b TP3 and TP4 monitor the heater thermocouple c TP5 and TP6 monitor the process gas or the calibration gas parameter DIAGNOSTIC LEDS ES AT ROSEMOUNT HEATER DIAGNOSTIC HEATER ALARMS 02 CELL o CALIBRATION CALIBRATION RECOMMENDED 02 CELL mV TEST 02 CELL mv POINTS HEATER T C HEATER T C TEST GAS PROCE
82. aken the readings LED will turn off and the CAL using the first calibration gas LED will flash continuously and the CAL LED will flash The Hazardous Area Oxymit continuously The flashing ter 4000 can be configured indicates the Hazardous Area so that the 4 20 mA signal Oxymitter 4000 is ready to will hold the last value The take readings using the sec default condition is for the ond calibration gas output to track A flashing LED indicates that the Hazardous 5 Remove the first calibration Area Oxymitter 4000 is ready gas and apply the second to accept the first calibration calibration gas Electronics gas will abort the calibration if step 6 is not done within 30 3 Apply the first calibration gas minutes Electronics will abort the cali bration if step 4 is not done 6 Push the CAL key the CAL LED will be solid timer 4 Push the CAL key the CAL is activated for the second LED will be on solid A timer is calibration Gas Vinen activated to allow the calibra timer times out the CAL LED tion gas adequate time to flow will flash a 2 pattern flash or a default time of five minutes 3 pattern flash 2 pattern flash When the timer times out the equals a valid calibration 3 pattern flash equals an invalid 9 4 Maintenance and Service Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 calibration If the slope or the constant is out of specifica tion
83. al IB 106 340C Rev 4 1 July 2004 SECTION 7 5 1 C The HART option is not protected by energy limiting barriers It must not be interfaced from within the hazardous area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case even when using the in trinsically safe version of the handheld communicator OVERVIEW The HART Communicator is a handheld com munications interface device It provides a common communications link to all microproc essor based instruments that are HART com patible The handheld communicator contains an 8 x 21 character liquid crystal display LCD and 25 keys A pocket sized manual included with the HART Communicator details the spe cific functions of all the keys 7 2 To interface with the Hazardous Area Oxymitter 4000 the HART Communicator requires a ter mination point along the 4 20 mA current loop and a minimum load resistance of 250 ohms between the communicator and the power supply Rosemount Analytical Inc A Division of Emerson Process Management The HART 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 Hazardous Area Oxymitter 4000 s 4 20 mA current loop The HART communicator does not disturb the 4 20 mA signal since no net energy is added to the loop Th
84. al damage will occur during shipping In a cover letter describe completely 1 The symptoms from which it was determined that the equipment is faulty 2 The environment in which the equip ment has been operating housing weather vibration dust etc 3 Site from which equipment was removed 4 Whether warranty or nonwarranty service is requested Rosemount Analytical Inc A Division of Emerson Process Management 5 Complete shipping instructions for return of equipment 6 Reference the return authorization number Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Rosemount Return Authorization prepaid to Rosemount Analytical Inc RMR Department 1201 N Main Street Orrville Ohio 44667 If warranty service is requested the defec tive unit will be carefully inspected and tested at the factory If failure was due to conditions listed in the standard Rosemount warranty the defective unit will be repaired or replaced at Rosemount s option and an operating unit will be returned to the cus tomer in accordance with shipping instruc tions furnished in the cover letter For equipment no longer under warranty the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions Return of Material 10 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 400
85. alytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 Power Requirements Probe 175 W nominal 5 tau 10 W nominal sad ode sudo 500 W C Fisher Rosemount has satisfied all obligations coming from the European legislation to harmonize the product requirements in Europe 1 8 HAZARDOUS AREA CERTIFICATIONS a Hazardous Area Oxymitter 4000 with Integral Electronics KEMA ATEX I 2 G EEx d IIB H T6 Elect Comp T2 Probe CSA Class Division 1 Groups B C D T2 Class 1 Zone 1 Ex d IIB H T2 Class Zone 1 AEX d IIB H T2 FM Class I Division 1 Groups B C D T2 Class Zone 1 AEx d IIB H T2 b Hazardous Area Oxymitter 4000 with Remote Electronics KEMA ATEX I 2 G EEx d IIB H T2 Remote Probe 2 G EEx de IIB H T6 Remote Electronics CSA Class I Zone 1 Ex d IIB H T2 Remote Probe Class I Zone 1 Ex de IIB H T6 Remote Electronics Class I Zone 1 AEx d IIB H T2 Remote Probe Class I Zone 1 AEX de IIB H5 Remote Electronics FM Class Zone 1 AEX d IIB H5 T2 Remote Probe Class I Zone 1 AEX de IIB H5 Remote Electronics Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 13 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardo
86. amp cycle Refer to Section B TROUBLESHOOTING to determine the cause of the error Clear continues until the cell is up to operating i temperature the error cycle power and the operating display should return u HEATER TC O O O ROSEMOUNT HEATER e e o _ HEATERTIO e e e o ARUS O2CELL O CALIBRATION e e e CALIBRATION o CALIBRATION RECOMMENDED 2 CELL mV LIGHTING SEQUENCE DURING WARM UP STARTUP DISPLAY O2 CELL mv HEATER T C HEATER T C TEST POINTS m HEATERTIIC O O O e O HEATER 00 O QO 0 O O 5 O2 CALIBRATION O O O 1 2 3 4 1 2 3 4 LIGHTING SEQUENCE DURING NORMAL OPERATION OPERATING DISPLAY 22220056 Figure 5 1 Startup and Normal Operation Rosemount Analytical Inc A Division of Emerson Process Management Startup and Operation with Keypad 5 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 d Keypad The five membrane keys on the membrane keypad are only used during calibration to adjust the high and low gas and to initiate the calibration sequence Figure 5 2 Reference Air Ensure reference air if used is set to 56 6 I hr 2 scfh 5 2 OPERATION a Overview Ensure the Hazardous Area Oxymitter 4000 is at normal operation The di
87. analyzers has proven to withstand the high tempera tures in process heaters while providing the same advantages offered by the in situ sensor Inconel or Kanthal steel tubes pro vide effective resistance to corrosion and the package uses no moving parts air pumps or other components common to other sampling systems For more information call Rosemount Analytical at 1 800 433 6076 26170024 Rosemount Analytical Inc A Division of Emerson Process Management Optional Accessories 12 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 IMPS 4000 INTELLIGENT MULTIPROBE TEST GAS SEQUENCER The IMPS 4000 Intelligent Multiprobe Test Gas Sequencer is housed within an IP56 NEMA 4X enclosure and has the intelligence to provide calibration gas sequencing of up to four Hazardous Area Oxymitter 4000 units to accommodate auto matic and semi automatic calibration routines This sequencer works in conjunction with the Hazardous Area Oxymitter 4000 CALIBRATION RECOMMENDED feature eliminating out of calibration occurrences and the need to send a technician to the installation site In addition the SPS 4000 provides a remote contact input to initiate a calibration from a remote location and relay outputs to alert when a calibration is in progress a Hazardous Area Oxymitter 4000 is out of calibration calibration gases are on or calibration gas pressure is low For more information
88. ardous Area Oxymitter 4000 or in parallel to the 250 ohm load resistor NOTE the warmup period ends to continue C The opening menu displayed on the LCD is different for on line and off line operations When powering up a disconnected off line communicator the LCD will display the Main Menu When powering up a connected on line communicator the LCD will display the On line Menu Refer to the HART Communicator manual for detailed menu information HART AMS 7 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 7 5 LOGIC I O CONFIGURATIONS 7 6 HART AMS MENU TREE FOR HAZARDOUS AREA OXYMITTER 4000 APPLICATIONS The Hazardous Area Oxymitter 4000 logic I O output can be configured for ten different modes This section consists of a menu tree for the through HART AMS The factory default condi HART Communicator This menu is specific to tion is Mode 5 A list of possible configurations Hazardous Area Oxymitter 4000 applications appear in Table 7 1 The Unit Alarm configuration available for Modes 1 3 5 and 7 refers to the diagnostic alarm faults in Table 8 11 Table 7 1 Logic I O Configuration as set at HART AMS or LOI Mode Configuration 00 The unit is not configured for any alarm condition The unit is configured for a Unit Alarm The unit is configured for Low The unit is configured for both a Unit Alarm and Low 4 The unit is configured for a High AC Im
89. arth c Loose Integrated Circuits The Hazardous Area Oxymitter 4000 uses a microprocessor and supporting integrated circuits IC If the electronics are handled roughly during installation or located where subjected to severe vibration the ICs could Troubleshooting Hazardous Area Oxymitter 4000 8 3 work loose Before troubleshooting the system ensure all ICs are fully seated d Electrostatic Discharge Electrostatic discharge can damage the ICs used in the electronics Before removing or handling the processor board or the ICs ensure you are at ground potential ALARM INDICATIONS The majority of the fault conditions for the Hazardous Area Oxymitter 4000 will be indi cated by one of the four LEDs referred to as diagnostic or unit alarms on the operator s key pad Figure 8 2 An LED will flash a code that will correspond to an error message Only one LED will blink at a time An alarm code guide is provided inside the screw on cover for the electronics Alarm indications will be also available via the optional LOI or the HART Model 275 375 hand held communicator Rosemount s Asset Management software When the error is cor rected and or power is cycled the diagnostic alarms will clear or the next error on the priority list will appear DIAGNOSTIC LEDS ROSEMOUNT HEATER HEATER DIAGNOSTIC ALARMS 02 CELL CALIBRATION CALIBRATION RECOMMENDED 02
90. ate the need to rent gas bottles For more information call Rosemount Analytical at 1 800 433 6076 26170021 Rosemount Analytical Inc A Division of Emerson Process Management Optional Accessories 12 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 12 4 Optional Accessories Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 Instruction Manual IB 106 340C Rev 4 1 July 2004 SECTION 13 INDEX This index is an alphabetized listing of parts terms and procedures having to do with the Hazardous Area Oxymitter Every item listed in this index refers to a location in the manual by one or more page numbers A Abrasive Shield 2 1 2 4 2 7 2 9 2 11 11 2 Absolute Temperature 1 1 Accuracy 1 12 Alarm Modes 3 4 4 4 7 4 Alarms 3 4 4 4 5 2 7 4 8 2 Alarms Diagnostic 8 4 Alarms Unit 8 4 AMS Software 1 1 1 5 3 2 4 2 9 3 12 1 Analog Output Signal 4 20 mA 1 1 1 3 1 4 1 5 1 9 1 12 2 9 2 11 3 2 3 3 4 2 4 3 7 1 7 2 7 3 Arithmetic Constant 1 1 Autocalibration 9 1 9 2 B By Pass Packages 12 1 C Calibration 7 8 7 9 9 1 Calibration Gas 1 9 2 15 3 3 9 1 9 5 12 2 12 3 Calibration Handshake 2 9 2 11 2 14 3 4 4 4 CALIBRATION RECOMMENDED 1 4 3 4 4 4 5 2 7 4 9 3 12 2 Cell 1 3 8 17 8 18 9 1 9 15 Cell Constant 1 1 Cell Replacement Kit 9 15 11 1 Check Valve 1 9 Co
91. ated instructions are displayed on the LOI All other parameters are display only 37260018 Figure 6 4 Local Operator Interface Menu Tree Sheet 2 of 2 July 2004 CONTINUED FROM SHEET 1 Calib Setup Input Output SYSTEM Parameters Software Status 6 6 HAZARDOUS AREA OXYMITTER 4000 SETUP AT THE In setting up the Hazardous Area Oxymitter 4000 from the LOI it s best to start at the SYSTEM Calibration Setup menu Figure 6 4 a SYSTEM Calibration Setup 1 O2 Gas 1 Enter the high or low cal gas value the order is not important 2 O2 Gas 2 Enter the second cal gas value NOTE Refer to MAINTENANCE AND SERVICE for calibration instructions 6 4 Startup and Operation with LOI NOTE Rosemount Analytical recommends 0 4 and 8 for calibration gases 3 O2 Reset Values Resets factory default values 4 O2 Output Tracks 4 to 20 mA signal can be held at the last value during calibration or the signal can be left to track the cal gases 5 O2 Cal Interval If automatic calibra tion is selected this selects the interval between calibrations 6 O2 Next Cal If automatic calibration is selected this selects the time until the first initial calibration takes place Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 7 Gas Time How long should each cal gas flow Factory default is 300 sec onds but the user may wa
92. ational g ltigen Normen und Richtlinien einhalten l Alle intern und extern vorgesehenen Erdungen der Ger te m ssen ausgef hrt werden 2 Nach Installation Reparatur oder sonstigen Eingriffen in das Ger t m ssen alle Sicherheitsabdeckungen und Erdungen wieder installiert werden Die Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gest rt sein 3 Die Netzspannungsversorgung mu den Anforderungen der IEC227 oder IEC245 gen gen 4 Alle Verdrahtungen sollten mindestens bis 75 ihre Funktion dauerhaft erf llen 5 Alle Kabeldurchf hrungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so gew hlt werden daf diese eine sichere Verkabelung des Ger tes erm glichen 6 Um eine sichere Funktion des Ger tes zu gew hrleisten mu die Spannungsversorgung ber mindestens 10 A abgesichert sein Im Fehlerfall mu dadurch gew hrleistet sein dab die Spannungsversorgung zum Ger t bzw zu den Ger ten unterbrochen wird Ein mechanischer Schutzschalter kann in dieses System integriert werden Falls eine derartige Vorrichtung nicht vorhanden ist mu eine andere M glichkeit zur Unterbrechung der Spannungszufuhr gew hrleistet werden mit Hinweisen deutlich gekennzeichnet werden Ein solcher Mechanismus zur Spannungsunterbrechung mu mit den Normen und Richtlinien f r die allgemeine Installation von Elektroger ten wie zum Beispiel der IEC947 bereinstimmen 7 dem Symbol sind Ger te oder Abdeckun
93. be displayed Refer to TROUBLESHOOTING to deter mine the cause of the error Clear the error cycle power and the Os display should return d LOI The Local Operator 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 LOI menu Figure 6 4 e Reference Air Ensure the reference air if used is set to 56 6 I hr 2 scfh 6 2 START UP OXYMITTER 4000 CALIBRATION Refer to MAINTENANCE AND SERVICE for calibration instructions Rosemount Analytical Inc A Division of Emerson Process Management 02 0 00 367dgC ROSEMOUNT Eo warm up 37260035 Figure 6 1 Startup Display 02 2 59 LK normal ROSEMOUNT De 37260036 Figure 6 2 Normal Display Startup and Operation with LOI 6 1 Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 TOUCH CONFIRMATION SELECTION LED SELECTION ARROW ARROW LCD DISPLAY WINDOW 6 3 NAVIGATING THE LOCAL OPERATOR SELECTION ARROWS 37260054 Figure 6 3 LOI Features 6 4 INTERFACE a 6 2 Startup and Operation with LOI Overview The Local Operator Interface LOI shown in Figure 6 3 utilizes a bright blue gas florescent display Intensity is adjustable There is an Infra red LED source and a detector for each key The detectors can detect a finger placed above the butt
94. call Rosemount Analytical at 1 800 433 6076 SPS 4000 SINGLE PROBE AUTOCALIBRATION SEQUENCER HAZARDOUS AREA OXYMITTER 4000 Rosemount Analytical specifically designed the SPS 4000 Single Probe Autocalibration Sequencer to provide the capability to perform automatic or on demand Oxymitter 4000 calibrations The SPS 4000 system must be installed a remote safe area if the Hazardous Area Oxymitter 4000 probe is installed in a hazardous area The SPS 4000 works in conjunction with the Oxymitter 4000 s CALIBRATION RECOMMENDED feature eliminating out of calibration occurrences and the need to send a technician to the installation site In addition the SPS 4000 provides a remote contact input to initiate a calibration from a remote location and relay outputs to indicate when a calibration is in progress or the Hazardous Area Oxymitter 4000 is out of calibration SPS 4000 IN A SAFE AREA For more information call Rosemount Analytical at 1 800 433 6076 26310009 12 2 Optional Accessories Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 O CALIBRATION GAS Rosemount Analytical s O Calibration Gas and Service Kits have been carefully designed to provide a more convenient and fully portable means of testing calibrating and servicing Rosemount Analytical s oxygen analyzers These lightweight disposable gas cylinders elimin
95. ce Output Forces the output state of the signal to either open or closed This is used primarily when diagnosing potential problems with this signal c SYSTEM Parameters 1 O2 Slope slope is data regarding the strength of the sensing cell output This information is automatically cal culated after a calibration and the user does not normally input this data O2 Constant constant is the amount of voltage a cell generates with ambient air as the calibration gas Again this is normally calculated as a result of calibration and is not normally input by the user O2 T90 Time Some users may feel that the reading is too active for certain processes This feature permits the user to dampen the signal The default value is zero seconds damp ening Auto Tune The electronics detects the line voltage powering the instru ment automatically and picks proper algorithms for heater control User can force a high voltage algorithm or a low but Auto Tune is the default and is recommended Lockout Time Keypad lockout time default is 30 sec but is user configur able A Z keypad pattern will unlock the keypad Revert Time Once a user goes one level deep into the menu structure an additional revert time is provided to prevent nuisance lockouts One hour is the default and it is user configurable Luminance Gas florescence bright ness is user adjustable S
96. ceramic diffusion element using the ceramic diffusion ele ment replacement kit in This consists of a diffusion element cement setscrews anti seize compound and instructions h Test fit replacement ceramic diffu sion element to be sure seat is clean CAUTION Do not get cement on ceramic diffu sion element except where it touches the hub Any cement on ceramic diffu sion element blocks airflow through element Wiping wet cement off of the ceramic only forces cement into pores Also do not get any cement onto the flame arrestor element i Thoroughly mix cement and insert tip of squeeze bottle into cement port Tilt bottle and squeeze while simultaneously turning ceramic Maintenance and Service 9 17 Instruction Manual IB 106 340C Rev 4 1 July 2004 diffusion element into seat Do not 4 get any cement on upper part of ceramic diffusion element Ensure complete penetration of cement around 3 grooves in hub Cement should extrude from opposite hole Wipe excess material back into 9 holes and wipe top fillet of cement to form a uniform fillet A Q Tip is useful for this Clean any excess cement from hub with water j Allow filter to dry at room tem perature overnight or 1 to 2 hours 6 at 93 200 F K Wipe a heavy layer of anti seize compound onto the threads and mating surfaces of the flame arre stor diffusion hub and probe tube I Assemble flame arrestor and diffu 7
97. cess Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 STARTUP AND OPERATION OF HAZARDOUS AREA OXYMITTER 4000 WITH LOI ii Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 LIST OF ILLUSTRATIONS Figure 1 1 Installation with Drip Loop and Insulation Remoxval Remote Electronics Mounting Electrical Installation Hazardous Area Oxymitter 4000 with Integral Electronics Electrical Installation Hazardous Area Oxymitter 4000 with Remote Electronics Fault 5 Open Heater Fault 6 High High Heater Temp Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Figure 8 10 Fault 8 Low Heater Temp Figure 8 11 Fault 9 High Heater Temp Figure 8 12 iV Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 PREFACE The purpose of this manual is to provide information concerning the components func tions installation and maintenance of the Oxymitter 4000 Hazardous Area Oxygen Transmitter Some sections may describe equipment not used in your configuration The user should become thor
98. cess Management Troubleshooting 8 15 Instruction Manual IB 106 340C Rev 4 1 July 2004 ROSEMOUNT HEATER T C DIAGNOSTIC HEATER SW2 ALARMS O2 CELL CALIBRATION CALIBRATION RECOMMENDED O O2 CELL mv TP2 HEATER T C TP3 O2 CELL mV TP1 TEST Oo POINTS HEATER T C RED YEL SS GRN ORG INC INC es HGH LOW GAS GAS TEST GAS 5 sss O2 KEYPAD Alarms 02 Cell Bad ROSEMOUNT De LOI 37260029 Figure 8 14 Fault 12 EEprom Corrupt 8 16 Troubleshooting Hazardous Area Oxymitter 4000 Fault 12 EEprom Corrupt igure 8 14 shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view Membrane Keypad When Fault 12 is detected the O2 CELL LED flashes four times pauses for three seconds and repeats 1 This alarm can occur if the EEprom is changed for a later version At power up the EEprom is not updated 2 o correct this problem power down and then restore power The alarm should clear If the alarm occurs while the unit is running there is a hardware problem on the microprocessor board 4 f cycling the power does not clear the alarm see paragraph Electronic Assembly Re
99. ctions in paragraph 9 4alto remove the Hazardous Area Oxymitter 4000 from the stack or duct IN The flame arrestor and flame arrestor hub are among the critical compo nents of this type of protection See Safety Data Sheet 1A99078 2 If the probe uses snubber diffuser use a spanner wrench to remove the flame arrestor snubber diffuser assem bly NOTE To determine if the diffuser needs to be replaced refer to paragraph Maintenance and Service 9 15 Instruction Manual IB 106 340C Rev 4 1 July 2004 M5 0 8 x 5 mm LOCKING SET SCREW USE 2 5 mm HEX KEY THREADED SPANNER PROBE FLANGE WRENCH CERAMIC DIFFUSION i ELEMENT M6 1 x 6 mm SETSCREW USE 3mm FLAME MEX KEY ARRESTER c HUB CEMENT CEMENT FILLET DEFLECTOR 27540008 Figure 9 10 Ceramic Diffuser Element Replacement 3 Remove the locking set screw from the flame arrestor Use spanner wrenches from the probe disassembly kit Table 11 1 11 1 to turn the flame arrestor hub free from the probe flange If equipped with the flame arrestor with ceramic diffuser remove and discard the setscrews and remove the vee dellec tor Figure 9 10 Inspect the ceramic diffuser damaged replace using paragraph 9 4il 4 Loosen the four socket head cap screws from the cell and flange as sembly Remove the assembly and the corrugated seal The cell flange has a notch that may be used to gently pry the flange
100. e available in three length options giving the user the flexibility to use an in situ penetra tion appropriate to the size of the stack or duct The options on length are 457 mm 18 in 0 91 m 3 ft and 1 83 m 6 ft The electronics control probe temperatures and provide an isolated output 4 20 mA that is proportional to the measured oxygen concentration The power supply can accept voltages of 90 250 VAC and 48 62 Hz no setup procedures are required The oxygen sensing 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 produces the outputs to be used by remotely con nected devices The output is an isolated 4 20 mA linearized current Rosemount Analytical Inc A Division of Emerson Process Management 26310002 Figure 1 2 Hazardous Area Oxymitter 4000 Autocalibration System Options The Oxymitter 4000 transmitter is available with an integral or remote electronics pack age wo calibration gas sequencers are available to the Hazardous Area Oxymitter 4000 but they must be installed in a non hazardous explosive free environment the IMPS 4000 and the SPS 4000 Figure 1 2 oystems with multiprobe applications may employ an optional IMPS 4000 Intelligent Multiprobe Test Gas Sequencer The IMPS 4000 provides automatic calibration gas sequencing for up to four Hazardous Ar
101. e HART Communicator may be interfaced with a personal computer PC providing that special software has been installed To connect the HART Communicator to a PC an interface adapter is required Refer to the proper HART Communicator documentation in regard to the PC interface option HART COMMUNICATOR SIGNAL LINE CONNECTIONS The HART Communicator can connect to the Hazardous Area Oxymitter 4000 s analog output signal line at any wiring termination in the 4 20 mA current loop There are two methods of connecting the HART 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 For applications in which the signal line load resistance is less than 250 ohms refer to method 2 HART AMS 7 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 a Method 1 For Load Resistance gt 250 b Method 2 For Load Resistance lt 250 Ohms Ohms Refer to Figure 7 1 the following steps Refer to and the following steps to connect the HART Communicator to a to connect the HART Communicator to a signal line 250 ohms or more of load signal line with less than 250 ohms load resistance resistance 1 N IN C WNA 1 N IN C Explosions can result in death or seri Explosions can result in death or seri dix j ous injury Do not make connections ous injury Do not make connections to the HART Communicator s serial
102. e cell replacement kit See Table 11 1 The cell replacement kit Figure 9 9 con tains a cell and flange assembly corrugated seal setscrews socket head cap screws and anti seize compound The items are carefully packaged to preserve precise surface finishes Do not remove items from the packaging until they are ready to be used Spanner and hex wrenches needed for this procedure are part of an available special tools kit See Table 11 1 PROBE TUBE NOT INCLUDED IN KIT CALIBRATION GAS PASSAGE SOCKET HEAD CAP SCREWS 26310016 Figure 9 9 Cell Replacement Kit Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Spanner and hex wrenches needed for this procedure are part of an available special tools kit See Table 11 1 WARNING Use heat resistant gloves and clothing when removing the probe Do not at tempt to work on these components until they have cooled to room tem perature Probe components can be as hot as 300 C 572 F This can cause severe burns Disconnect and lock out power before working on any electrical components There is voltage of up to 115 VAC CAUTION Do not remove the cell unless certain it needs to be replaced Removal may damage the cell and platinum pad Go through the complete troubleshooting procedure to make sure the cell needs to be replaced before removing it 1 Follow the instru
103. e flow stream Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 11 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 1 7 SPECIFICATIONS Range Standard tee deet Oto 10 Oto 25 0 to 40 via HART ACCURACY 0 5 of reading or 0 05 whichever is greater System Response to Calibration Gas Initial less than 3 sec T90 less than 8 sec Temperature Limits PrOGES m 0 to 04 C 32 to 1300 F up to 1300 C 2400 F with optional accessories Electronics Housing 40 to 70 40 to 158 F ambient Electronics Package 40 to 85 C 40 to 185 F operating temperature of electronics inside instrument housing as measured by a HART communicator or Rosemount Asset Management Solutions software Local Operator Interface 40 to 70 C 40 to 158 F ambient 40 to 85 C 40 to 185 F internal At temperatures above 70 158 F inside instrument housing the infrared keypad will cease to function but the Oxymitter 4000 will continue to operate properly PrODE LENUS o uu na eas 18 in 457 mm 3 ft 0 91 m 6 ft 1 83 m Mounting and Mounting Position Vertical or horizontal a spool piece P N 3D39761G02 is available to offset transmitter housing from hot
104. e net concentration of in the industrial process A calibration record sheet is provided on the previous page Use photocopies of the calibration record sheet to track transmitter performance Before calibrating the Hazardous Area Oxymitter 4000 verify that the calibration gas parameters are correct by setting the gas concentrations See paragraph or 6 5 used when calibrating the unit and by setting the calibration gas flowmeter Rosemount Analytical Inc A Division of Emerson Process Management The calibration gas flowmeter regulates the calibration gas flow and must be set to 5 scfh However only adjust the flowmeter to 5 scfh after placing a new diffuser on the end of the probe Adjusting the flowmeter at any other time can pressurize the cell and bias the calibration In applications with a heavy dust loading the Os probe diffusion element may become plugged over time causing a slower speed of response The best way to detect a plugged diffusion element is to note the time it takes the Hazardous Area Oxymitter 4000 to return to the normal process reading after the last calibration gas is removed and the calibration gas line is blocked off A plugged diffusion element also can be indicated by a slightly lower reading on the flowmeter Change the diffusion element when the calibration gas flowmeter reads slightly lower during calibration or when response to the process flue gases becomes very slow Each time the diffus
105. e proper elec trical 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 Rosemount Unauthorized parts and procedures can affect the product s per formance 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 CAUTION 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 Fisher Rosemount Service Group or National Response Center at 1 800 433 6076 or 1 888 433 6829 Emerson Process Management Rosemount Analytical Inc Process Analytic Division 1201 N Main St Orrville 44667 0901 T 330 682 9010 F 330 684 4434 e mail gas csc EmersonProcess com http www processanalytic com E M E RSO N P 3 through P 14 1 1 1 2 1 3 1 4 1 5 1 6 1 8 1 12 1 13 1 14 1 16
106. ea Oxymitter 4000 units and accommodates autocalibrations based on the CALIBRA TION RECOMMENDED signal from the Hazardous Area Oxymitter 4000 a timed interval set up in HART or the IMPS 4000 or whenever a calibration request is initiated Description and Specifications 1 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 For systems with one or two Hazardous Area Oxymitter 4000 units per combustion process an optional remote mounted SPS 4000 Single Probe Autocalibration Sequencer can be used with each Hazard ous Area Oxymitter 4000 to provide auto HEATERT C matic calibration gas sequencing The DIAGNOSTIC C 5 02 CELL c sequencer performs autocalibrations based CALIBRATION on the CALIBRATION RECOMMENDED signal from the Hazardous Area Oxymitter 4000 a timed interval set up in HART or whenever a calibration request is initiated d System Features 1 The cell output voltage and sensitivity i Y ji d CALIBRATION RECOMMENDED 02 CELL mV 02 CELL mv HEATER T C HEATER T C TEST POINTS d f INC The CALIBRATION RECOMMENDED feature detects when the sensing cell aot o is likely out of limits This may eliminate TEST GAS the need to calibrate on a time since PEC PROCESS 02
107. ectronics b Connect Line Voltage Connect the line or L1 wire to the L1 terminal and the neutral or L2 wire to the N terminal Figure 2 10 The Hazardous Area Oxymitter 4000 will automatically configure itself for 90 250 VAC line voltage and 50 60 Hz To avoid a shock hazard the power terminal cover must be installed c Connect 4 20 mA Signal and Calibration Handshake Logic I O Leads Figure 2 10 1 4 20 mA Signal The 4 20 mA signal represents the value and can also operate the Model 751 Loop LCD Dis play or any other loop powered display Superimposed on the 4 20 mA signal is HART information that is accessible through a Model 275 375 Handheld Communicator or AMS software Installation 2 11 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 TYPE K OXYGEN THERMOCOUPLE HEATER POWER Enk L BELOW COVER m TERMINAL BLOCK GRN YEL or GRN REMOTE ELECTRONICS __ GROUND i LUGS CALIBRATION Z 4 20 mA HANDSHAKE SIGNAL LOGIC I O LINE VOLTAGE me X INTERCONNECTING WIRING DIAGRAM CABLE TO ELECTRONICS TERMINAL 2 BLOCK 4 O T GROUND LUGS 2 GENERAL PURPOSE D OXYMITTER HAZARDOUS AREA OXYMITTER i FROM PROBE TO IMPS 4000 IF USED REFER TO IMPS 4000 mea 5 T INSTRUCTION MANUAL 4 20 mA 4 20 mA GROU
108. efer to for a view of the LOI menu tree To calibrate the Hazardous Area Oxymitter 4000 from the LOI access the CALIBRATION Start Calibration menu a CALIBRATION Start Calibration This is the starting point for calibrations The LOI will instruct the user through this entire pro cedure You can select Abort Calib at any time to abort the calibration 1 The LOI displays the following Apply Gas 1 Hit E when ready The Oxymitter 4000 is ready to accept the first calibration gas Apply the first calibration gas Electronics will abort the calibration if this step is not done within 30 minutes 2 Touch the Enter key to start the Gas 1 flow A timer is activated to allow the calibration gas adequate time to flow default time of five minutes The LOI displays Flow Gas 1xxxxs Read Gas 1xxxxs Done Gas 1 The display counts down the seconds remaining to flow Gas 1 then the time remaining for sensing the concen tration of Gas 1 Done Gas 1 indicates completion 3 Remove the first calibration gas and apply the second calibration gas Electronics will abort the calibration if this step is not done within 30 min utes The LOI displays the following Apply Gas 2 Hit E when ready Maintenance and Service 9 5 Instruction Manual IB 106 340C Rev 4 1 July 2004 4 Touch the Enter arrow to start the Gas 2 flow The timer is activated and the LOI displays Flow Gas 2xxxxs Read Gas 2xxxxs Done Gas 2 Sto
109. elijk na 45 min nog te heet zijn om aan te raken 9 Waar de apparatuur of de beschermdeksels kappen gemarkeerd zijn met het volgende symbool dient men de bedieningshandleiding te raadplegen 10 Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende standaarden EN 61010 1 IEC 417 amp ISO 3864 Rosemount Analytical Inc A Division of Emerson Process Management P 5 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 TARKEAA Turvallisuusohje jota on noudatettava laitteen asentamisessa ja kaapeloinnissa Seuraavat ohjeet patevat erityisesti EU n jasenvaltioissa Niita taytyy ehdottomasti noudattaa jotta taytettaisiin EU n matalajannitedirektiivin Low Voltage Directive yhteensopivuus Myos EU hun kuulumattomien valtioiden tulee nou dattaa tata ohjetta elleiv t kansalliset standardit esta sita 1 2 10 P 6 Rutt v t maadoituskytkenn t tehtava kaikkiin maadoituspisteisiin sisaisiin Ja ulkoisiin Asennuksen ja vianetsinnan J lkeen on kaikki suojat Ja suoJamaat asennettava takaisin 1 Maadoitusliittimen kunnollinen toiminta t ytyy aina yll pit J nnitesy tt johtimien t ytyy t ytt IEC227 ja IEC245 vaatimukset Kaikkien johdotuksien tulee toimia gt 75 C l mp tiloissa Kaikkien l pivientiholkkien sis halkaisijan t ytyy olla sellainen ett kaapeli lukkiutuu kun nolla kiinni Turvallisen toiminnan va
110. en ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management P 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 VIGTIGT Sikkerhedsinstruktion for tilslutning og installering af dette udstyr Folgende sikkerhedsinstruktioner gzelder specifikt i alle EU medlemslande Instruktionerne skal noje folges for overholdelse af Lavsspzendingsdirektivet og ber ogsa felges i ikke EU lande medmindre andet er specificeret af lokale eller nationale standarder 1 2 10 4 Passende Jordforbindelser skal tilsluttes alle Jordklemmer interne og eksterne hvor disse forefindes Efter installation eller fejlfinding skal alle sikkerhedsdeeksler og jordforbindelser reetableres Forsyningskabler skal opfylde krav specificeret 1 IEC227 eller IEC245 Alle ledningstilslutninger skal veere konstrueret til omgivelsestemperatur hojere end 75 C Alle benyttede kabelforskruninger skal have en intern dimension s passende kabelaflastning kan etableres For opn else af sikker drift og betjening skal der skabes beskyttelse mod indirekte ber ring gennem afbryder min 10A som vil afbryde alle kredsl b med elektriske ledere 1 fejlsitua tion Afbryderen skal indholde mekanisk betjent kontakt Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og meerkes som s dan Afbrydere eller kontakter skal overholde en kendt standard som IEC947 Hvor udstyr eller d ksler e
111. en en aardingen om reden van veiligheid weer aangebracht te worden 3 Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of IEC 245 4 Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven 75 5 Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankering van de kabel wordt verkregen 6 een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats te vinden via een meerpolige automatische zekering min 10A die alle spanningvoerende geleiders verbreekt indien een foutconditie optreedt Deze automatische zekering mag ook voorzien zijn van een mechanisch bediende schakelaar Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen Zekeringen en schakelaars dienen te voldoen aan een erkende standaard zoals IEC 947 7 Waar de apparatuur of de beschermdeksels kappen gemarkeerd zijn met het volgende symbool kunnen zich hieronder spanning voerende delen bevinden die gevaar op kunnen leveren Deze beschermdeksels kappen mogen uitsluitend verwijderd worden door getraind personeel als de spanning is afgeschakeld 8 Waar de apparatuur of de beschermdeksels kappen gemarkeerd zijn met het volgende symbool kunnen zich hieronder hete oppervlakken of onderdelen bevinden Bepaalde delen kunnen mog
112. er 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view Membrane Keypad When Fault 9 is detected the HEATER LED flashes five times pauses for three seconds and repeats 1 If the thermocouple produces a voltage in excess of approximately 30 7 mV the high heater temp alarm activates 2 The 4 20 mA signal returns to the default value 4 or 20 mA 3 This alarm is self clearing When tem perature control is restored and the thermocouple voltage returns to the normal range the alarm clears 4 If the temperature continues to rise the next alarm will be the high high heater temp alarm LOI When Fault 9 is detected the LOI displays the O2 Temp message Refer to the comments and procedures in para graphs 1 through 4 above Troubleshooting 8 13 Instruction Manual IB 106 340C Rev 4 1 July 2004 ROSEMOUNT HEATERT C DIAGNOSTIC HEATER o SW2 ALARMS O2 CELL o a L CALIBRATION o CALIBRATION RECOMMENDED O O2CELLmV TP1 PEST O2 CELL mv 2 C C POINTS HEATER T C TP3 e oO zao 2555 oa o HIGH LOW GAS GAS TEST GAS 5 pcr 0 O2 KEYPAD Alarms 02 Cell Open ROSEMOUNT p 9 LOI 37260028 Figure 8 12 Fa
113. esponse j When the second calibration gas is turned off note the number of seconds required for the value to begin migrating back to the process value Responses When the second calibration gas is turned off note the number of seconds required for the value to settle out at the process value 9 0 Maintenance and Service Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 SECTION 9 Instruction Manual IB 106 340C Rev 4 1 July 2004 MAINTENANCE AND SERVICE OVERVIEW This section identifies the calibration methods available and provides the procedures to main tain and service the Hazardous Area Oxymitter 4000 WA C When working on this equipment on the laboratory bench be aware that the Hazardous Area Oxymitter 4000 probe tube and flame arrestor hub can be hot up to 300 C 572 F in the region of the probe heater 1 N IN C Install all protective equipment covers and safety ground leads after equip ment repair or service Failure to in stall covers and ground leads could result in serious injury or death CALIBRATION HAZARDOUS AREA OXYMITTER 4000 WITH KEYPAD a During a calibration two calibration gases with known concentrations are applied to the Hazardous Area Oxymitter 4000 Slope and constant values calculated from the two calibration gases determine if the Hazardous Area Oxymitter 4000 is correctly measuring th
114. ev 4 1 July 2004 c Connect 4 20 mA Signal and Calibration Handshake Logic I O Leads 1 4 20 mA Signal The 4 20 mA signal represents the Os value and can also operate the Model 751 Loop LCD Dis play or any other loop powered display Superimposed on the 4 20 mA signal is HART information that is accessible through a Model 275 375 Handheld Communicator or AMS software IN C If using an IMPS 4000 or an SPS 4000 install it in a non hazardous explosive free environment 2 Calibration Handshake Logic I O The output signal can be used to trigger an alarm or to provide a calibration hand shake signal to an IMPS or SPS 4000 If autocalibration is not utilized a common bi directional logic contact is provided for any of the equipment alarms listed in The assign ment of alarms that will actuate this contact is modified by one of seven additional configuration settings mode 1 through mode 7 listed in The logic contact is self powered 5 VDC with a 340 ohm series resis tance An interposing relay is required if the logic contact will annunciate a higher voltage device such as a light or horn An interposing relay may also be required for certain DCS input cards A Potter amp Brumfield model R10S E1Y1 J1 0K 3 2 mA DC or equal interposing relay will be mounted where the contact wires terminate in the control relay room Install cover 17 Figure 9 3 and secure with captive washer
115. ever tamper with safety devices in valves or cylinders 6 Do not store full and empty cylinders together Serious suckback can occur when an empty cylinder is attached to a pres surized system 7 No part of cylinder should be subjected to a temperature higher than 52 C 125 F A flame should never be permitted to come in contact with any part of a compressed gas cylinder 8 Do not place cylinders where they may become part of an electric circuit When electric arc welding precautions must be taken to prevent striking an arc against the cylinder P 22 Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 SECTION 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 DESCRIPTION AND SPECIFICATIONS COMPONENT CHECKLIST OF TYPICAL SYSTEM PACKAGE CONTENTS A typical Rosemount Hazardous Area Oxymitter 4000 Oxygen 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 first page of this manual 1 N IN C The Oxymitter 4000 is offered in both hazardous area and general purpose configurations The hazardous area version has special markings on the approval label The general purpose version does not If you received the general purpose version ensure you do not install it in a potentially explo sive atmosphere Also use the product matrix
116. ew and a Hazardous Area Oxymitter 4000 with an LOI lower view The upper view also shows J1 and test points TP1 through TP6 located on the microprocessor board below the membrane keypad or the LOI module Membrane Keypad When Fault 3 is detected the HEATER T C LED flashes three times pauses for three seconds and repeats 1 Using a multimeter measure the volt age from TP3 to TP4 If the reading is negative the thermocouple wiring is reversed 2 Check red and yellow wires in the J1 connector for the proper placement 3 If the wiring is correct the fault is in the PC board See paragraph 4c Electronic Assembly Replacement LOI When Fault 3 is detected the LOI displays the O2 T C Reversed message 1 Remove power Unscrew and remove the LOI module from the electronic assembly 2 Reconnect power to the Oxymitter 4000 3 Perform the diagnostic steps 1 through 3 shown for the membrane keypad Troubleshooting 8 7 Instruction Manual IB 106 340C Rev 4 1 July 2004 ROSEMOUNT HEATERT C O DIAGNOSTIC HEATER SW2 ALARMS O2 CEI L CALIBRATION o CALIBRATION RECOMMENDED O O2CELL mV TP1 TEST O2 CELL mV c POINTS HEATER T C L HEATERT C pace CAL TEST GAS PROCESS O2
117. ey also doubles as an Enter key once numbers are entered and when the cursor is moved to it s left most position The new data entry value will appear in the top line of the LOI display once it s accepted The blue key bottom left acts as a selector when choosing from among a number of menu items This key also will move the cursor to the right when entering numbers Up Down keys to the left side of the keypad are used to increment up and down when selecting from a series of menu picks They are also used for incrementing values up and down for data input Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 6 5 O2 2 59 LK normal Use Z pattern touch command to unlock menu LOI MENU TREE This LOI menu for the Oxymitter 4000 is shown in Figure 6 4 This menu tree is specific to the Oxymitter 4000 The menu tree will assist in navigating the LOI Temperatures Voltages Output Values SENSOR DATA Start Calib Abort Calib Cal Constants Cal Status NOTE CALIBRATION CONTINUED ON SHEET 2 Current Calib Failed Calib Instruction Manual IB 106 340C Rev 4 1 July 2004 Menu items in normal text display information only Menu Items in italics permit data entry Menu items in bold text are procedures O2 Temp O2 Temp MAX Board Temp Board Temp MAX O2 Sensor O2 Se
118. f repeating blinks define the problem A con densed table of the errors and the correspond ing blink codes can be found on the inside right cover of the electronics housing Table 8 1 also identifies the blink code and fault status of each LED as well as the output of the 4 20 mA signal line and a fault number that corresponds to the troubleshooting instructions provided in this section For a Hazardous Area Oxymitter 4000 with the optional LOI alarm messages are displayed on the LOI display window when the alarm status display is accessed via the LOI menu A listing of the alarm fault messages and the related fault status descriptions and fault numbers are shown in Table 8 2 Troubleshooting 8 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Table 8 1 Diagnostic Unit Alarm Fault Definitions Membrane Keypad Only HEATER T C HEATER CELL CALIBRATION OPEN SHORTED REVERSED A D COMM ERROR OPEN HIGH HIGH TEMP HIGH CASE TEMP LOW TEMP HIGH TEMP HIGH mV BAD EEPROM CORRUPT INVALID SLOPE INVALID CONSTANT LAST CALIBRATION FAILED CALIBRATION RECOMMENDED Dependent on position 3 of SW2 Dependent on position 3 of SW2 Dependent on position 3 of SW2 Dependent on position 3 of SW2 Dependent on position of SW2 Dependent on position 3 of SW2 Dependent on position 3 of SW2 Dependent on position 3 of SW2 Dependent on position of SW2 Dependent on p
119. for more information d HART Use the HART Communi cator to access the O CALIBRATE menu and perform the O CAL method Refer to paragraph 7 7 for the complete calibration procedure e AMS Refer to AMS documentation for more information f Remote Contact Initiate a calibra tion from a remote location via the remote contact input connection provided by an IMPS 4000 or SPS 4000 Refer to the documentation available for the control system in use for more information Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Once a semi automatic calibration is initiated by any of the methods previ ously described the Hazardous Area Oxymitter 400075 CALIBRATION RECOMMENDED alarm signals an IMPS 4000 or SPS 4000 to initiate a calibration The sequencer sends an in cal signal to the control room so that any automatic control loops can be placed in manual Then the sequencer begins to sequence the calibration gases Manual Calibration with Membrane Keypad Manual calibrations must be performed at the Hazardous Area Oxymitter 4000 site and will require operator intervention throughout the process Manual calibration instruc tions in condensed form can also be found on the inside of the right elec tronics housing cover See Use the following procedure to perform a manual calibration a Place control loop in manual Verify the cal
120. g 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 Analytical Inc 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 that the sensor being supplied with ac power and reference air will not be subjected to component deterioration 3727 3732 07 04 Instruction Manual IB 106 340C Rev 4 1 July 2004 Emerson Process Management Rosemount Analytical Inc Process Analytic Division 1201 N Main St Orrville OH 44667 0901 T 830 682 9010 F 330 684 4434 E gas csc emersonprocess com ASIA PACIFIC Fisher Rosemount Singapore Private Ltd 1 Pandan Crescent Singapore 128461 Republic of Singapore 65 777 8211 F 65 777 0947 http www processanalytic com Rosemount Analytical Inc 2003 Hazardous Area Oxymitter 4000 Hazardous Area Oxymitter 4000 Part no Serial no Order no Fisher Rosem
121. gen gekennzeichnet die eine gef hrliche Netzspannung Spannung f hren Die Abdeckungen d rfen nur entfernt werden wenn die Versorgungsspannung unterbrochen wurde Nur geschultes Personal darf an diesen Ger ten Arbeiten ausf hren 8 Mit dem Symbol sind Ger te oder Abdeckungen gekennzeichnet in bzw unter denen hei e Teile vorhanden sind Die Abdeckungen d rfen nur entfernt werden wenn die Versorgungsspannung unterbrochen wurde Nur geschultes Personal darf an diesen Ger ten Arbeiten ausf hren Bis 45 Minuten nach dem Unterbrechen der Netzzufuhr k nnen derartig Teile noch ber eine erh hte Temperatur verf gen 9 Mit dem Symbol sind Ger te oder Abdeckungen gekennzeichnet bei denen vor dem Eingriff die entsprechenden Kapitel 1m Handbuch sorgf ltig durchgelesen werden m ssen 10 Alle in diesem Ger t verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgend aufgef hrten Standards EN61010 1 IEC417 amp ISO3864 P 8 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 IMPORTANTE Norme di sicurezza per il cablaggio e l installazione dello strumento Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell Unione Europea la cui stretta osservanza richiesta per garantire conformit alla Direttiva del Basso Voltaggio Esse si applicano anche agli stat
122. he membrane keypad or LOI Allow adequate clearance for removal of the Hazardous Area Oxymitter 4000 Figure 2 1 or Figure 2 3 CAUTION Do not allow the temperature of the Hazardous Area Oxymitter 4000 elec tronics to exceed 85 C 185 F or dam age to the unit may result b Probe Installation 1 Ensure all components are available to install the Hazardous Area Oxymitter 4000 If equipped with a ceramic dif fuser make sure the diffuser is not damaged 2 The Hazardous Area Oxymitter 4000 probe may be installed intact as it is received NOTE An abrasive shield is recommended for high velocity particulates in the flue stream such as those in coal fired boilers kilns and recovery boilers 3 Weld or bolt mounting plate Figure 2 5 onto the duct Installation 2 1 Qq31ON SASIMYSHLO SSA INN SASSAHLNAYVd NI SdHONI H LIM SHALANFTTIN 3HV SNOISNAWIG TIV 35910002 aauvad AHNSSAHd LON ANY SNH3LIVd SIF 8 NIC ISNV OL OAHNLIVANNYN S39NV 154 d3OVd 1 14 ASAHL SALON 21 SS3OOV TVAOW3H H3AOO Hazardous Area Oxymitter 4000 Instruction Manual IB 106 340C Rev 4 1 July 2004
123. i non appartenenti all Unione Europea salvo quanto disposto dalle vigenti normative locali o nazionali 1 Collegamenti di terra idonei devono essere eseguiti per tutti 1 punti di messa a terra interni ed esterni dove previsti 2 Dopo Vinstallazione o la localizzazione dei guasti assicurarsi che tutti 1 coperchi di protezione siano stati collocati e le messa a terra siano collegate L integrit di ciscun morsetto di terra deve essere costantemente garantita 3 Icavidi alimentazione della rete devono essere secondo disposizioni IEC227 o IEC245 4 L intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore a 75 5 dimensioni di tutti 1 connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggio al cavo 6 Per garantire un sicuro funzionamento dello strumento 11 collegamento alla rete di alimentazione principale dovr essere eseguita tramite interruttore automatico min 10A in grado di disattivare tutti 1 conduttori di circuito in caso di guasto Tale interruttore dovr inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione dell alimentazione chiaramente identificabile Gli interruttori dovranno essere conformi agli standard riconosciuti quali IEC947 7 simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza di elevati voltaggi Tali coperchi di protezione devono essere rimossi esclusivame
124. ibration gas parame ters are correct per paragraph c If performing a manual calibration with the CALIBRATION RECOM MENDED LED off and the CAL LED off start at step 1 d If performing a manual calibration with the CALIBRATION RECOM MENDED LED on and the CAL LED on start at step 2 1 Push the CAL key The CALI BRATION RECOMMENDED LED will come on and the CAL LED will be on solid If a multimeter is attached across 5 TP6 the reading will display the percentage of oxygen seen by the cell Maintenance and Service 9 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 MANUAL ALARMS CALIBRATION PLACE CONTROL LOOP LED FLASHES STATUS GATED ON MN GO TO STEP 2 HEATER TC 5 REVERSED 1 FU C LED ON i AID COMM 2 PUSH CAL ERROR CAL LED FLASH 1 OPEN 3 APPLY TG1 MO ous PUSH CAL HEATER ME 4 LOW TEMP 5 REMOVE TG1 amp APPLY TG2 2 SEN PO SAL LED ON SOLID 02 CELL 3 DAD 6 2FLASH VALID CAL 4 3 FLASH INVALID CAL 1 nb SLOPE 7 REMOVE TG2 CALIBRATION 2 CONSTANT g PU GAL LED ON FOR AE CAL LED OFF SW2 DIP SWITCH HART LOCAL 0 10 0 25 4mA 20mA NOT USED NOT USED 29770005 Figure 9 2 Inside Right Cover 2 Push the CAL key The CALI Hazardous Area Oxymitter BRATION RECOMMENDED 4000 has t
125. ibration handshake CALIBRATION RECOMMENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4000 The default condition for a Hazardous Area Oxymitter 4000 without an IMPS 4000 or SPS 4000 The default condition for a Hazardous Area Oxymitter 4000 with an IMPS 4000 or SPS 4000 Configuration with Keypad Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 3 3 RECOMMENDED CONFIGURATION a 4 20 mA Signal Upon Critical Alarm Rosemount recommends that the factory default be utilized The 4 20 mA signal will go to the 3 5 mA level upon any critical alarm which will cause the Os reading to be unusable Customer can also select 21 6 mA as the failure setting if normal opera tions cause readings to go below the zero 3 5 mA level If the measurement is being utilized as part of an automatic control loop the loop should be placed into manual upon this failure event or other appropriate action should be taken Calibration Rosemount recommends utilizing an auto calibration system actuated by the calibra tion recommended diagnostic New cells may operate for more than a year but older cells may require recalibration every few weeks as they near the end of their life This strategy ensures that the reading is always accurate and eliminates many unnecessary calibrations based on calendar days or weeks since previous calib
126. in Table 1 1 at the end of this section to compare your order num ber 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 Oxymitter 4000 Ensure the features and options specified by your order number are on or included with the unit SYSTEM OVERVIEW a Scope This Instruction Bulletin provides the infor mation needed to install start up operate and maintain the Hazardous Area Oxymitter 4000 Signal conditioning electronics out puts a 4 20 mA signal representing an O value and provides a membrane keypad or full function Local Operator Interface LOI for setup calibration and diagnostics This same information plus additional details can be accessed with the Rosemount Analytical Inc A Division of Emerson Process Management HART Model 275 375 handheld communi cator or Asset Management Solutions AMS software System Description The Hazardous Area Oxymitter 4000 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 probe is permanently posi tioned within an exhaust duct or stack and performs its task without the use of a sampling system The equipment measures oxygen percent age by reading the voltage developed across a heated electrochemical cell which consists of a small yttria stabilized zirconia disc Both sides of the di
127. ion element is changed reset the calibration gas flowme ter to 5 scfh and calibrate the Hazardous Area Oxymitter 4000 To change the diffu sion element refer to paragraph 9 4il Three types of calibration methods are available automatic semi automatic and manual NOTE A calibration can be aborted any time during the process Press the CAL key Figure 9 1 on the Hazardous Area Oxymitter 4000 keypad three times within three seconds or abort via the LOI HART AMS or an IMPS 4000 An aborted calibration will retain the values of the previous good calibration Maintenance and Service 9 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 WARNING The HART option is not protected by energy limiting barriers It must not be interfaced from within the hazardous area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case even when using the intrinsically safe version of the hand Hazardous Area Oxymitter 4000 ROSEMOUNT DIAGNOSTIC HEATER ALARMS O2 CELL c CALIBRATION CALIBRATION RECOMMENDED held communicator 1 N IN C Do not install an IMPS 4000 or SPS 4000 within the hazardous area Installing the unit in a potentially explosive environment could cause serious injury or death and equipment damage Ensure the sequencer is installed in a safe area 1 Automatic Calib
128. ive erosion Examine the ceramic diffusion element whenever removing the probe for any purpose Replace if damaged Damage to the diffusion element may become apparent during calibration Compare probe response with previous response broken diffusion element will cause a slower response to cali bration gas Hex wrenches needed to remove setscrews and socket head screws in the following procedure are available as part of a Probe Disassembly Kit Table 11 1 2 Replacement Procedure a Follow the instructions given in paragraph 9 4a to remove the Hazardous Area Oxymitter 4000 from the stack or duct Loosen setscrews Figure 9 10 using hex wrench from Probe Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Disassembly Kit Table 11 1 and remove vee deflector Inspect setscrews If damaged replace with stainless setscrews coated with anti seize compound On systems equipped with abra sive shield remove dual dust seal gaskets d Use spanner wrenches from the Probe Disassembly Kit 11 1 to turn hub free from retainer e Put the hub in vise Break out old ceramic diffusion element with chisel along cement line and 9 5 mm 3 8 in pin punch through cement port f Break out remaining ceramic diffu sion element by tapping lightly around hub with hammer Clean grooves with pointed tool if neces sary g Replace
129. kerhetsh ljen och s kerhetsjord terplaceras Samtliga jordterminaler m ste h llas obrutna hela tiden 3 Matningsspanningens kabel m ste verensst mma med f reskrifterna 1 IEC227 eller IEC245 4 kablage skall vara l mpligt f r anv ndning 1 en omgivningstemperatur h gre n 75 C 5 Alla kabelf rskruvningar som anv nds skall ha inre dimensioner som motsvarar adekvat kabelf rankring 6 F r att s kerst lla s ker drift av denna utrustning skall anslutning till huvudstr mmen endast g ras genom en s kring min 10 som skall frankoppla alla str mf rande kretsar n r n got fel uppst r S kringen kan ven ha en mekanisk fr nskiljare Om s inte r fallet m ste ett annat f rfarande f r att fr nskilja utrustningen fr n str mf rs rjning tillhandah llas och klart framg genom markering S kring eller omkopplare m ste verensst mma med en g llande standard s som t ex IEC947 7 D r utrustning eller h lje r markerad med vidstaende symbol f religgerisk f r livsfarlig sp nning 1 n rheten Dessa h ljen f r endast avl gsnas n r str mmen eJ r ansluten till utrustningen och d endast av utbildad servicepersonal 8 Nar utrustning eller h lje r markerad med vidst ende symbol f religger risk f r br nnskada vid kontakt med uppv rmd yta Dessa h ljen f r endast avl gsnas av utbildad servicepersonal n r str mmen kopplats fr n utrustningen Vissa ytor kan vara mycket varma att vidr ra
130. l Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 f Once the cell is up to operating tempera ture the O percentage can be read 1 To access TP5 and TP6 under the LOI module Figure 4 2 power down the Oxymitter 4000 and remove the LOI module Attach alligator leads from a multimeter across TP5 and TP6 Instruction Manual IB 106 340C Rev 4 1 July 2004 ess gases can now be monitored When a calibration has been initiated the value at TP5 and TP6 is the seen by the cell Oxygen levels as seen on the multimeter are 8 0 O gt 8 0 VDC 0 4 O gt 0 4 VDC Figure 3 2 Install the LOI module and power up the Oxymitter 4000 Allow time for the cell to reach operating 2 HART AMS 3 Model 751 The loop driven LCD temperature The calibration and proc display 0 4 20 n 2 IS INTERNALLY HART O RANGE SET BY HART AMS POWERED FROM 0 TO 40 O HART LOCAL DEFAULT LOCAL O RANGE SET BY POS 2 10 Oy 10 O 0 TO 25 25 RANGE 35mA 21 6 mA 3 5 mA 21 6 mA WHEN ALARM EXISTS OR ON POWER UP CURRENT 220V 115 V OUTPUT GOES TO THIS VALUE DEFAULT 4 20 mA REQUIRES POSITION EXTERNAL POWER EX FACTORY NOTE THE 115 V OPTION AT SWITCH SW2 POSITION 4 IS ACTIVE ONLY WHEN THE HEATER VOLTAGE OPTION IS SET TO MANUAL IN THE SOFTWARE
131. larm modes The factory default is mode 5 for Hazardous Area Oxymitter 4000 units without an IMPS 4000 or SPS 4000 In this mode the output will signal when a unit alarm or a CALIBRA TION RECOMMENDED indication occurs Calibration Handshake Signal If using an optional IMPS 4000 or SPS 4000 the logic I O must be configured for calibration handshaking Of the ten modes in only modes 8 and 9 are con figured for calibration handshaking For a Hazardous Area Oxymitter 4000 with an IMPS 4000 or an SPS 4000 the factory sets the default to mode 8 In this mode the logic I O will be used to communicate between the Hazardous Area Oxymitter 4000 and the sequencer and to signal the sequencer when a CALIBRATION REC OMMENDED indication occurs Table 4 1 Logic I O Configuration as set at HART AMS or LOI The unit is configured for a High AC Impedance CALIBRATION RECOMMENDED The unit is configured for both a Unit Alarm and a High AC Imped ance CALIBRATION RECOMMENDED The unit is configured for both a Low and High AC Imped ance CALIBRATION RECOMMENDED The unit is configured for a Unit Alarm a Low O gt and a High AC Im pedance CALIBRATION RECOMMENDED The unit is configured for a calibration handshake with IMPS 4000 or SPS 4000 CALIBRATION RECOMMENDED will initiate the calibra tion cycle The unit is configured for a calibration handshake CALIBRATION RECOMMENDED will not initiate the calibration cycle with the IMPS
132. later kan v re for varme til a ber res 1 opp til 45 minutter etter spenningsforsyning frakoblet Der hvor utstyret eller deksler er merket med symbol vennligst referer til instruksjonsmanualen for instrukser Alle grafiske symboler brukt 1 dette produktet er fra en eller flere av folgende standarder EN61010 1 IEC417 amp ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 IMPORTANTE Instru oes de seguranca para ligac o e instalacao deste aparelho As seguintes instruc es de seguranca aplicam se especificamente a todos os estados membros da UE Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tens o Relativamente aos estados que n o pertencam UE dever o cumprir igualmente a referida directiva exceptuando os casos em que a legislac o local a tiver substituido l Devem ser feitas liga es de terra apropriadas a todos os pontos de terra internos ou externos 2 Ap s a instala o ou eventual repara o devem ser recolocadas todas as tampas de seguran a e terras de protec o Deve manter se sempre a integridade de todos os terminais de terra 3 Os cabos de alimenta o el ctrica devem obedecer as exig ncias das normas IEC227 ou IEC245 4 cabos fios utilizados nas liga es el ctricas devem ser adequados para utiliza o a uma temperatur
133. librate and com municate with the Hazardous Area Oxymitter 4000 in one of three ways CAUTION Accessing the probe keypad requires opening the electronics housing Opening the electronic housing will cause the loss of ALL hazardous per mits Opening the electronics housing in hazardous areas may cause an ex plosion resulting in loss of property severe personal injury or death It may be required to get a hot work permit from your company safety offi cer before opening the electronic housing a Membrane Keypad The mem brane keypad housed within the right side of the electronics hous ing provides fault indication by way of flashing LEDs Calibration can be performed from the mem brane keypad LOI The optional LOI takes the place of the membrane keypad and allows local communication with the electronics Refer to Sec tion 4 for more information Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 VV AA EZ NEN The HART option is not protected by energy limiting barriers It must not be interfaced from within the hazardous area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case even when using the in trinsically safe version of the handheld communicator c Optional HART Interface The Hazardous Area Oxymitter 4000 s 4 20 mA output line transmits an
134. licon Dioxide CHEMICAL NAME N A CHEMICAL FORMULA N A MANUFACTURER S NAME AND ADDRESS Watlow Columbia 573 474 9402 2101 Pennsylvania Drive 573 814 1300 ext 5170 Columbia MO 65202 HEALTH HAZARD SUMMARY WARNING e Possible cancer hazard based on tests with laboratory animals e May be irritating to skin eyes and respiratory tract e May be harmful if inhaled e Cristobalite crystalline silica formed at high temperatures above 1800 F can cause severe respiratory disease Rosemount Analytical Inc A Division of Emerson Process Management P 15 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 SECTION Il PHYSICAL DATA APPEARANCE AND ODOR Cream to white colored fiber shapes With or without optional white to gray granular surface coating and or optional black surface coating SPECIFIC WEIGHT 12 25 Ib cubic foot BOILING POINT N A VOLATILES BY WT N A WATER SOLUBILITY N A SECTION Ill HAZARDOUS INGREDIENTS MATERIAL QUANTITY AND THRESHOLD EXPOSURE LIMIT VALUES Aluminosilicate vitreous 99 1 fiber cc TWA CAS No 142844 00 06 10 fibers cc CL Zirconium Silicate 0 10 5 mg cubic meter TLV Black Surface Coating 0 1 5 mg cubic meter TLV Armorphous Silica Silicon Dioxide 0 10 20 mppcf 6 mg cubic meter PEL OSHA 1978 3 gm cubic meter Respirable dust 10 mg cubic meter Intended TLV ACGIH 1984 85 Composition is a trade secret SECTION IV FIRE AND
135. ltered Termination ATEX Certification 13 Remote Electronics requires cable Standard Filtered Termination ATEX Certification 14 HART Remote Electronics requires cable Transient Protected Termination ATEX Certification HART Integral Electronics Standard Filtered Termination CSA FM Certification HART Integral Electronics Transient Protected Termination CSA FM Certification HART Remote Electronics requires cable Standard Filtered Termination CSA FM Certification HART Remote Electronics requires cable Transient Protected Termination CSA FM Certification 3 3 1 1 t Bempe 1 14 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 Table 1 1 Product Matrix Continued Operator Interface 1 Membrane Keypad HART Capable 2 Membrane Keypad HART Capable Glass Window LOI HART Capable Glass Window English Only Code Language English 2 German Italian Termination Filtering 00 No Option Specified as part of Electronic Housing Calibration Accessories 00 NoHardware SS Cal Ref Flowmeters and Ref Pressure Regulator IMPS 4000 Safe Area Only SPS 4000 Remote Mounted Safe Area Only Hazardous Area Approval 00 opecified as part of the electronics 00 NoCable
136. lts DC 0 4 O 0 4 volts DC b CAL The CAL key can 1 Initiate a calibration 2 Sequence through calibration 3 Abort the calibration NOTE Refer to MAINTENANCE AND SERVICE for calibration instructions b Model 751 Remote Powered Loop LCD Display Optional Refer to Remote Powered Loop LCD manual for calibration and operation LIGHTING SEQUENCE DURING NORMAL OPERATION 22220055 Figure 5 3 Normal Operation Rosemount Analytical Inc A Division of Emerson Process Management Startup and Operation with Keypad 5 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 5 4 Startup and Operation with Keypad Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 Instruction Manual IB 106 340C Rev 4 1 July 2004 SECTION 6 STARTUP AND OPERATION OF HAZARDOUS AREA OXYMITTER 4000 WITH LOI 6 1 POWER UP a Startup Display When power is applied to the probe the cell heater turns on It takes approximately one half hour for the cell to heat to operating temperature This condition is indicated by a warm display on the LOI Figure 6 1 This message will continue to display until the cell is up to operating temperature b Operating Display The normal operating display is the concentration The normal display is shown in Figure 6 2 c Error If there is an error condition at startup alarm message will
137. ly 736 C 1357 F The external temperature of the probe body may exceed 450 C 842 F If operating conditions also contain high oxygen levels and com bustible gases the Hazardous Area Oxymitter 4000 may self ignite If necessary the O range can be con figured from 0 to 40 To select values within this range set SW2 position 1 to HART and then enter the range via HART AMS Do not change SW2 position 1 to LOCAL unless you want to operate in the range specified by SW2 position 2 3 Position 3 determines the output at startup or at an alarm The settings are 3 5 mA or 21 6 mA The factory setting is 3 5 mA At startup the current at the analog output is 3 5 mA or 21 6 mA 4 Position 4 can be used to set the heater for 115 or 220 Vac operation This switch is functional only when the software is set for manual voltage selection Auto Tune No Otherwise the internal electronics auto detect the input line voltage and sets the heater voltage accordingly Auto Tune Yes f Once the cell is up to operating tempera ture the O percentage can be read Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 1 Access 5 and TP6 next to the mem brane keypad Attach a multimeter across TP5 and TP6 The calibration and process gases can now be moni tored Pressing the INC or DEC once will cause the output to switch from the process gas to the calibration gas
138. ment Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 HAZARDOUS AREA OXYMITTER 4000 When the cell is at operating temperature and there are unequal oxygen concentra tions 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 Oxymitter 4000 to provide exceptional sensitivity at low oxygen concentrations The Hazardous Area Oxymitter 4000 meas ures net oxygen concentration in the pres ence 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 IMPS 4000 1 TO 4 PROBES MUST BE INSTALLED analysis will in general indicate a lower IN A SAFE AREA SPS 4000 percentage of oxygen The difference will OR BE X OR Z PURGED 1 PROBE be proportional to the water content of the BY THE CUSTOMER MUST BE INSTALLED IN A SAFE AREA sampled gas stream System Configuration Hazardous Area Oxymitter 4000 units ar
139. n electrica peligrosa dicho aloJamtento solamente se abrira una vez que se haya Interrumpido la alimentacion electrica al equipo asimismo la intervencion sera llevada cabo por personal entrenado para estas labores Cuando las tapas o el equipo Impreso el simbolo hay superficies con alta temperatura por tanto se abrira una vez que se haya interrumpido la alimentacion electrica al equipo por personal entrenado para estas labores y al menos se esperara unos 45 minutos para enfriar las superficies calientes Cuando el equipo o la tapa lleve impreso el simbolo se consultara el manual de instrucciones Todos los simbolos graficos usados en esta hoja estan de acuerdo a las siguientes normas EN61010 1 IEC417 amp ISO 3864 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 S kerhetsf reskrifter for kablage och installation av denna apparat Foljande sakerhetsforeskrifter ar tillampliga for samtliga EU medlemsl nder De skall f ljas 1 varje avseende for att verensst mma med Lagspannings direktivet EU medlemsl nder skall ocks f lja nedanstaende punkter savida de inte vergrips av lokala eller nationella foreskrifter 1 Till mplig jordkontakt skall utf ras till alla jordade punkter s v l internt som externt dar sa erfordras 2 Efter installation eller fels kning skall samtliga s
140. n of Emerson Process Management Maintenance and Service 9 9 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 f Restore power to the system refer to paragraph 6 1 or 6 11 When the probe is at operating temperature calibrate the probe per paragraph 9 2 NOTE Recalibration is required whenever electronic cards or sensing cell is replaced b Replacement of Entire Electronics with Housing Hazardous Area Oxymitter 4000 with Integral Electronics 1 Follow the instructions in paragraph 9 remove the Hazardous Area Oxymitter 4000 probe from the stack or duct CAUTION Do not force the probe housing when installing or removing from the inte gral electrical barrier feedthrough Figure 9 3 Damage to the aluminum probe housing can occur 2 Remove four screws 22 Figure 9 3 and washers 21 from the probe tube assembly 23 Remove the probe tube assembly from the housing 11 3 Disconnect the heater and signal wire connectors from the mating connectors on the heater strut assembly 32 NOTE The integral electrical barrier feed through is thread locked into the elec trical housing and cannot be removed 4 Make sure the O ring 31 is in good condition Replace O ring if damaged 5 Make sure that the conduit port of the electronic housing is on the same side as the CAL and REF gas ports Install four washers 21 and screws 22 Tighten screws
141. n when using the intrin sically safe version of the handheld communicator 1 Hazardous Area Oxymitter 4000 status HART or LOCAL 2 Oxygen range 0 to 1096 O gt or 0 to 2596 to 4096 is also configur able only through HART AMS 3 The 4 20 mA signal at fault or power up 3 5 mA or 21 6 mA CAUTION Remove power from the Hazardous Area Oxymitter 4000 before changing defaults If defaults are changed under power damage to the electronics package may occur d SW1 The two settings are internally or externally powering the 4 20 mA signal The factory setting is for the 4 20 mA signal to be inter nally powered e SW2 The factory sets this switch as follows 1 Position 1 is HART LOCAL This switch setting controls the configuration of the Configuration with Keypad July 2004 Hazardous Area Oxymitter 4000 Hazardous Area Oxymitter 4000 The defaults cannot be changed via HART AMS unless the switch is in the HART position Placing SW2 position 1 in the LOCAL position forces the range to the setting of position 2 The position 1 switch must be placed in the LOCAL position or changes in SW2 position 2 will have no effect 2 Position 2 determines the range This can be set to either 0 to 10 or to 25 Os The factory setting is 0 to 10 WARNING Typically the probe s sensing cell in direct contact with the process gases is heated to approximate
142. nsor T C Board Temp IC O2 Analog O2 Analog mA mA O2 Slope O2 Constant O2 Cell Imped Pre O2 Slope Pre O2 Constant mV Idle Recommend Cal Bad O2 Slope ____ Apply Gas 1 Bad O2 Constant mV Flow Gas 1 Read Gas 1 Done Gas 1 Calib Step Apply Gas 2 Calib Time Next O2 Cal Flow Gas 2 Read Gas 2 Done Gas 2 Cal Abort Stop Gas Purge NOTE For this menu column the selections in talics are user configurable All other parameters are display only 37260017 Figure 6 4 Local Operator Interface Menu Tree Sheet 1 of 2 Rosemount Analytical Inc A Division of Emerson Process Management Startup and Operation with LOI 6 3 Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 O2 Gas 1 96 O2 Gas 2 _ 96 O2 Reset Vals Yes No O2 Out Tracks O2 Cal Intervl __ O2 Next Cal H Gas Time Sec Purge Time _ Sec Auto Calib Yes No O2 Type O2 Range O2 Alarm Level Do O2 Trim Logic Mode See Table 4 1 Low O2 Alarm See para 9 3b Input State ___ Force Output Digital O2 Slope O2 Constant O2 T90 Time Auto Tune Lockout Time Revert Time Luminance Version Checksum Build Number Build Date Test Code SW Err File SW Err Line Alarms PES PID Parameters 115 220 Reset Device Yes No Cal required after reset NOTE In column four of this menu the selections in talics are user configurable Bold text selections are procedures rel
143. nstant 8 18 Contact and Thermocouple Assembly 9 18 D Diffusion Element 2 7 9 1 9 17 Drip Loop 2 7 2 8 E EEPROM 8 16 Electrical Installation 2 8 2 11 Electrical Noise 8 2 Electrostatic Discharge 8 2 Equipment Return 10 1 Error 5 1 Rosemount Analytical Inc A Division of Emerson Process Management F Fuse 9 12 G Grounding 8 2 H HART 1 4 3 2 4 2 7 1 9 2 9 3 12 1 HART Communicator 1 1 1 2 1 4 12 1 HART Menu Tree 7 5 7 6 7 7 Hazardous Area Certifications Heater 1 5 1 13 8 9 8 11 Heater Strut Assembly 9 13 9 14 11 1 IMPS 4000 1 2 1 3 1 6 1 8 1 9 3 4 3 5 4 4 4 5 9 2 9 3 12 2 Instrument Air 1 9 2 14 Insulation 2 7 2 8 9 7 Integral Electronics 1 2 1 3 1 5 3 1 4 1 Integrated Circuits 8 2 K Keypad Membrane 4 3 6 1 L Languages 1 5 LEDs 5 1 5 2 8 2 9 4 Length 1 3 1 12 Line Voltage 1 5 1 12 2 9 2 10 2 11 2 13 Logic I O 1 8 1 12 3 4 4 4 7 4 LOI 1 4 6 1 6 4 6 6 8 4 Manual Calibration 9 3 Mechanical Installation 2 1 3 1 4 1 Membrane Keypad 1 4 4 3 5 1 6 1 9 2 Mounting Plate 1 2 2 1 2 5 2 6 2 7 N Nernst Equation 1 1 Optional Accessories 13 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 O Optional Accessories 12 1 Oxygen Range 1 12 3 2 4 2 P Power Requirements 1 13 Power Supply 1 3 Probe Disassembly Kit 11 3 Product Matrix 1 1 1 14 R Reference Air Set 1 2 2 15
144. nt Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 3 Always note the time it takes for the 2 One can calibrate the probe without cell to recover to the normal process pressurizing the cell by adjusting the value after the cal gas is removed As calibration gas flow rate downward the diffuser plugs this recovery time before calibration For instance say will get longer and longer Use the the process is at 3 and the first Calibration Record form provided in calibration gas is 8 Adjust the flow this manual of cal gas downward until the reading begins to migrate from 8 to lower Can calibrate a badly plugged diffuser values indicating that process gases are now mixing in with the calibration 1 It may not be possible to immediately gases replace a plugged diffuser while the process is on line 3 Adjust the flow rate back up until this mixing is just eliminated Calibrate at this flow rate Replace the diffuser at the first opportunity Rosemount Analytical Inc A Division of Emerson Process Management Troubleshooting 8 21 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Calibration Record For Rosemount Analytical In Situ Probe Probe Serial Number Probe Tag Number Probe Location Date Placed Into Service Date Slope Constant Impedance Responseiitia Responsefina Notes R
145. nt to vary this depending upon the length of cali bration gas tubing runs 8 Purge Time Used if the output is selected to hold the last value during calibration After the second cal gas is removed how long until the sensor comes back to the normal process reading and the 4 20 mA signal can be released 9 Auto Calib Select Yes if an SPS or IMPS autocalibration system is part of the system b SYSTEM Input Output 1 Analog Pertaining to the analog 4 20 mA signal representing a O2 Type 4 20 mA signal may be configured to increase with increasing or the reverse b O2 Range Upper range is user selectable c O2 Alarm Level User can config ure the digital output to alarm ata given O level d Do O2 Trim Procedure for cali brating the 4 20 mA signal to a precision mA source Procedure is intuitive 2 Digital A bi directional logic signal may be configured as an alarm or as a calibration handshake signal a Logic I O Mode One of 9 different sets of conditions can be set for the digital signal See Table 8 2 Low O2 Alarm If any of the con ditions noted above include a low process alarm set the value here Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Input State Notes the current condition of the bi directional digital signal d For
146. nte da personale qualificato dopo aver tolto alimentazione allo strumento 8 simbolo riportato sullo strumento o sui coperchi di protezione indica rischio di contatto con superfici ad alta temperatura Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato dopo aver tolto alimentazione allo strumento Alcune superfici possono mantenere temperature elevate per oltre 45 minuti 9 Selo strumento o il coperchio di protezione riportano il simbolo fare riferimento alle istruzioni del manuale Operatore 10 Tutti 1 simboli grafici utilizzati In questo prodotto sono previsti da uno o pi dei seguenti standard EN61010 1 IEC417 e ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management P 9 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 VIKTIG Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret F lgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i E S avtalen Instruksjonene skal f lges n ye slik at installasjonen blir i henhold til lavspenningsdirektivet Den b r ogs f lges i andre land med mindre annet er spesifisert av lokale eller nasjonale standarder l 2 10 10 Passende Jordforbindelser m tilkobles alle Jordingspunkter interne og eksterne hvor disse forefinnes Etter installasjon eller feilsgking skal alle sikkerhetsdeksler og Jordforbindelser reetableres
147. o align the hole on the back plate of the strut with the calibration gas line When the hole and the calibration gas line are aligned cor rectly the strut will slide in the rest of the way Maintenance and Service 10 11 12 13 14 15 As the strut installation nears comple tion install the guide rod into the cali bration gas tube to assist in guiding the calibration gas tube through the hole in the end of the strut Push down on the back plate of the strut to make sure you have spring tension and then install the strut pres sure clamp 34 on the back plate Install gas port fittings 29 in the CAL REF and VENT ports Replace the CAL and REF gas silicon tubes 34 and tube clamps 33 Install the entire electronics per para graph steps 4 and 5 Follow the instructions in paragraph 2 1b to install the Hazardous Area Oxymitter 4000 into the stack or duct Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 WARNING When working on this equipment on the laboratory bench be aware that the Hazardous Area Oxymitter 4000 probe tube and flame arrestor hub can be hot up to 300 C 572 F in the region of the probe heater h Cell Replacement This paragraph covers cell replacement Do not attempt to replace the cell until all other possibilities for poor performance have been considered If cell replacement is needed order th
148. o switches that configure Hazardous Area Oxymitter 4000 outputs Figure 4 2 To access these switches the LOI module must be removed SW1 determines if the 4 20 mA signal is internally or externally powered SW2 determines 3 N IN HART option is not protected energy limiting barriers It must not be interfaced from within the hazardous area The 4 20 mA cables should be routed and the connections made out side the hazardous area Note that this is the case even when using the intrin sically safe version of the handheld communicator setting controls the configuration of the Hazardous Area Oxymitter 4000 The defaults cannot be changed via HART AMS or the LOI unless the switch is in the HART position Placing SW2 position 1 in the LOCAL position forces the range to the setting of position 2 The position 1 switch must be in the LOCAL position or changes in SW2 position 2 will have no effect Position 2 determines the range This can be set to either 0 to 10 or 0 to 25 Os The factory setting is to 10 1 N IN C Typically the probe s sensing cell in direct contact with the process gases is heated to approximately 736 C 1357 F The external temperature of 1 Hazardous Area Oxymitter 4000 the probe body may exceed 450 C status HART or LOCAL 842 F If operating conditions also contain high oxygen levels and com 2 Oxygen range 0 to 10 O gt or 0
149. obes a One contact closure per probe from the control room to the SPS 4000 or IMPS 4000 for calibration initiate One contact output per probe from the SPS 4000 or IMPS 4000 to the control room for in calibration notification One contact output per probe from the SPS 4000 or IMPS 4000 to the control room for calibration failed notification Includes output from pressure switch indicating cal gas bottles empty Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 2 Additional IMPS 4000 Alarm Contacts a One contact per IMPS 4000 for low calibration gas flowing b One contact per IMPS 4000 for high calibration gas flowing NOTE The 4 20 mA signal can be configured to respond normally during any cali bration or can be configured to hold the last value upon the initiation of calibration Factory default is for the 4 20 mA signal to operate normally throughout calibration NOTE Holding the last O value may be useful if several probes are being averaged for the purpose of automatic control Unless several probes are being aver aged always place any control loops using the signal into manual prior to calibrating IDENTIFYING AND CORRECTING ALARM INDICATIONS For a Hazardous Area Oxymitter 4000 with a membrane keypad faults are indicated by four diagnostic or unit alarm LEDs A pattern o
150. on through the glass window There is no need to open the instrument in bad weather or in hazardous areas in order to access the electronics It should be noted that the Hazardous Area Oxymitter 4000 also utilizes HART commu nications permitting access to all instrument functionality anywhere the 4 20 mA signal terminates via a HART model 275 375 handheld communicator b Lockout The Local Operator Interface LOI has a lockout feature that prevents nuisance actuation by someone brushing against the glass window raindrops dirt insects etc This lockout mode is automatically estab lished when no buttons are pushed for 30 seconds default This countdown to lock out is configurable In order to unlock the display input a pattern First push the top left gray arrow then the top right followed by the bottom left and finally the bottom right The LK notation in the upper right corner of the display will now disappear Push the gray arrow at the top left hand corner once more to enter into the menu structure Once one moves deeper into the menu structure additional time is provided to the user so that the lockout initiation does not become a nuisance This additional revert time is defaulted at one hour and is also user con figurable LOI KEY DESIGNATIONS The gray key top left key will move one level higher in the menu structure When entering numbers this key will move the cursor to the left This k
151. onnel Where equipment or covers are marked with the symbol to the right there is a danger from hot surfaces beneath These covers should only be re moved by trained service personnel when power is removed from the equipment Certain surfaces may remain hot to the touch Where equipment or covers are marked with the symbol to the right refer to the Operator Manual for instructions 10 All graphical symbols used in this product are from one or more of the fol lowing standards EN61010 1 IEC417 and ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 BELANGRIJK Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten Hier moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn Low Voltage Directive te verzekeren Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften l Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten intern en extern 2 installatie of controle moeten alle veiligheidsdeksels en aardingen terug geplaatst worden Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven 3 Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC
152. or snubber diffusion as sembly is satisfactory for most applications This element is also available with a dust seal for use with an abrasive shield c Abrasive Shield Assembly The abrasive shield assembly Figure 1 11 is a stainless steel tube that surrounds the probe assembly The shield protects against particle abrasion and condensations Figure 1 9 Flame Arrestor Ceramic Diffusion provides a guide for ease of insertion and Assembly acts as a position support especially for longer probes The abrasive shield assembly uses a modified diffusor and vee deflector assembly fitted with dual dust seal packing 36220005 1 10 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 A 187 A 187 INSIDE 0 FOR SMOOTH ROUNDED EDGE ON A BOTH ENDS OF CHAMFER 45 MIN B 6 00 E LO CN lt SKIN CUT FACE FOR 90 VIEW A VIEW B 0 0 75 THRU 4 PLS EQ SP ON 4 75 NOTES WELD ON BOTH SIDES WITH EXPANDING CHILL BLOCK JA BEFORE WELDING BUTT ITEM 2 WITH ITEM 1 AS SHOWN Z DIA ON A 7 50 DIA B C REF 37270015 Figure 1 11 Abrasive Shield Assembly NOTE In highly abrasive applications rotate the shield 90 degrees at normal service intervals to present a new wear surface to the abrasiv
153. osition 3 of SW2 Track Dependent on position 3 of SW2 Self Clearing NO NO Critical alarm conditions will render the O2 measurement as unusable and any of these events will cause the 4 20 mA signal to go to a user selectable limit of 3 5 mA or 21 6 mA position 3 of SW2 Factory default value is 3 5 mA Alarms which are not self clearing will require recycling of power to the electronics The CALIBRATION RECOMMENDED alarm flashes the Calibration Recommended alarm LED on the opera tor s keypad Message O2 T C OPEN O2 T C SHORTED O2 T C REVERSED ADC ERROR O2 HEATER OPEN VERY HI O2 TEMP BOARD TEMP HI O2 TEMP LOW O2 TEMP HI O2 CELL OPEN O2 CELL BAD EEPROM CORRUP CALIB FAILED LINE FREQ ERROR 8 4 Troubleshooting Table 8 2 Diagnostic Unit Alarm Fault Definitions LOI HEATER T C OPEN 7 O2 CELL FAILED 11 13 14 EEPROM FAILED LAST CALIBRATION FAILED INCORRECT INPUT LINE FREQUENCY DETECTED ON POWER UP Self Clearing YES YE _ _ Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 ROSEMOUNT HEATERT C DIAGNOSTIC HEATER SW2 ALARMS O2 CELL o CALIBRATION o CALIBRATION RECOMMENDED O O2CELLmV 1 TEST O2 CELL mv 2 m POINTS HEATER Ps
154. oughly 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 WARNING CAUTION Highlights an operation or maintenance Highlights an operation or maintenance procedure practice condition state procedure practice condition state ment etc If not strictly observed could ment etc If not strictly observed could result in injury death or long term result in damage to or destruction of health hazards of personnel equipment or loss of effectiveness NOTE Highlights an essential operating procedure condition or statement EARTH GROUND TERMINAL PROTECTIVE CONDUCTOR TERMINAL N RISK OF ELECTRICAL SHOCK N WARNING REFER TO INSTRUCTION BULLETIN NOTE TO USERS The number in the lower right corner of each illustration in this publication is a manual illus tration number It is not a part number and is not related to the illustration in any technical manner Rosemount Analytical Inc A Division of Emerson Process Management P 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 P 2 Hazardous Area Oxymitter 4000 IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states They should be strictly adhered to in order to ass
155. ount GmbH amp Co Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884209 EUROBPE MIDDLE EAST AFRICA Fisher Rosemount Ltd Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 LATIN AMERICA Fisher Rosemount Av das Americas 3333 sala 1004 Rio de Janeiro RJ Brazil 22631 003 T 55 21 2431 1882 EMERSON
156. ower before connecting the unit to the power supply WARNING Install all protective equipment covers and safety ground leads after installa tion Failure to install covers and ground leads could result in serious injury or death 1 N IN meet the Safety Requirements of IEC 1010 EC requirement and ensure safe operation of this equipment con nection to the main electrical power supply must be made through a circuit breaker min 10 A which will discon nect all current carrying conductors during a fault situation This circuit breaker should also include a me chanically 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 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 1 N IN probe and probe abrasive shield are heavy Use proper lifting and car rying procedures to avoid personnel injury WARNING To maintain explosion proof protec tion all cable entry devices and blanking elements for unused aper tures must be certified flameproof suitable for the conditions of use and be properly installed a Remove screw 18 Figure 9 4 cover lock 19 captive washer 20 and left side blind cover 17 from the remote el
157. ower supply board Make sure the connector is secure 11 Holding the J1 connector leads slide the electronic assembly the rest of the way into the housing Seat the electronic assembly on the mating connector pins 12 Gently try to rotate the electronic assembly to check for full seating If the electronic assembly rotates remove the assembly and repeat step 11 13 Reconnect the J1 connector to the microprocessor board Figure 9 5 Ensure the connector is secure 14 Tighten the three captive screws 10 Figure 9 3Jor Figure 9 4 the top of the microprocessor board 5 Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 15 Replace right housing cover 1 9 3 make sure it is tight Secure the cover using captive washer 20 cover lock 19 and screw 18 16 Install and tighten cover 1 make sure itis tight Secure the cover using cap tive washer 20 cover lock 19 and screw 18 WNA N IN C When working on this equipment on the laboratory bench be aware that the Hazardous Area Oxymitter 4000 probe tube and flame arrestor hub can be hot up to 300 C 572 F in the region of the probe heater f Entire Probe Replacement Excluding Electronics Do not attempt to replace the probe until all other possibilities for poor performance have been considered If probe replacement is needed see Table 11 1 for part numbers
158. p 2B EMERGENCY FIRST AID PROCEDURES EYE CONTACT Flush eyes immediately with large amounts of water for approximately 15 minutes Eye lids should be held away from the eyeball to insure thorough rinsing Do not rub eyes Get medical attention if irritation persists INHALATION Remove person from source of exposure and move to fresh air Some people may be sensitive to fiber induced irritation of the respiratory tract If symptoms such as shortness of breath coughing wheezing or chest pain develop seek medical attention If person experiences continued breathing difficulties administer oxygen until medical assistance can be rendered INGESTION Do not induce vomiting Get medical attention 1f irritation persists SKIN CONTACT Do not rub or scratch exposed skin Wash area of contact thoroughly with soap and water Using a skin cream or lotion after washing may be helpful Get medical attention if irritation persists SECTION VI REACTIVITY DATA STABILITY CONDITIONS TO AVOID Stable under normal conditions of use HAZARDOUS POL YMERIZATION CONDITIONS TO AVOID N A INCOMPATIBILITY MATERIALS TO AVOID Incompatible with hydrofluoric acid and concentrated alkali HAZARDOUS DECOMPOSITION PRODUCTS N A P 18 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 SECTION VII SPILL OR LEAK PROCEDURES STEPS TO BE TAKEN IF MATE
159. p Gas Hit E when ready 5 Remove the second calibration gas and cap off the calibration gas port Then touch the Enter arrow to indicate completion The timer is activated and the LOI displays Purgexxxxs The default purge time is three min utes When the gas purge timer times out the Oxymitter 4000 begins to read the process Os b Abort Calibration Exits the calibration After calibration gases are removed and the purge times out the instrument goes back to normal operational mode 9 6 Maintenance and Service Hazardous Area Oxymitter 4000 Cal Constants Results of the Calibration Current calibration If the calibration passed these values will be updated Log these values onto the calibration log sheet supplied If the process has high levels of particulate the response back to the process after cal gas is also removed 2 Previous Calibration Values from the prior good calibration 3 Failed Calibration Bad calibration values are not loaded into the elec tronics d Calibration Status Calibration Step The current step in an active calibration procedure 2 Calibration Time Time until the next scheduled calibration 3 Next O2 Cal Time until the next O calibration if different than the next scheduled calibration Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 9 4 HAZARDOUS AREA OXYMITTER 4000
160. pedance CALIBRATION RECOMMENDED lt The unit is configured for both a Unit Alarm and a High AC Imped ance CALIBRATION RECOMMENDED 8 The unit is configured for both a Low and High AC Impedance CALIBRATION RECOMMENDED 7 The unit is configured for a Unit Alarm a Low O gt and a High AC Impedance CALIBRATION RECOMMENDED The unit is configured for a calibration handshake with an IMPS 4000 or SPS 4000 CALIBRATION RECOMMENDED will initiate the calibration cycle ELM The unit is configured for a calibration handshake CALIBRATION RECOM MENDED will not initiate the calibration cycle with an IMPS 4000 or SPS 4000 The default condition for a Hazardous Area Oxymitter 4000 without an IMPS 4000 or SPS 4000 The default condition for a Hazardous Area Oxymitter 4000 with an IMPS 4000 or SPS 4000 7 44 HART AMS Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 VIEW FLD DEV VARS PROCESS VARIABLES VIEW OUTPUT VARS VIEW FLD DEV mV DEVICE SETUP PV PV AO PV LRV PV URV STATUS DIAG SERVICE LOOP TEST O2 CALIBRATE CONTINUED ON SHEET 2 D A TRIM O2 value O2 cell temp CJ temp PV is PV O2 value PV rnge VIEW PV Aout PV AO SV is Cold Junct VIEW SV M oe TV is Cell VIEW TV TV mV 4V is Cell TC VIEW 4V 4V Cell mV Open T C Cell TC mV Shorted T C CJ mV Reversed T C
161. placement LOI When Fault 12 is detected the LOI displays the EEprom Corrupt message Refer to the comments and procedures in paragraphs 1 through 4 above Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 ROSEMOUNT m HEATERT G DIAGNOSTIC HEATER swe ALARMS O2CELL o L CALIBRATION CALIBRATION RECOMMENDED O2CELL mV TP1 TEST O2 CELL mv 2 POINTS HEATER TP3 e HEATERT C 4 CAL TEST GAS PROCESS O2 KEYPAD Alarms 02 Cell Bad ROSEMOUNT Eo oy LOI 37260031 Figure 8 15 Fault 13 Invalid Slope Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Fault 13 Invalid Slope igure 8 15 shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view Membrane Keypad When Fault 13 is detected the CALIBRATION LED flashes once pauses for three seconds and repeats 1 During a calibration the electronics calculates a slope value If the value of the slope is less than 35 mV dec or more than 52 mV dec the slope alarm will be active until the end of the pu
162. port 4 20 mA signal line or NiCad re charger jack in an explosive to the HART Communicator s serial port 4 20 mV signal line or NiCad re charger jack in an explosive atmosphere atmosphere Using the supplied lead set connect the 1 Ata convenient point break the analog HART Communicator in parallel with to the output 4 20 mA signal line and install Hazardous Area Oxymitter 4000 Use any the optional 250 ohm load resistor wiring termination points in the analog out 2 Plug the load resistor into the loop put 4 20 mA signal line connectors located on the rear panel of the HART Communicator AC 11 AC N 2 RL gt 2500 4 20 mA SIGNAL LINE HTE ANALOG OUTPUT DEVICE TERMINAL BLOCK LOOP CONNECTORS i 00275 0013 ONLY wO HART COMMUNICATOR LEAD SET HART COMMUNICATOR REAR PANEL mE Figure 7 1 Signal Line Connections 2 250 Ohms Load Resistance 7 2 HART AMS Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 AC L1 QD e TO 2 TERMINAL BLOCK LOOP CONNECTORS USI 00 oto HART COMMUNICATOR D HART COMMUNICATO REAR PANEL 4 20 mA SIGNAL LINE HE G Instruction Manual IB 106
163. r l appareil et doit tre signalis comme tel Disjoncteurs et interrupteurs doivent tre conformes une norme reconnue telle IEC947 Lorsque les quipements ou les capots affichent le symbole suivant cela signifie que des tensions dangereuses sont pr sentes Ces capots ne doivent tre d mont s que lorsque l alimentation est coup e et uniquement par un personnel comp tent Lorsque les quipements ou les capots affichent le symbole suivant cela signifie que des surfaces dangereusement chaudes sont pr sentes Ces capots ne doivent tre d mont s que lorsque l alimentation est coup e et uniquement par un personnel comp tent Certaines surfaces peuvent rester chaudes jusqu 45 mn Lorsque les quipements ou les capots affichent le symbole suivant se reporter au manuel d instructions Tous les symboles graphiques utilis s dans ce produit sont conformes un ou plusieurs des standards suivants EN61010 1 IEC417 amp ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management P 7 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Wichti Sicherheitshinweise f r den Anschlu und die Installation dieser Ger te Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europ ischen Gemeinschaft g ltig Sie mussen strickt eingehalten werden um der Niederspannungsrichtlinie zu gentigen Nichtmitgliedsstaaten der europ ischen Gemeinschaft sollten die n
164. r m rket med dette symbol er farlige sp ndinger normalt forekom mende bagved Disse d ksler b r kun afmonteres n r forsyningssp ndingen er frakoblet og da kun af instrueret servicepersonale Hvor udstyr eller d ksler er m rket med dette symbol forefindes meget varme overflader bagved Disse d ksler b r kun afmonteres af instrueret servicepersonale n r forsyningssp nding er frakoblet Visse overflader vil stadig v re for varme at ber re 1 op til 45 minutter efter frakobling Hvor udstyr eller d ksler er m rket med dette symbol se da 1 betjeningsmanual for instruktion Alle benyttede grafiske symboler 1 dette udstyr findes i n eller flere af f lgende standarder EN61010 1 IEC417 amp ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 BELANGRIJK Veiligheidsinstructies voor de bedrading en installatie van dit apparaat Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden Ook niet EU lidstaten dienen zich aan het volgende te houden tenzij de lokale wetgeving anders voorschrijft l Alle voorziene interne en externe aardaansluitingen dienen op adequate wijze aangesloten te worden 2 installatie onderhouds of reparatie werkzaamheden dienen alle beschermdeksels kapp
165. ragraph Heater Strut Replacement LOI When Fault 2 is detected the LOI displays the O2 T C Shorted message A 1 Remove power Unscrew and remove Alarms the LOI module from the electronic 02 T C Shorted sss ROSEMOUNT 2 Reconnect power to the Oxymitter 4000 3 Perform the diagnostic steps 1 through 4 shown for the membrane keypad LOI 37260020 Figure 8 4 Fault 2 Shorted Thermocouple 8 6 Troubleshooting Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 ROSEMOUNT HEATERT C DIAGNOSTIC HEATER O ALARMS 2 CELE CALIBRATION CALIBRATION RECOMMENDED O2CELLmV TP1 TEST O2 CELLmv 2 POINTS HEATER T C TP3 HEATER T C TP4 RED YEL GRN lt ORG NEVO I s HIGH LOW GAS GAS TEST GAS TP5 EE PR 0 O2 KEYPAD Alarms 02 T C Reversed JEE ROSEMOUNT po e LOI 37260021 Figure 8 5 Fault 3 Reversed Thermocouple Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Fault 3 Reversed Thermocouple Wiring or Faulty PC Board Figure 8 5lshows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper vi
166. ration When utilizing the SPS 4000 or IMPS 4000 consider wiring some or all associated alarm contacts 1 CALIBRATION INITIATE Contact from the control room to an SPS 4000 or IMPS 4000 one per probe provides the ability to manually initiate a calibra tion at any time from the control room Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Note that calibrations can also be initiated from a HART handheld com municator from Asset Management Solutions software or from the keypad on the Hazardos Area Oxymitter 4000 IN CALIBRATION One contact per probe provides notification to the con trol room that the calibration recom mended diagnostic has initiated automatic calibration through the SPS 4000 or IMPS 4000 If the signal is being utilized in an automatic control loop this contact should be utilized to place the control loop into manual during calibration CALIBRATION FAILED One contact per probe from an SPS 4000 or IMPS 4000 to the control room for notification that the calibration procedure failed Grouped with this alarm is an output from a pressure switch which indicates when the calibration gas bottles are empty 4 20 mA SIGNAL DURING CALIBRATION The 4 20 mA signal can be configured to respond normally during any calibration or it can be con figured to hold the last value upon the initiation of calibration
167. ration Automatic calibrations require no operator action However the calibration gases must be permanently piped to the Hazard ous Area Oxymitter 4000 an SPS 4000 or IMPS 4000 must be installed to sequence the gases and the logic I O must be set to mode 8 via HART AMS so the sequencer and Hazardous Area Oxymitter 4000 can communicate Depending on your system setup an automatic calibration can be initiated by the following methods a The Hazardous Area Oxymitter 4000 s CALIBRATION RECOM MENDED alarm signals that a calibration is required b Use the HART AMS or the LOI to enter a time since last cal CAL INTRVL parameter that will initiate an automatic calibration at a scheduled time interval in hours To configure the CAL INTRVL parameter refer to paragraph for the HART AMS or paragraph 6 5 for the LOI 9 2 Maintenance and Service O2 CELL mV TEST O2CELL mv C POINTS HEATER T C HEATER T C NC Nc CAL HIGH LOW GAS GAS TEST GAS DEC DEC PROCESS O2 e 22220067 Figure 9 1 Membrane Keypad c If using an IMPS 4000 enter time interval via the IMPS 4000 keypad that will initiate an auto matic calibration at a scheduled time interval in hours To set the CallntvX parameter of the CHANGE PRESETS display mode refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for mo
168. rd a Make sure that the calibration gas line is capped tightly between cali brations If autocal is used make sure the check valve is seating properly b If an abrasive shield is installed to protect the entire probe from particulate erosion a leak in the probe flange gasket can allow ambient air to migrate down the annular space between the probe and shield and then into the cell Always install a new probe flange gasket when re installing a probe 2 There may be a leak inside the probe itself permitting the reference air 20 95 to mix with the process gases at the cell To confirm this leak condition instrument air will need to be connected for reference Pressurize the inside reference side of the probe by plugging the reference air exhaust port with your finger for 1 minute The reading should decrease slightly If the reading increases during this test there is a leak inside the probe a Acid condensation inside the probe can degrade the red silicon tube item 38 that carries the cal gas to the cell Remove the housing 11 to inspect this hose See MAINTENANCE AND SERVICE 8 20 Troubleshooting Hazardous Area Oxymitter 4000 CORRUGATED REFERENCE AIR PROBE HEAD SEAL EXHAUST PORT Bm J
169. re information Once an automatic calibration is initi ated by any of the methods previously described the Hazardous Area Oxy mitter 4000 s CALIBRATION REC OMMENDED alarm signals an IMPS 4000 or SPS 4000 to initiate a calibra tion The sequencer sends an in cal signal to the control room so that any automatic control loops can be placed in manual Then the sequencer begins to sequence the calibration gases Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 2 Semi Automatic Calibration Semi automatic calibrations only require operator initiation However the cali bration gases must be permanently piped to the Hazardous Area Oxymitter 4000 an SPS 4000 or IMPS 4000 must be installed to sequence the gases and the logic I O must be set to mode 8 or 9 via HART AMS to allow the sequencer and the Hazardous Area Oxymitter 4000 to communicate Depending on your system setup a semi automatic calibration can be initiated by the following methods a Hazardous Area Oxymitter 4000 with membrane keypad Press the CAL key on the Hazardous Area Oxymitter 4000 keypad b Hazardous Area Oxymitter 4000 with LOI Select Start Calib from the CALIBRATION menu c IMPS 4000 Use the IMPS 4000 keypad to change the InitCalX parameter of the CHANGE PRE SETS display mode from 0000 to 0001 Refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin
170. rements of IEC 1010 EC requirement and ensure safe operation of this equipment con nection to the main electrical power supply must be made through a circuit breaker min 10 A which will discon nect all current carrying conductors during a fault situation This circuit breaker should also include a me chanically 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 WARNING The probe and probe abrasive shield are heavy Use proper lifting and car rying procedures to avoid personnel injury 1 N IN C To maintain explosion proof protec tion all cable entry devices and blanking elements for unused aper tures must be certified flameproof suitable for the conditions of use and be properly installed a Remove screw 18 Figure 9 3 cover lock 19 and captive washer 20 Remove cover 17 from terminal block 15 b Connect Line Voltage Connect the line or L1 wire to the L1 terminal and the neutral or L2 wire to the N terminal See The Hazardous Area Oxymitter 4000 automatically will configure itself for 90 250 VAC line voltage and 50 60 Hz To avoid a shock hazard the power terminal cover must be installed Rosemount Analytical Inc A Division of Emerson Process Management d Instruction Manual IB 106 340C R
171. rge Cycle 2 See paragraph Calibration Verify the calibration by carefully repeating it Ensure the calibration gases match the calibration gas parameters If you attach a multimeter to TP1 and TP2 sample gas measurements are 8 23 mV 0 4 O 85 mV 3 Power down the Hazardous Area Oxymitter 4000 and remove it from the stack 4 Replace the cell per paragraph Cell Replacement LOI When Fault 13 is detected the LOI displays the O2 Cell Bad message Refer to the comments and procedures in para graphs 1 through 4 above Troubleshooting 8 17 Instruction Manual IB 106 340C Rev 4 1 July 2004 HEATERT C DIAGNOSTIC HEATER O SW2 ALARMS O2 CELL o CALIBRATION o CALIBRATION RECOMMENDED O Q2CELLmV rP1 MEST O2 CELL mv TP2 CO POINTS HEATER TP3 HEATER T C 4 Ee EGO INC INC CAL e HIGH LOW GAS GAS TEST GAS TP5 DEG DEC PROCESS TPe O2 KEYPAD Alarms 02 Cell Bad ROSEMOUNT Eo oy LOI Figure 8 16 Fault 14 Invalid Constant 8 18 Troubleshooting 37260032 Hazardous Area Oxymitter 4000 n Fault 14 Invalid Constant igure 8 16 shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area O
172. rm of crystalline silica which can cause severe respiratory disease Pneumoco niosis The amount of cristobalite present will depend on the temperature and length of time in service See Section IX for permissible exposure levels SPECIAL TOXIC EFFECTS The existing toxicology and epidemiology data bases for RCF s are still preliminary Information will be up dated as studies are completed and reviewed The following is a review of the results to date EPIDEMIOLOGY At this time there are no known published reports demonstrating negative health outcomes of workers exposed to refractory ceramic fiber RCF Epidemiologic investigations of RCF production workers are ongoing 1 There is no evidence of any fibrotic lung disease interstitial fibrosis whatsoever on x ray 2 There is no evidence of any lung disease among those employees exposed to RCF that had never smoked 3 A statistical trend was observed in the exposed population between the duration of exposure to RCF and a decrease In some measures of pulmonary function These observations are clinically insignificant In other words if these observations were made on an individual employee the results would be interpreted as being within the normal range 4 Pleural plaques thickening along the chest wall have been observed in a small number of employees who had a long duration of employment There are several occupational and non occupational causes for pleural plaque It sho
173. rmistamiseksi t ytyy j nnitesy tt varustaa turvakytkimell min 10A joka kytkee irti kaikki j nnitesy tt johtimet vikatilanteessa Suojaan t ytyy my s sis lty mekaaninen erotuskytkin Jos ei niin j nnitesy tt on pystytt v katkaisemaan muilla keinoilla ja merkitt v siten ett se tunnistetaan sellaiseksi Turvakytkimien tai kat kaisimien t ytyy t ytt IEC947 standardin vaatimukset n kyvyydest Mik li laite tai kosketussuoja on merkitty t ll merkill on merkinn n takana tai alla hengenvaarallisen suuruinen j nnite Suojaa ei saa poistaa j nniteen ollessa kytkettyn laitteeseen ja poistamisen saa suorittaa vain alan asian tuntija Mik li laite tai kosketussuoja on merkitty t ll merkill on merkinn n takana tai alla kuuma pinta Suojan saa poistaa vain alan asiantuntija kun j nnite sy tt on katkaistu T llainen pinta voi s ily kosketuskuumana jopa 45 mi nuuttia Mik li laite tai kosketussuoja on merkitty t ll merkill katso lis ohjeita k yt t ohjekirjasta Kaikki t ss tuotteessa k ytetyt graafiset symbolit ovat yhdest tai useammasta seuraavis ta standardeista EN61010 1 IEC417 amp ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 IMPORTANT Consignes de s curit concernant le raccordement et l installation de cet appareil Les consignes de s curit ci dessous
174. roduto baseiam se em uma ou mais das seguintes normas EN61010 1 IEC417 e ISO3864 Rosemount Analytical Inc A Division of Emerson Process Management P 11 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 IMPORTANTE Instrucciones de seguridad para el montaje y cableado de este aparato Las siguientes instrucciones de seguridad son de aplicacion especifica a todos los miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension 1 10 12 Se deben preveer 1 tterra del equipo tanto externa como Internamente en aquellos terminales previstos al efecto Una vez finalizada las operaciones de mantenimiento del equipo se deben volver a colocar las cubiertas de seguridad aasi como los terminales de tierra Se debe comprobar la integridad de cada terminal Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245 Todo el cableado sera adecuado para una temperatura ambiental de 75 Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables Para un manejo seguro del equipo la alimentacion electrica se realizara a traves de un interruptor magnetotermico min 10 A el cual desconectara la alimentacion electrica al equipo en todas sus fases durante un fallo Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio Cuando las tapas o el equipo lleve Impreso el simbolo de tensio
175. s adressent particuli rement a tous les tats membres de la communaut europ enne Elles doivent tre strictement appliqu es afin de satisfaire aux directives concernant la basse tension Les tats non membres de la communaut europ enne doivent galement appliquer ces consignes sauf si elles sont en contradiction avec les standards locaux ou nationaux 1 2 10 Un raccordement ad quat la terre doit tre effectu e chaque borne de mise la terre interne et externe Apr s installation ou d pannage tous les capots de protection et toutes les prises de terre doivent tre remis en place toutes les prises de terre doivent tre respect es en permanence Les cables d alimentation lectrique doivent tre conformes aux normes IEC227 ou IEC245 Tous les raccordements doivent pouvoir supporter une temp rature ambiante sup rieure 75 Tous les presse toupes utilis s doivent avoir un diam tre interne en rapport avec les cables afin d assurer un serrage correct sur ces derniers Afin de garantir la s curit du fonctionnement de cet appareil le raccordement l alimentation lectrique doit tre r alis exclusivement au travers d un disjoncteur minimum 104A isolant tous les conducteurs en cas d anomalie Ce disjoncteur doit galement pouvoir tre actionn manuellement de facon m canique Dans le cas contraire un autre syst me doit tre mis en place afin de pouvoir isole
176. s 1 through 4 shown for the membrane keypad Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 k Fault 11 Bad Cell 12 igure 8 13 shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a ROSEMOUNT HEATERT C DIAGNOSTIC HEATER SW Hazardous Area Oxymitter 4000 with ALARMS O2CELL o CALIBRATION LOI lower view s DET Membrane Keypad When Fault 11 is O2CELLmV TP1 TEST O2 CELL mv TP2 POINTS HEATER T C TP3 HEATERT C TP4 detected the O2 CELL flashes three times pauses for three seconds and repeats Q 2 gt 1 The bad cell alarm activates when the INC INC ons cell exceeds the maximum resistance HIGH LOW value GAS GAS DEC DEC ie 2 The cell should be replaced See para O2 graph Cell Replacement for cell C replacement instructions KEYPAD LOI When Fault 11 is detected the LOI displays the O2 Cell Bad message Refer to the comments and procedures in para graphs 1 and 2 above Alarms 02 Cell Bad ROSEMOUNT Eo oy LOI 37260029 Figure 8 13 Fault 11 Bad Cell Rosemount Analytical Inc A Division of Emerson Pro
177. s Area Oxymitter 4000 with an LOI lower view Membrane Keypad When Fault 5 is detected the HEATER LED flashes once pauses for three seconds and repeats 1 Remove power 2 Remove the electronic assembly per paragraph Electronic Assembly Replacement 3 Using a multimeter measure the re sistance across the terminals of heater connector J8 4 The measurement should be approxi mately 72 ohms If the heater is open see paragraph Heater Strut Replacement LOI When Fault 5 is detected the LOI dis plays the O2 Heater Open message 1 Remove power Unscrew and remove the LOI module from the electronic as sembly 2 Perform the diagnostic steps 2 through 4 shown for the membrane keypad Troubleshooting 8 9 Instruction Manual IB 106 340C Rev 4 1 July 2004 ROSEMOUNT HEATERT C O DIAGNOSTIC HEATER O SW2 ALARMS O2 CELL o md L CALIBRATION CALIBRATION RECOMMENDED O 2 mV TP1 TEST O2 CELL mv TP2 OQ POINTS HEATER TP3 HEATER T C INC INC E HIGH LOW GAS GAS TESTERS Z O2 KEYPAD Alarms Very Hi O2 Temp TP5 e TP6 e TP4 ROSEMOUNT De oy LOI VE GRN ORG 37260024 Figure 8 8 Fault 6 High High Heater Temp 8 10 Troubleshooting Hazardous
178. sc 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 KT log10 P1 P2 C Where 1 P2 is the partial pressure of the oxy gen in the measured gas on one side of the cell 2 P1 is the partial pressure of the oxy gen in the reference air on the oppo site side of the cell T is the absolute temperature C is the cell constant 5 Kis an arithmetic constant For best results use clean dry instru ment air 20 95 oxygen as the refer ence air Description and Specifications 1 1 Instruction Manual IB 106 340C Rev 4 1 SS Ot July 2004 Hazardous Area Oxymitter 4000 Instruction Bulletin 37270007 IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Optional Hazardous Area Oxymitter 4000 with Integral Electronics SPS 4000 Single Probe Autocalibration Sequencer Optional Shown with reference air option Safe area only HART Communicator Package Model 375 Optional Mounting Plate with Mounting Hardware and Gasket Hazardous Area Oxymitter 4000 with Remote Electronics Optional Reference Air Set used if SPS 4000 without reference air option or IMPS 4000 not supplied Figure 1 1 Typical System Package Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Manage
179. skin contact Use separate lockers for work clothes to pre vent fiber transfer to street clothes Wash work clothes separately from other clothing and rinse washing ma chine thoroughly after use EYE PROTECTION Wear safety glasses or chemical worker s goggles to prevent eye contact Do not wear contact lenses when working with this substance Have eye baths readily available where eye contact can occur Rosemount Analytical Inc A Division of Emerson Process Management P 19 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 SECTION IX SPECIAL PRECAUTIONS PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING General cleanliness should be followed The Toxicology data indicate that ceramic fiber should be handled with caution The handling practices de scribed in this MSDS must be strictly followed In particular when handling refractory ceramic fiber in any application special caution should be taken to avoid unnecessary cutting and tearing of the material to mini mize generation of airborne dust It is recommended that full body clothing be worn to reduce the potential for skin irritation Washable or dis posable clothing may be used Do not take unwashed work clothing home Work clothes should be washed separately from other clothing Rinse washing machine thoroughly after use If clothing is to be laundered by someone else inform launderer of proper procedure Work clothes and street clothes should
180. sposable dust respirator e g 3M 9970 or equivalent Half face air purifying respirator equipped with high efficiency particulate air HEPA filter cartridges e g 3M 6000 series with 2040 filter or equivalent Full face air purifying respirator with high efficiency particulate air HEPA filter cart ridges e g 3M 7800S with 7255 filters or equivalent or powered air purifying respirator PARR equipped with HEPA filter cartridges e g W3265S with W3267 filters or equivalent Full face positive pressure supplied air respira tor e g 3M 7800S with W9435 hose amp W3196 low pressure regulator kit connected to clean air supply or equivalent If airborne fiber or cristobalite concentrations are not known as minimum protection use NIOSH MSHA approved half face air purifying respirator with HEPA filter cartridges P 20 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 Insulation surface should be lightly sprayed with water before removal to suppress airborne dust As water evapo rates during removal additional water should be sprayed on surfaces as needed Only enough water should be sprayed to suppress dust so that water does not run onto the floor of the work area To aid the wetting process a sur factant can be used After RCF removal is completed dust suppressing cleaning methods such as wet sweeping or v
181. stor Fitting Cap O Ring Heater Strut Assembly Tube Clamp Silicon Tube Strut Pressure Clamp 37270004 Figure 9 3 Hazardous Area Oxymitter 4000 with Integral Electronics Exploded View 9 8 Maintenance and Service Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 106 340 Rev 4 1 Hazardous Area Oxymitter 4000 July 2004 REMOTE ELECTRONICS 20 P 18 Note The Electronic Assembly item 2 consists of items 3 through 10 INTERCONNECTING CABLE 1 Blind Cover Integral 1A Window Cover 2 4 Electrical 2 Electronic Assembly Barrier 3 Screw 26 4 Membrane Keypad 29 48 4A Module 24 Junction Box 5 Microprocessor Board 15 Terminal Block 25 Adapter Plug 6 Analog Board 16 Captive Screw 26 O Ring 7 Fuse Cap 17 Blind Cover 27 Harness Assembly 8 Fuse 17A O Ring 28 Spacer Block Refer to Figure 9 3 for 9 Power Supply Board 18 Screw 29 Connecting Cable Signal component parts of probe 10 Captive Screw 19 Cover Lock 30 Connecting Cable Heater 11 Housing 20 Captive Washer 31 Interconnecting Cable 12 Screw 21 Lock Washer 32 Terminal Block Remote Probe Head 13 Lock Washer 22 Screw 33 Probe 14 Cable Clamp 23 Mounting Kit 34 Housing adiri Figure 9 4 Hazardous Area Oxymitter 4000 with Remote Electronics Exploded View Rosemount Analytical Inc A Divisio
182. sults are normally obtained if the Hazardous Area Oxymitter 4000 is positioned near the center of the duct 40 to 60 insertion Longer ducts may require several Hazardous Area Oxymitter 4000 units since the can vary 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 The sensing point should be selected so the proc ess gas temperature falls within a range of 0 to 704 C 32 to 1300 F Figure 2 tthrough Figure 2 3 provide mechanical installation references The ambient temperature of the elec tronics housing must not exceed 70 C 150 F For higher ambient tempera tures we recommend the remote mounted electronics option Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 NOTE At temperatures up to 85 C 185 F inside the housing the infrared keypad will cease to function but the transmit ter will continue to operate properly 2 Check the flue or stack for holes and air leakage The presence of this con dition will substantially affect the accu racy of the oxygen reading Therefore either make the necessary repairs or install the Hazardous Area Oxymitter 4000 upstream of any leakage 3 Ensure the area is clear of internal and external obstructions that will interfere with probe installation and access to t
183. t Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 SECTION 3 CONFIGURATION OF HAZARDOUS AREA OXYMITTER 4000 WITH MEMBRANE KEYPAD IN C 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 GENERAL a Verify Mechanical Installation Ensure the Hazardous Area Oxymitter 4000 is installed correctly See INSTALLATION WARNING Opening the electronics housing in hazardous areas may cause an explo sion causing severe injury or death It may be required to get a hot work permit from your company safety offi cer before you open the housing b Verify Terminal Block Wiring Remove screw 18 Figure 9 3 sss gemount Analytical Inc 44667 0901 4338076 ROSEMOUNT 400 0 SERIAL FAMILY 9 5 500 5 Amps 2 4 20 mA SIGNAL TERMINAL BLOCK LOGIC I O GROUND LUGS Instruction Manual IB 106 340C Rev 4 1 July 2004 Figure 9 4 cover lock 19 and cap tive washer 20 that secure cover 17 on left side of housing 11 Remove the cover Check the terminal block wiring
184. tartup and Operation with LOI 6 5 Instruction Manual IB 106 340C Rev 4 1 July 2004 a Hazardous Area Oxymitter 4000 d SYSTEM Status c Board Temp The temperature inside the Oxymitter electronics 1 Alarms Diagnostic alarms See housing 85 C is the max TROUBLESHOOTING 2 PID Parameter Displays the line volt age powering the Oxymitter and infers the temperature control algorithm being used to control heater temperature d Board Temp Max This is the maximum temperature that the electronics has experienced over time 6 7 LOI INSTALLATION 3 Reset Device Device can be reset here as opposed to re powering Cali The LOI connects to the top of the electronic bration parameters will be lost assembly in the electronics housing There are four matching connectors on the back of the LOI SYSTEM Software module that allow the LOI to be ori This is data regarding the Oxymitter 4000 ented as desired by the user software version and errors that may have occurred CONNECTOR RECEPTACLES f SENSOR DATA Displays information about the cell and thermocouple Sooo 1 Temperatures 9 ee 3 OOSA a O2 Temp Indicates the thermo couple temperature at the sensing cell this should always be 736 C b O2 Temp Max Maximum tem perature the cell has seen Some LOI MODULE REAR VIEW process temperatures can exceed the 73
185. the FROM PROBE side of the terminal block Figure 2 10 WARK ING 1 If using an IMPS 4000 or an SPS 4000 install it in a non hazardous explosive free environment 3 N IN If using 5 4000 or SPS 4000 2 Calibration Handshake Logic I O The output signal can be used to trigger an alarm or to provide a calibration hand install it in a non hazardous explosive shake signal to an IMPS or SPS 4000 free environment If autocalibration is not utilized a common bi directional logic contact is provided for any of the equipment alarms listed in Table 8 1 The assign ment of alarms that will actuate this contact is modified by one of seven additional configuration settings mode 1 through mode 7 listed in Table 4 1 The logic contact is self powered 5 VDC with a 340 ohm series resis tance An interposing relay is required if the logic contact will annunciate a higher voltage device such as a light or horn An interposing relay may also be required for certain DCS input cards A Potter amp Brumfield model R10S E1Y1 J1 0K 3 2 mA DC or equal interposing relay will be mounted where the contact wires terminate in the control relay room d Install cover 17 Figure 9 4 and secure with captive washer 20 cover lock 19 and screw 18 e Install Interconnecting Cable NOTE If interconnect cable was not purchased with the Hazardous Area Oxymitter 4000 cons
186. tion status updates When CALSTATE displays COMPLETE the calibration is finished Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 7 8 DEFINING A TIMED CALIBRATION VIA HART Use the following procedure to specify a time interval in hours at which the Hazardous Area Oxymitter 4000 will be automatically calibrated If necessary use the menu tree in sheet 2 of 3 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 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 From the DEVICE SETUP screen select DETAILED SETUP From the DETAILED SETUP screen select CALIBRATION From the CALIBRATION screen select menu item 6 CAL MODE Set the CAL MODE to AUTO Return to the CALIBRATION screen and select menu item 7 CAL INTRVL At the prompt input a time interval in hours at which an automatic calibration Will occur then press ENTER HART AMS 7 9 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 7 10 5 Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 8 1 SECTION 8 Instruction
187. uld be noted that plaques are not pre cancer nor are they associated with any measurable effect on lung function Rosemount Analytical Inc A Division of Emerson Process Management P 17 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 TOXICOLOGY number of studies on the health effects of inhalation exposure of rats and hamsters are available Rats were exposed to RCF in a series of life time nose only inhalation studies The animals were exposed to 30 16 9 and 3 mg m which corresponds with approximately 200 150 75 and 25 fibers cc Animals exposed to 30 and 16 mg m were observed to have developed a pleural and parenchymal fibroses animals exposed to 9 mg m had developed a mild parenchymal fibrosis animals exposed to the lowest dose were found to have the response typically observed any time a material is inhaled into the deep lung While a statistically significant increase in lung tumors was observed following exposure to the highest dose there was no excess lung cancers at the other doses Two rats exposed to 30 mg m and one rat exposed to 9 mg m de veloped masotheliomas The International Agency for Research on Cancer IARC reviewed the carcinogenicity data on man made vit reous fibers including ceramic fiber glasswool rockwool and slagwool in 1987 IARC classified ceramic fi ber fibrous glasswool and mineral wool rockwool and slagwool as possible human carcinogens Grou
188. ult 10 High Cell mV 8 14 Troubleshooting Hazardous Area Oxymitter 4000 Fault 10 High Cell mV igure 8 12 shows the electronic assembly for a Hazardous Area Oxymitter 4000 with a membrane keypad upper view and a Hazardous Area Oxymitter 4000 with an LOI lower view The upper view also shows J1 and test points TP1 through TP6 located on the microprocessor board below the membrane keypad or the LOI module Membrane Keypad When Fault 10 is detected the O2 CELL flashes once pauses for three seconds and repeats 1 Using a multimeter measure across TP1 to TP2 If you measure 204 mV to 1 volt DC the cell reading is due to high combustibles This is a self clearing alarm once the combustible conditions go away If you measure 1 2 VDC the cell wires either orange or green have become detached from the input 2 One possible cause is connector J1 The orange or green wire has come loose from the crimped connection 3 The platinum pad could also be at fault The pad could have broken free from the back of the cell 4g Heater Strut Replacement If necessary replace the cell and flange assembly per paragraph Cell Replacement 4 Replace heater strut per paragraph LOI When Fault 10 is detected the LOI displays the O2 Cell Open message 1 Remove power Unscrew and remove the LOI module from the electronic assembly 2 Reconnect power to the Oxymitter 4000 3 Perform the diagnostic step
189. ult the factory for the proper wire type and gauge Installation EN 2 Loosen screw 18 Figure 9 3 cover lock 19 and washer 20 at the probe head Remove cover 17 3 See Figure 2 10 Connect the heater power leads the thermocouple leads and the oxygen signal leads of the in terconnecting cable to the terminal block The cable leads are tagged for polarity To avoid a shock hazard the heater power terminal cover must be installed 4 Install covers 17 Figure 9 3 and and secure with captive washers 20 cover locks 19 and screws 18 PNEUMATIC INSTALLATION Reference Air Package After the Hazardous Area Oxymitter 4000 is installed connect the reference air set to the Hazardous Area Oxymitter 4000 Refer to Figure 2 11 Instrument Air Reference Air 68 95 kPa gage 10 psig minimum 1551 38 kPa gage 225 psig maximum at 0 5 scfm 0 25 l hr maximum less than 40 parts per million total hydrocarbons Regulator outlet pres sure should be set at 35 kPa 5 psi Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 NOTE DIMENSIONS ARE IN MILLIMETERS WITH INCHES IN PARENTHESES ALL PIPING SPECIFIED IN U S STANDARDS SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY TO HAZARDOUS AREA OXYMITTER 4000 PROBE HEAD
190. unt Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 POWER SUPPLY BOARD 37270022 Figure 9 6 J8 Connector 3 Loosen the three captive screws 9 Figure 9 3 or Figure 9 4 Slide electronic assembly 2 partially out of housing 11 4 See Figure 9 6 Squeeze the sides of the J8 connector and carefully remove the J8 connector heater leads from the power supply board o Remove the electronic assembly 2 Figure 9 3 or Figure 9 4 from the housing 1 1 6 Slide the new electronic assembly 2 partially into the housing 11 T Reconnect the J8 connector to the power supply board Make sure the connector is secure 8 Holding the J1 connector leads slide the electronic assembly the rest of the way into the housing Seat the electronic assembly on the mating connector pins 9 Gently try to rotate the electronic assembly to check for full seating If the electronic assembly rotates remove the assembly and repeat step 8 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 July 2004 10 Reconnect the J1 connector to the microprocessor board Figure 9 5 Ensure the connector is secure 11 Tighten the three captive screws 9 Figure 9 3 or in the top of the microprocessor board 5 12 Install and tighten cover 1 make sure
191. unt Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 July 2004 Table 11 1 Replacement Parts for Probe Continued Figure and Index No Part Number Description Bypass Gas Pickup Tube 3 Bypass Gas Pickup Tube 6 Bypass Gas Pickup Tube 9 4507C26G07 4507626608 4507626609 1005677601 1005677602 1005677603 1005677604 1005677605 1005677606 1L03650H01 2636152601 771 635 01 3535B42G03 5 10130 01 6292 74 02 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340C Rev 4 1 Flame Arrestor with Ceramic Diffuser Flame Arrestor with Ceramic Diffuser and Dust Seal Flame Arrestor with Ceramic Diffuser and Spare Dust Seal Flame Arrestor with Snubber Diffuser Flame Arrestor with Snubber Diffuser and Dust Seal Flame Arrestor with Snubber Diffuser and Spare Dust Seal Flame Arrestor Diffusion Hub Setscrew M5 0 8 x 5 mm Reference Gas Air Set Calibration Gas Flowmeter Probe Disassembly Kit Strut Pressure Clamp Ceramic Diffusion Element Replacement Kit HEX KEYS SS ue SPANNER WRENCH ANTI SEIZE COMPOUND PHILIPS SCREWDRIVER TUBE INSERTION TUBE 26310008 Figure 11 2 Probe Disassembly Kit Replacement Parts 11 3 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Table 11 2 Replacement Parts for Electronics Figure and Index No Part Number Description 9 3 1 1
192. ure compliance with the Low Voltage Directive Non EU states should also comply with the following unless superseded by local or National Standards 1 Adequate earth connections should be made to all earthing points internal and external where provided After installation or troubleshooting all safety covers and safety grounds must be re placed The integrity of all earth terminals must be maintained at all times Mains supply cords should comply with the requirements of IEC227 or IEC245 All wiring shall be suitable for use in an ambient temperature of greater than 75 C All cable glands used should be of such internal dimensions as to provide adequate cable anchorage To ensure safe operation of this equipment connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation The circuit breaker may also include a mechanically operated iso lating switch If not then another means of disconnecting the equipment from the supply must be provided and clearly marked as such Circuit breakers or switches must comply with a recognized standard such as IEC947 All wiring must conform with any local stan dards Where equipment or covers are marked with the symbol to the right haz ardous voltages are likely to be present beneath These covers should only be removed when power is removed from the equipment and then only by trained service pers
193. us Area Oxymitter 4000 Table 1 1 Product Matrix OXT4C OXYMITTER 4000 EXPLOSION PROOF IN SITU OXYGEN TRANSMITTER Explosion Proof Oxygen Transmitter Instruction Book Sensing Probe Type with Flame Arrestor 2 Snubber Diffusion Element ANSI 3 in 150 Ibs 6 Snubber Diffusion Element JIS 7 _ Ceramic Diffusion Element ANSI 3 in 300105 0 00 0 0 0 22 i Ceramic Diffusion Element ANSI 4 in 300 Ibs Probe Assembly 18 in 457 mm Probe 18 in 457 mm Probe with 3 ft 0 91 Bypass 18 in 457 mm Probe with Abrasive Shield O 2 3 ft 0 91 m Probe 7 3 ft 0 91 m Probe with Abrasive Shield 6 ft 1 83 m Probe 6 6 1 83 m Probe with Abrasive Shield Code Mounting Adapter Stack Side No Adapter Plate 0 must be chosen under Mounting Adapter Probe Side below New Installation Square weld plate with studs Model 218 Mounting Plate with Model 218 Shield Removed Competitor s Mount Mounting Adapter Probe Side No Adapter Plate Probe Only ANSI ION 4 Probe Only DIN o8 New Bypass or New Abrasive Shield DIN Probe Only JIS New Bypass or New Abrasive Shield JIS Code Electronic Housing and Filtered Customer Termination NEMA 4X IP66 11 HART Integral Electronics Standard Filtered Termination ATEX Certification HART Integral Electronics Transient Protected Fi
194. view menu item 1 CAL STATE menu item 2 TIMERE MAIN and menu item 3 PRESENT as the calibration status updates When CALSTATE displays APPLY GAS 2 return to the O CAL procedure When the Loop should be removed from automatic control warning appears press OK At the APPLY GAS 2 status prompt select menu item 2 NEXT CAL STEP When the status displays GAS 2 FLOW select menu item 4 EXIT to leave the CAL procedure From the PERFORM CAL screen view menu item 3 CALSTATE to monitor the calibration status as it updates Or access the O CALIBRATE screen and select menu item 2 Oo CAL STATUS to view menu item 1 CAL STATE menu item 2 TIMERE MAIN and menu item 3 PRESENT as the calibration status updates When CALSTATE displays STOP GAS return to the O CAL procedure When the Loop should be returned to automatic control message appears return the Hazardous Area Oxymitter 4000 to the automatic control loops previously removed and press OK At the STOP GAS status prompt select menu item 2 NEXT CAL STEP When the status displays PURGING select menu item 4 EXIT to leave the CAL proce dure From the PERFORM O CAL screen view menu item 3 CALSTATE to monitor the calibration status as it updates Or access the O5 CALIBRATE screen and select menu item 2 O2 CAL STATUS to view menu item 1 CAL STATE menu item 2 TIMERE MAIN and menu item 3 PRESENT as the calibra
195. with an abrasive shield install the dust seal gaskets with joints 180 apart Follow instructions in paragraph to install the Hazardous Area Oxymitter 4000 into the stack or duct If there is an abrasive shield in the stack make sure the dust seal gaskets are in place as they enter the 15 reducing cone STRUT CONTACT AND THERMOCOUPLE ASSEMBLY oN C r gt QP M WG VD 2 Y i H 3 Use a pencil to mark locations of the SUPPORTS SPRING spring clips on the ceramic rod of the contact and thermocouple assembly SPRING 26310022 Figure 9 11 Contact and Thermocouple Assembly 9 18 Maintenance and Service Replacement Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 SECTION 10 Instruction Manual IB 106 340C Rev 4 1 July 2004 RETURN OF MATERIAL If factory repair of defective equipment is required proceed as follows a Secure a return authorization number from a Rosemount Analytical Sales Office or rep resentative before returning the equipment Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted In no event will Rosemount be responsible for equipment returned without proper authorization and identification b Carefully pack defective unit a sturdy box with sufficient shock absorbing material to ensure that no addition
196. wo pressure regulators for calibration gas bottles 1A99119G03 Bottle rack Calibration gas bottles cannot be shipped via airfreight When the bottles are used with CALIBRATION RECOMMENDED features the bottles should provide 2 to 3 years of calibrations in normal service Table 1 3 Intelligent Multiprobe Test Gas Sequencer Versions Part Number of Hazardous Area Number Description Oxymitter 4000 Units 12039695601 12039695602 303969560 303969564 13039695605 30396956066 30396956077 30396956088 12039695609 3039695610 3039695611 3039695612 1 16 Description Specifications Rosemount Analytical Inc Division of Emerson Process Management Hazardous Area Oxymitter 4000 SECTION 2 INSTALLATION 1 N IN C The Hazardous Area Oxymitter 4000 and probe abrasive shield are heavy Use proper lifting and carrying proce dures to avoid personal injury 1 N Lb C Install all protective equipment covers and safety ground leads after installa tion Failure to install covers and ground leads could result in serious injury or death 2 1 MECHANICAL INSTALLATION a Selecting Location 1 The location of the Hazardous Area Oxymitter 4000 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process The Hazardous Area Oxymitter 4000 must be positioned so the gas it measures is representative of the process Best re
197. xymitter 4000 with an LOI lower view Membrane Keypad When Fault 14 is detected the CALIBRATION LED flashes twice pauses for three seconds and repeats 1 After a calibration has been performed the electronics calculates a cell con stant value 2 If the cell constant value is outside of the range 4 mV to 10 mV the alarm will activate See paragraph Cali bration and verify the last calibration was performed correctly 3 Power down the Hazardous Area Oxymitter 4000 and remove it from the stack 4 Replace the cell per paragraph Cell Replacement LOI When Fault 14 is detected the LOI displays the O2 Cell Bad message Refer to the comments and procedures in para graphs 1 through 4 above Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter 4000 ROSEMOUNT HEATERT C DIAGNOSTIC HEATER swe ALARMS O2 CELL o L CALIBRATION CALIBRATION RECOMMENDED 2 CELL mV TP1 TEST O2 CELL mv 2 C POINTS HEATER T C TP3 e TP4 CAL TEST GAS PROCESS O2 KEYPAD etn Alarms Calib Failed ROSEMOUNT Eo LOI 37260033 Figure 8 17 Fault 15 Last Calibration Failed Rosemount Analytical Inc
198. y See To avoid a shock hazard the power INSTALLATION terminal cover must be installed w For units with remote electronics VARNING check the terminal block wiring at the Opening the electronics housing in probe and at the remote electronics hazardous areas may cause an explo unit sion causing severe injury or death It be required to get a hot work 3 Install the cover 17 or permit from your company safety offi Figure 9 4 over terminal block 15 cer before you open the housing and secure with captive washer 20 cover lock 19 and screw 18 HAZARDOUS AREA _ OXYMITTER 4000 HE A ELECTRONICS IN 2 Rosemount SMART FAMILY HOUSING SERIAL NO VAC 48 62Hz WATTS 500 VA E Amps LOGIC I O mc or 4 20 m A rm SIGNAL TERMINAL BLOCK lt LO GROUND LUGS 37270010 Figure 4 1 Electronics Housing Terminals with LOI Rosemount Analytical Inc A Division of Emerson Process Management Configuration with LOI 4 1 Instruction Manual IB 106 340C Rev 4 1 July 2004 Hazardous Area Oxymitter 4000 Verify Hazardous Area Oxymitter 4000 1 Position 1 is HART LOCAL This switch Configuration Located on the microprocessor board are tw

Emerson Process Management OXYMITTER 4000 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents