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Emerson ib-106-340cdr Oxygen Equipment User Manual

1. Hazardous Area Oxymitter DR To replace the EPROM proceed as follows Shut off and lock out power to the electronics package Open electronics enclosure On the Main PCB Figure 2 12 locate and remove old EPROM Replace with new EPROM Close electronics enclosure and power up system U19 R58 R57 C7 R59 R16 oO O Installation D12 R81 CR9
2. WIG SJS3HAIN3UHVd NI S3HONI HLIM SH3 L3IWETTIIN NI SNOISNAWIG 1 55 LON ANY SNH3 LIVd ASSY HO1O3143q ASSY Was LI 38 v lisa 2 Z N zo Lk m di Iwas Lsna daganns L 061 J 0072 6 6 Eve 8 1 66 3dO HAN3 TVAOW3H SIF 8 NIC ISNV OL GSYNLOVANNVW S39NV TJ Q39v 4 SSSHL SALON Figure 2 2 Hazardous Area Oxymitter DR with Abrasive Shield 2 3 Installation A Division of Emerson Process Management Rosemount Analytical Inc Instruction Manual Hazardous Area Oxymitter DR 2 o 2 E D f O SE Oo N ida m G s QTSIHS 3AISVH8V H3LLIWAXO Va3HV SNOGYVZVH aod SONILNNOW q 5 NO 5 ATIVNOA SdlOH GACVAYHL 8 Jovduns ACISLNO OL 3lVld AO ONILIOd 1319 5 OL 5 39 AVIN SHaNHOO Qd3HOJIVHSSOHO 687 8 2 067 002 061 L6L Z X 9LIN X OZIN LL SC9 O c6 v 76 2 001 LoL 2 6 2 6 00 6 3AISVH8V HLIM 0007 H3 LLIINAXO SNOCGYVZVH
3. CR20 R1 R2 R7 2 2001A F1 2001A Before beginning operation it is important 1 that the probe heater setpoint of the existing electronics be changed to support the Haz ardous Area Oxymitter DR In Situ Oxygen 2 Probe To convert the Model 132 Digital Electronics Package for use with the DR 3 probe an EPROM change is necessary The replacement EPROM needed is as identified below 4 United States IM03222G01 9 N C39 8 i eo 962 5 5 5 x EB 5 29 5 n 8 55 89 8 x 09 aur gt 5 80 T EEE 2 89 60 8 en Peg ETT 3 i O cO C38 a i 7280 U1 L 5 E 18 105 2149 z 2 s 2140 8 z 09 o v0 620 5 E FIL1 Figure 2 12 Main PCB Model 132 EPROM Replacement Rosemount Analytical Inc A Division of Emerson Process Management MOV1 MOV2 R1 MTR T C CELL ML O P ALARM T83 C11 T82 ON OFF SW1 T81 HEATER MAIN INPUT P0022 Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 f
4. 1 2 scfh clean dry instrument quality air 20 95 regulated to 34 kPa 5 psi Optional Heater Voltage 115 10 VAC 50 60 Hz 200VA TAGHIMOCOUDIC c Power Requirements premia 175 W uuu ss 500 W Ambient Operating Temperature Junction BOX 93 C 200 F 71 C 160 F max for YEW replacement Fisher Rosemount has satisfied all obligations coming from the European legislation to harmonize the product requirements in Europe 1 6 Description and Specifications Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 Table 1 1 Product Matrix Explosion Proof Oxymitter DR In Situ Oxygen Transmitter Explosion Proof Explosion Proof Exchange Probe Instruction Book Probe Instruction Book Sensing Probe Type Ceramic Diffusion Element Probe ANSI 3 in 150 Ibs 2 Snubber Diffusion Element Probe ANSI 3 in 150 Ibs Ceramic Diffusion Element Probe DIN 2572 1 4 in Tube Fittings Snubber Diffusion Element Probe 15 2572 1 4 in Tube Fittings Ceramic Diffusion Element Probe JIS 6 Snubber Diffusion Element Probe JIS Probe Assembly 18 in 457 mm Probe
5. 2 I a WMS g T38vi iis SNOILIGNOO H3HJV3M LN3Ig8INAV HOLO31H30 OL OL dl ALWINSNI 1O3dS3H NOLLO3HIG SIHL NI 38 LSNW SS30O0ud 13MSY9 MHL NI 6900 A Division of Emerson Process Management Rosemount Analytical Inc Figure 2 1 Hazardous Area Oxymitter DR Installation Installation 2 2 Instruction Manual CN gt 0O nO gt J m oS Y O e cO en Hazardous Area Oxymitter DR SVD NI 3ATVA MOSHO QQV 9 Sif NI v E ISNV 3439 WO T od 8p 4 8p 4 067 SAKO 06 061 061 sa1oH 8 r6 0 8470 640 VIG v2 6L 6L Sz 6 92 6 006 VIG 622 Nid SIP ISNV FONVIS 006ed GTSIHS 3AISVHSYV r 318VL NOLLO3NNOO WOIYLOATA LAN v 0706 69 2820 092 ee Ge cp WIG WIG 38OHd TWAOWSY NOLLVTIVLSNI 3 18V L 35910003
6. 18 in 457 mm Probe with 3 ft 0 91 m Bypass 9 3 Ld EE 18 in 457 mm Probe with Abrasive Shield Lai 3 ft 0 91 m Probe 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 Hardware Stack Side No Mounting Hardware 0 must be chosen under Mounting Hardware Probe Side below New Installation Square weld plate with studs 1 2 3 4 5 Mounting to Model 218 Mounting Plate with Model 218 Shield Removed Competitors Mount Mounting Hardware Probe Side No Mounting Hardware Probe Only ANSI N American Std 0 New Bypass or Abrasive Shield ANSI 4 Probe Only DIN European Std Te New Bypass or Abrasive Shield DIN Probe Only JIS Japanese Std New Bypass or Abrasive Shield JIS Code Filtered Customer Termination NEMA 4X IP66 Standard Filtered Termination Transient Protected Filtered Termination 3 2 1 3 ame HIGH SULFUR SERVICE For high sulfur applications please add an additional line item to your purchase order requesting high sulfur cell part number 4847B63G02 in lieu of the standard ZrO cell Cell replacement kits for high sulfur service are also available NOTES Recommended usages High velocity particulates in flue stream installation within 11 5 ft 3 5 m of soot blowers or heav
7. IB 106 340CDR Original Issue Instruction Manual January 2002 WOLLOS 69 9 009 cane ee 0 1 ves do i S31OH p 149 Bru m 2 L2 81 62 6 via OH AN N 029 m s vid en 116 WY M 042 061 FONVIE OLE 181 NI 8L _ Nid ISNV INJA LIASY9 TVAOW3H NOLLY TTVLSNI 318V L e sir HIHV3 t t S 9 NIG JdOT3AN3 TVAON3N TVNH3LNI 7 569 ISNV TNA 4 uasnadia OINVHSO 33H uwa HaganNs H LIM LAN ve 561 Eve HLIM V NIG OL Gav TIVNH3JX3 NNOO 9313 L L _ 8 2 96 e 5 H LE ISNA INI F E eli ee 5 f L
8. m On systems equipped with an abrasive shield install the dust seal gaskets with joints 180 apart n Reinstall the probe and gasket on the stack flange o Follow the instructions in paragraph 4 3b to install the Hazardous Area Oxymitter DR 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 p Turn on power and monitor thermocouple output It should stabilize at 29 3 0 2 mV Rosemount Analytical Inc 4 8 A Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue January 2002 Set reference air flow at 56 6 I hr 2 scfh After the Hazardous Area Oxymitter DR sta bilizes calibrate the unit If new components have been installed repeat calibration after 24 hours of operation CERAMIC DIFFUSION ELEMENT REPLACEMENT NOTE This refers to the ceramic diffusion element only a General The diffusion element protects the cell from particles in process gases Normally it does not need to be replaced because the vee deflector protects it from particulate erosion In severe environments the filter may be broken or subject to excessive erosion Ex amine the ceramic diffusion element when ever removing the probe for any purpose Replace if damaged Damage to the ceramic diffusion element may become apparent during calibration Compare probe response with previous re spons
9. Incompatible with hydrofluoric acid and concentrated alkali HAZARDOUS DECOMPOSITION PRODUCTS N A SECTION VII SPILL OR LEAK PROCEDURES STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED Where possible use vacuum suction with HEPA filters to clean up spilled material Use dust suppressant where sweep ing if necessary Avoid clean up procedure which may result in water pollution Observe Special Protection Informa tion Section VIII WASTE DISPOSAL METHODS The transportation treatment and disposal of this waste material must be conducted in compliance with all applicable 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 suitable equipment Pending the results of long term health effects studies engineering control of airborne fibers to the lowest levels attain able 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 formaldehyde may accom pany binder burn off during first heat Use adequate ventilation or other precautions to eliminate vapors resulting from binder burn off Exposure to burn off fum
10. NOTE ALL MASONRY STACK WORK AND JOINTS EXCEPT ADAPTOR PLATE NOT FURNISHED BY ROSEMOUNT WITHOUT ABRASIVE SHIELD BOLT MOUNTING PLATE TO OUTSIDE WALL SURFACE FIELD WELD PIPE TO MOUNTING PLATE 82 5 3 25 MIN DIA HOLE IN WALL STACK OR DUCT METAL WALL JOINT MUST BE AIRTIGHT OUTSIDE WALL WELD OR BOLT MOUNTING SURFACE PLATE TO METAL WALL NOTE DIMENSIONS IN MILLIMETERS WITH INCHES IN PARENTHESES PIPE 3 5 IN SCHED 40 PIPE SEEEVE NOT BY ROSEMOUNT LENGTH BY CUSTOMER MASONRY STACK WALL 36220007 Figure 2 4 Hazardous Area Oxymitter DR Adapter Plate Installation Rosemount Analytical Inc Division of Emerson Process Management Installation 2 5 Instruction Manual IB 106 340CDR Original Issue January 2002 4 f using the optional ceramic diffusion element the vee deflector must be cor rectly oriented Before inserting the Hazardous Area Oxymitter DR check the direction of gas flow in the duct Ori ent the vee deflector so the apex points upstream toward the flow Figure 2 5 This may be done by loosening the setscrews and rotating the vee deflector to the desired position Retighten the setscrews 5 In vertical installations ensure the sys tem cable drops vertically from the Haz ardous Area Oxymitter DR and the conduit is routed below the level of the termination housing This drip loop minimizes the possibili
11. cylinders and the instrument air Disconnect the calibration gas and in strument air lines from the Hazardous Area Oxymitter DR While facing the Hazardous Area Oxymitter DR and looking at the Rosemount label remove screw 11 Figure 4 1 captive washer 13 and cover lock 12 securing left housing cover 10 Remove the cover to ex pose the terminal block Figure 4 2 Loosen the screw on the heater termi nal cover and slide the cover back to access the heater terminals Loosen the heater terminal screws and remove the leads Loosen the ground lug screws and remove the leads Slide the heater power leads out of the heater power port Loosen the oxygen and heater thermo couple signal terminal screws Remove the leads from the terminals and slide the wires out of the signal port Remove insulation to access the mounting bolts Unbolt the Hazardous Area Oxymitter DR from the stack and take it to a clean work area Maintenance and Service 4 1 Instruction Manual IB 106 340CDR Original Issue January 2002 Note Not all parts shown 28 4 2 Maintenance and Service PT Rosemount Analytical Inc Integral Electrical Barrier Feedthrough Figure 4 1 Hazardous Area Oxymitter Exploded View Senora YS Hazardous Area Oxymitter DR Right Housing Cover Connecting Cable Heater Connecting
12. 8 50 215 90 FLOW SET MAX POINT KNOB 20 50 80 2 MOUNTING HOLES 3 19 81 03 LG THROUGH BODY FOR 0 312 7 92 DIA BOLTS DRAIN VALVE 10 0 254 0 250 OR 6 MM O D REF REPLACEMENT PARTS TUBE COMPRESSION FLOWMETER 0 2 2 0 SCFH 771 635 02 FITTING 2 PRESSURE GAGE 0 15 PSIG 275431 006 COMBINATION FILTER REG 0 30 PSIG 4505C21G01 INSTRUMENT AIR SUPPLY 10 225 PSIG MAX PRESSURE AIR SET 0 250 OR 6 MM O D TUBING 2636152601 SUPPLIED BY CUSTOMER SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYMITTER DR PROBE HEAD 36210008 Figure 2 8 Air Set Plant Air Connection tional information can be found in IB 106 101 N Lb 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 SYSTEM SETUP a Overview This section covers the setup procedures for the Oxymitter DR In Situ Oxygen Probe The DR probe can be used with several electronics packages including Models 218 218A 225 132 analog and digital TC200 and ZA8C For Westinghouse Models 218 225 and 132 analog refer to paragraph Addi Rosemount Analytical Inc Division of Emerson Process Management For Westinghouse Model 218A refer to paragraph Additional informati
13. Cable Signal Termination Housing Screw Lock Washer Cable Clamp Terminal Block Captive Screw Left Housing Cover Screw Cover Lock Captive Washer Washer Screw Probe Tube Assembly Gasket Corrugated Seal Cell and Flange Assembly Retainer Screw Flame Arrester with Snubber Diffuser Tube Nut Inside Finned Housing Capillary Breather Tube Gas Port Cap Tube Nut O ring Strut Pressure Clamp Heater Strut Assembly Tube Clamp Silicon Tube 36220004 A Division of Emerson Process Management Hazardous Area Oxymitter DR HEATER POWER TYPEK THERMOCOUPLE SIGNAL OXYGEN SIGNAL LEFT SIDE OF OXYMITTER DR Instruction Manual IB 106 340CDR Original Issue January 2002 TERMINAL BLOCK HEATER POWER PORT Y LUGS SIGNAL PORT 36210002 Figure 4 2 Terminal Block 8 Allow the unit to cool to a comfortable working temperature b Install 1 Bolt the Hazardous Area Oxymitter DR to the stack and install insulation 2 Insert the oxygen and heater thermo couple signal leads in the signal port and connect to the oxygen and heater thermocouple screw terminals Figure 4 2 3 Insert the heater power leads in the heater power port and connect to the heater screw terminals Slide the heater terminal cover over the term
14. Instruction Bulletin applicable to your electronics Rosemount Analytical Inc Division of Emerson Process Management b System Description The Hazardous Area Oxymitter DR is de signed to measure the net concentration of oxygen in an industrial combustion process i e the oxygen remaining after all fuels have been oxidized The probe is permanently po sitioned within an exhaust duct or stack and performs its task without the use of a sam pling 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 disc are coated with porous metal electrodes When operated at the proper temperature the millivolt output volt age of the cell is given by the following Nernst equation EMF KT logio P4 P2 C Where 1 is the partial pressure of the oxygen in the measured gas on one side of the cell 2 is the partial pressure of the oxygen in the reference air on the opposite side of the cell 3 T is the absolute temperature 4 Cis the cell constant 5 Kis an arithmetic constant 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 deca
15. Original Issue January 2002 Hazardous Area Oxymitter DR 9 2 Appendices Rosemount Analytical Inc Division of Emerson Process Management Hazardous Area Oxymitter DR APPENDIX A Instruction Manual Appendix A January 2002 UPGRADING HAZARDOUS AREA OXYMITTER DR TO FULL HAZARDOUS AREA OXYMITTER UPGRADE PROCEDURE Perform the following procedure to upgrade the Hazardous Area Oxymitter DR to a full Hazard ous Area Oxymitter a b Rosemount Analytical Inc Remove power from the Oxymitter DR Remove the left and right covers from the Oxymitter termination housing Remove and discard the two cable assem blies 1 and 2 Figure 1 from the right side of the termination housing Place the new Oxymitter electronic assem bly 3 near the right side of the termination housing Plug the white connector with the two black wires into the white socket on the bottom power supply card Insert the electronics assembly into the ter mination housing Ensure the black 4 wire connector remains outside the housing and in the slot provided in the top card of the electronics assembly The electronics as sembly should seat on the bulkhead pins easily Do not force the assembly into place Plug the black 4 wire connector into the black socket on the microprocessor card Tighten three screws 4 securing the elec tronics assembly into the termination hous ing A Division of Emerson Process Manag
16. P 5 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 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 should be noted that plaques are not pre cancer nor are they associated with any measurable effect on lung function TOXICOLOGY A 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 ex posed 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 in crease 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 developed masotheliomas The International Agency for Research on Cancer IARC reviewed the carcinogenicity data on man made vitreous fi bers including ceramic fiber glasswoo
17. Pressure 1 1 Power Requirements 1 6 Probe 4 4 7 1 Probe Disassembly Kit 7 2 Probe Lengths 1 2 1 6 Process Temperature 1 6 Product Matrix 1 7 R Reference Air 1 3 1 6 2 2 2 3 Reference Air Set 1 2 Replacement Parts Probe 7 1 S opecifications 1 6 T Terminal Block 2 8 4 1 4 3 Thermocouple Heater 1 2 Troubleshooting 5 1 V Vee Deflector 2 6 Z Zirconia Disc 1 1 Index 10 1 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 10 2 Index 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 ap parent 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 WAR RANTIES 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
18. cold and TC mV output is less than setpoint Thermocouple continuity Cold heater resistance should be 67 ohm to 77 ohm Triac O P to heater A Division of Emerson Process Management CHECK FAULT Thermocouple failure Heater failure Failure of electronics REMEDY Replace thermocouple or return probe to Rosemount Replace heater or return probe to Rosemount Check electronics pack age Troubleshooting 5 1 Instruction Manual IB 106 340CDR Original Issue January 2002 SYMPTOM Heater is hot and T C mV output is at setpoint 0 2 mV 2 System responds to oxygen concentra tion changes but has incorrect indication Good response with incorrect indication 3 Probe does not give accurate indicationof applied test gas 4 Probe takes a long time to return to flue gas value after calibration gas is turned off 5 Probe heater temperature unstable 5 2 Troubleshooting able 5 1 Fault Finding Continued Recorder chart Cell mV input to elec tronics and cell mV at probe head Recorder or remote indicator System calibration Probe mounting and condition of duct Cell mV input to elec tronics Test gas input port Ceramic diffusion ele ment broken Plugged diffusion ele ment Proper voltage heater is Wrong heater installed Rosemount Analytical Inc CHECK FAULT Recorder failure No cell mV at probe when test gas applied Probe cell mV OK but no input
19. the Installation Instructions of the appropriate In struction Manual and per applicable local and national codes Connect all products to the proper electrical and pressure sources ensure proper performance use qualified personnel to install operate update program and maintain the product e 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 Emerson Process Management Rosemount Analytical Inc Process Analytic Division 1201 N Main St Orrville 44667 0901 T 330 682 9010 F 330 684 4434 SS e mail gas csc EmersonProcess com http www processanalytic com RSO N Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 TABLE OF CONTENTS Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area O
20. wetting process a surfactant can be used After RCF removal is completed dust suppressing cleaning methods such as wet sweeping or vacuuming should be used to clean the work area If dry vacuuming is 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 Division of Emerson Process Management P 9 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR Technical Support Hotline For assistance with technical problems please call the Customer Support Center CSC The CSC is staffed 24 hours a day 7 days a week Phone 1 800 433 6076 In addition to the CSC you may also contact Field Watch Field Watch coordinates Rosemount s field service throughout the U S and abroad Phone 1 800 654 RSMT 1 800 654 7768 Rosemount may also be reached via the Internet through e mail and the World Wide Web e mail GAS CSC frco com World Wide Web www processanalytic com P 10 Rosemount Analytical Inc Division of Emerson Process Management Hazardous Area Oxymitter DR 1 1 Instruction Manual IB 106 340CDR Original Issue January 2002 SECTION 1 DESCRIPTION AND SPECIFICATIONS COMPONENT CHECKLIST OF TYPICAL SYSTEM PACKAGE CONTEN
21. 09 ELECTRONICS 27 s Instruction Manual IB 106 340CDR Original Issue January 2002 site This packaging has been de signed to protect the product 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 A typical system installation is illustrated in Instrument air for reference is optional for most applications Ambient air will passively diffuse into the inside of the probe in suffi cient quantity for an accurate measurement Instrument air is required for applications where the ambient air at the probe location may not contain the typical 20 95 example would be an installation into a positive pressure flue gas duct which has many leaks into the surrounding air If the calibration gas bottles will be perma nently connected a blocking valve or check valve is required next to the calibration fit tings on the termination housing ADAPTER PLATE INSTRUMENT 12 SUPPLY AA REFERENCE AIR PRESSURE FLOWMETER REGULATOR CALIBRATION GAS 36210004 Figure 1 2 Typical System Installation Rosemount Analytical Inc Division of Emerson Process Management Description and Specifications 1 3 Instruction Manual IB 106 340CDR Original Issue January 2002 This check valve or blocking va
22. 0CDR Original Issue Hazardous Area Oxymitter DR January 2002 WIRE LOOP V DEFLECTOR CERAMIC SUPPORT ROD CERAMIC DIFFUSER ASSEMBLY CELL FLANGE HEATER 27540007 Figure 4 3 Heater Strut Assembly Grasp the wire loop and carefully slide the strut out of the probe tube Figure 4 3 When replacing the strut 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 to align the hole on the back plate of the strut with the calibra tion gas line When the hole and the cali bration gas line are aligned correctly the strut will slide in the rest of the way Push down on the back plate of the strut to make sure you have spring tension and then install the pressure clamp 28 on the back plate Install capillary breather tubes 23 and tube nuts 26 on the CAL REF and VENT ports Replace the CAL and REF gas silicon tubes Install the termination housing per the in Rosemount Analytical Inc Division of Emerson Process Management structions in paragraph 5 f through Follow the instructions in paragraph R 3b to install the Hazardous Area Oxymitter DR into the stack or duct CELL REPLACEMENT This paragraph covers oxygen sensing cell re placement Do not attempt to replace the cell until all other possibilities for poor performance have been considered If cell replacement is neede
23. 2002 Hazardous Area Oxymitter DR Hazardous Area Oxymitter DR Part no Serial no Order no Fisher Rosemount GmbH amp Co Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884209 EUROPE 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
24. 4507626608 Bypass Gas Pickup Tube ft 4507626609 Bypass Gas Pickup Tube 9 ft 263 152001 Reference Gas Set 771 635 01 Calibration Gas Rotometer 1L03650H01 F A Diffusion Hub Setscrew V Strut assembly includes contact and thermocouple assembly 2 Contact and thermocouple assembly includes platinum pad and inconel wire Cell replacement kit includes platinum pad and inconel wire NOTE The replacement parts listed above must be obtained only from the manu facturer or his agent Rosemount Analytical Inc Division of Emerson Process Management Replacement Parts 7 1 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR ANSI GASKET WIRE AND 7 PAD ASSEMBLY ANTI SEIZE COMPOUND PROBE TUBE NOT INCLUDED IN KIT 22 GA CORRUGATED s Ox CLOSED END CELL AND AN CONNECTOR FLANGE SET SCREWS TEFLON SOCKET HEAD TUBING CAP SCREWS CALIBRATION GAS PASSAGE 35830009 Figure 7 1 Cell Replacement Kit HEX KEYS p di SPANNER WRENCH ANTI SEIZE COMPOUND PHILIPS SCREWDRIVER WRENCH TUBE INSERTION 12 TUBE Figure 7 2 Probe Disassembly Kit 35830010 7 2 Replacement Parts Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 SECTION 8 OPTIONAL ACCESSORIES BY PASS PACKAGES The specially designed
25. 978 3 gm cubic meter Respirable dust 10 mg cubic meter Intended TLV ACGIH 1984 85 Composition is a trade secret SECTION IV FIRE AND 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 4 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 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 inflam mation of the lung leading to chest pain difficult breathing coughing and possible fibrotic change in the lung Pneumo coniosis Pre existing medical conditions may be aggravated by exposure specifically bronchial 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 broken ends of fibers EXPOSURE TO USED CERAMIC FIBER
26. DR is turned on and operating prior to firing up the combustion process 2 Heater Thermocouple Signal Connect Damage can result from having a cold the type K thermocouple signal lines Hazardous Area Oxymitter DR ex from the signal conditioning electronics posed to the process gases to the terminals indicated in Figure 2 7 During outages and if possible leave d Install left housing cover 10 Figure 4 1 all Hazardous Area Oxymitter DR units and secure with cover lock 12 captive running to prevent condensation and washer 13 and screw 11 premature aging from thermal cycling CAUTION 2 3 PNEUMATIC INSTALLATION If the ducts will be washed down dur If instrument air will be used as reference air ing outage MAKE SURE to power see System Considerations paragraph 1 2f down the Hazardous Area Oxymitter connect the reference air set to the Hazardous DR units and remove them from the Area Oxymitter DR The reference air set should wash area be installed in accordance with Figure 2 8 2 8 Installation Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 0 125 27 NPT FEMALE OUTLET CONNECTION 3 12 79 25 MAX NOTE DIMENSIONS ARE IN INCHES WITH 2 250 57 15 MILLIMETERS IN PARENTHESES OUTLET 4 81 1 0 25 18 FEMALE INLET CONNECTION
27. ETIN 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 Division of Emerson Process Management P 1 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 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 assure 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 2 After installation or troubleshooting all safety covers and safety grounds must be replaced The integrity of all earth terminals must be maintained at all times 3 Mains supply cords should comply with the requirements of IEC227 or 245 4 All wiring shall be suitable for use an ambient temperature of greater than 75 C 5 All cable glands used should be of such internal dimensions as to provide adequate cable anchorage 6 To ensure safe operation of this equipment connection to the mains supply should only be made through a circuit breaker which will disconnect all cir
28. Instruction Manual IB 106 340CDR Original Issue January 2002 Oxymitter DR Hazardous Area In Situ Oxygen Probe Certified to CENELEC IIB H2 CSA Class l Division 1 Groups B C D ROSEMOUNT Analytical EMERSON http www processanalytic com Process Management 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 e f 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 mainte nance of the product e Install your equipment as specified in
29. K AC LINE AC TERMINAL VOLTAGE PORT COVER TW LINE VOLTAGE 90 250 GROUND d _ 58 LUGS LOGIC OR CALIBRATION HANDSHAKE 4 20 mA SIGNAL 2 N SIGNAL LEFT SIDE OF PORT OXYMITTER 4000 Asie Figure A 2 Terminal Block and Wiring A 2 Appendices Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter DR Instruction Manual IB 106 340CDR Original Issue January 2002 SECTION 10 INDEX This index is an alphabetized listing of parts terms and procedures having to do with the Oxy mitter DR In Situ Oxygen Probe 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 3 2 7 Absolute Temperature 1 1 Adapter Plate 1 2 1 3 2 1 2 4 2 5 Arithmetic Constant 1 1 B By Pass Packages 8 1 C Calibration 4 1 Calibration Gas 1 3 1 6 2 2 2 3 4 1 8 1 Calibration Gas Bottles 1 8 Cell 1 2 4 5 Cell Constant 1 1 Cell Replacement Kit 7 2 Check Valve 1 4 D Diffusion Element 1 2 4 6 4 8 Drip Loop 2 6 E Equipment Return 6 1 H Heater 5 1 Heater Strut 4 4 Heater Thermocouple 1 2 Installation Electrical 2 7 Installation Mechanical 2 1 Installation Pneumatic 2 8 Instrument Air 1 3 2 8 4 1 Insulation 2 7 4 1 Rosemount Analytical Inc Division of Emerson Process Management M Mounting 1 6 N Nernst Equation 1 1 Packaging 1 1 Partial
30. LL JM3 JM6 add DIGITAL REMOVE JM3 JM6 218 PROBE 115V NEXT GENERATION DIRECT REPLACEMENT WORLD CLASS OR DR OXYMITTER NOTES 100 V A C OPERATION REQUIRES TRANSFORMER PART NUMBER 1M02961G02 36210014 Figure 2 14 Heater Power Supply HPS 3000 Jumper Configuration Rosemount Analytical Inc Division of Emerson Process Management Installation 2 15 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR THE YOKOGAWA 7 8 AND AVS8C ZA8C and AV8C Converters Connect the CONVERTER ELECTRONICS SETUP cabling from the ZA8C or AV8C terminal to the probe terminal in the junction box as The Hazardous Area Oxymitter DR probe shown in Figure 2 15 can be wired to work with the Yokogawa ZA8C OR AV8C TERMINAL C 3 CELL O 4 COLD O 5 DEVICE to THERMOCOUPLE O 6 COLD QOJ 7 JUNCTION Ote O m SHIELD HEATER ZA8C AV8C SHIELD STACK WALL ZA8C OR AV8C CONVERTER HEATER AND SIGNAL CABLE EXISTING MOUNTING N OXYMITTER DR PROBE WITH ADAPTER FLANGE NOTES 1 HEATER TEMPERATURE SET TO 1380 F 750 C 2 THE GREATER MASS OF THE OXYMITTER DIRECT REPLACEMENT PROBE REQUIRES LONGER TIME TO HEAT UP UPON STARTUP THE YOKOGAWA ELECTRONICS MAY INDICATE AN ERROR BECAUSE THE PROBE HAS NOT REACHED TEMPERATURE SETP
31. OINT IN THE NORMAL TIME REMOVE POWER FROM THE YOKOGAWA ELECTRONICS OR PROBE MODULE TO CLEAR THE ERROR AND RESTORE POWER THIS PROCEDURE MAY HAVE TO BE REPEATED A COUPLE OF TIMES BEFORE PROBE OPERATING TEMPERATURE IS REACHED 36210009 Figure 2 15 DR Probe Wired to the ZA8C or A V8C Converter 2 16 Installation Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 SECTION 3 STARTUP AND OPERATION 1 N N 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 3 1 GENERAL For startup and operation instructions refer to the Instruction Bulletin provided with your elec tronics package Rosemount Analytical Inc A Division of Emerson Process Management Startup and Operation 3 1 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 3 2 Startup and Operation Rosemount Analytical Inc Division of Emerson Process Management Hazardous Area Oxymitter DR 4 1 4 2 Rosemount Analytical Inc SECTION 4 MAINTENANCE AND SERVICE N Lb C When working on this equipment on the laboratory bench be aware that the probe probe tube and flame arre stor hub can be hot up to 370 C 698 F in the region of the probe heate
32. PRODUCT 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 which can cause severe respiratory disease Pneumoconiosis The amount of cristobalite present will depend on the temperature and length of time in service See Section IX for permissible expo sure levels SPECIAL TOXIC EFFECTS The existing toxicology and epidemiology data bases for RCF s are still preliminary Information will be updated as studies are completed and reviewed The following 15 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 re fractory ceramic fiber RCF Epidemiologic investigations of RCF production workers are ongoing 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 and a de crease 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 nor mal range Rosemount Analytical Inc Division of Emerson Process Management
33. Rosemount Analytical By Pass Package for oxygen 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 O CALIBRATION GAS SEQUENCER Rosemount Analytical s 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 eliminate 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 8 1 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 8 2 Optional Accessories Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 SECTION 9 APPENDICES APPENDIX A UPDATING DR OXYMITTER TO FULL OXYMITTER Rosemount Analytical Inc Division of Emerson Process Management Appendices 9 1 Instruction Manual IB 106 340CDR
34. SNOISNAWIG ONILNNOW avaaH L 78 7 SNOISNAMIG H3LLIWAXO V3HV SnOQHVZVH SONILNNOW 9 NO 5 ATIWNOA SLNN SH3HSVMMOO SGNLS SASAHLNAYVd NI SdHONI HLIM SNOISNAWIG 3 LON 009 F ZSL 715 GALS LL Sc9 0 SZ 261 YALLINAXO SNOCYVZVH SNOISNAWIG 3lVld ONILNNOW 3 18vL ANIILNO ALW1d ONILNNOW 36220002 Figure 2 3 Hazardous Area Oxymitter DR Adapter Plate Dimensions A Division of Emerson Process Management Rosemount Analytical Inc Installation 2 4 Hazardous Area Oxymitter DR INSTALLATION FOR METAL WALL STACK OR DUCT CONSTRUCTION WITH ABRASIVE SHIELD 13 0 50 BOLT MOUNTING PLATE TO OUTSIDE WALL SURFACE FIELD WELD PIPE TO r 7222222 Instruction Manual IB 106 340CDR Original Issue January 2002 INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION 13 0 50 MOUNTING PLATE MTG HOLES SHOWN ROTATED 45 OUT OF TRUE POSITION STACK OR DUCT METAL WALL JOINT MUST WELD OR BOLT MOUNTING BE AIRTIGHT PLATE TO METAL WALL OF STACK OR DUCT OUTSIDE WALL JOINT MUST BE AIRTIGHT SURFACE 222 RH 114 4 50 O D REF _ PIPE 4 00 SCHED 40 PIPE SLEEVE NOT BY ROSEMOUNT LENGTH BY CUSTOMER MASONRY STACK WALL
35. TS A typical Rosemount Hazardous Area Oxymitter DR In Situ Oxygen Probe should contain the items shown in Figure 1 1 Record the part num ber serial number and order number for each component of your system in the table located on the back cover of this manual N Lb C The Oxymitter DR is offered in both hazardous and general purpose con figurations The hazardous area ver sion has the EX and CSA symbols on the apparatus approval label The general purpose version does not have an approval label If you received the general purpose version ensure you do not install it in a potentially ex plosive atmosphere Also use the product matrix in Table 1 1 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 DR Ensure the features and options specified by your order number are on or included with the unit SYSTEM OVERVIEW a Scope This Instruction Bulletin is designed to supply details needed to install start up operate and maintain the Hazardous Area Oxymitter DR The Hazardous Area Direct Replace ment Oxymitter can be interfaced to a num ber of different earlier model electronics packages These electronic packages are not covered in this manual For specification information concerning calibration and op eration of the system refer to the
36. WORLD CLASS 3000 INTELLIGENT properly Refer to Figure 2 13 IFT FIELD TRANSMITTER SETUP jumper selection and Figure 2 14 HPS jumper selection For additional setup and The DR probe operates with a 115 VAC configuration information refer to IB 106 heater Ensure that the voltage selection 300NFX jumpers in the IFT or HPS if used are set ALWAYS DISCONNECT LINE VOLTAGE JUMPER FROM INTELLIGENT FIELD TRANSMITTER CONFIGURATION BEFORE CHANGING JUMPERS LINE VOLTAGE JUMPER PROBE HEATER JUMPER SELECTION INSTALL VOLTAGE SELECTION INSTALL 100 JM3 JM7 JM2 WORLD CLASS PROBE 44V 120 JM8 JM7 JM1 218 PROBE 115V 220 V A C JM6 5 JM WORLD CLASS DIRECT 240 V A C JM6 JM5 1 REPLACEMENT PROBE 115V OR OXYMITTER DIRECT REPLACEMENT PROBE 115V 36210015 Figure 2 13 IFT 3000 Power Supply Board Jumper Configuration CAUTION If incorrect heater voltage is selected damage to the Oxymitter DR may occur Refer to IB 106 300NFX for additional configuration information Always update the relevant labeling to reflect the set voltage ALWAYS DISCONNECT LINE VOLTAGE FROM HEATER POWER SUPPLY AND JUMPER ANALOG ELECTRONICS IF USED CONFIGURATIONS BEFORE CHANGING JUMPERS LINE VOLTAGE JUMPER HEATER SELECTION INSTALL POWER JUMPER 100 120 V A C JM4 JM1 REMOTE REMOVE JM2 PROBE HEATER JUMPER ELECTRONICS JUMPER VOLTAGE SELECTION INSTALL SELECTION WORLD CLASS PROBE ANALOG EXISTING INSTA
37. ate and remove old EPROM Replace with new EPROM Close electronics enclosure and power up system us VAVAUAU IOs Ot dete x 3 4 1 L d MAIN PCB P0020 Figure 2 10 Main PCB Model 218A EPROM Replacement Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 11 Instruction Manual IB 106 340CDR Original Issue January 2002 2 12 Hazardous Area Oxymitter DR d WESTINGHOUSE MODEL TC200 VERI 2 Heater Setpoint Adjustment The ad TRIM ELECTRONICS SETUP justment procedure required for the Model TC200 Electronics Package is Before beginning operation it is important as follows that the probe heater setpoint of the existing electronics be changed to support the Haz a Open keylocked enclosure to ac ardous Area Oxymitter DR In Situ Oxygen Probe To convert the Model TC200 Elec tronics Package for use with the DR probe b an EPROM change is necessary The re placement EPROM needed is part number 1M03154G02 1 EPROM replacement To replace the EPROM proceed as follows a Shut off and lock out power to the electronics package e b Open electronics enclosure c On the main PCB Figure 2 111 lo cate and remove old 5 011 g and U12 Replace with new 5 number 1M03154G02 being h careful to install U11 and U12 in their proper locations Close electronics enclosure and powe
38. b Ce ment should extrude from opposite hole Wipe excess material back into holes and wipe top fillet of cement to form a uniform fillet A cotton swab is useful for this Clean any excess ce ment from hub with water VEE DEFLECTOH 27540008 Figure 4 5 Ceramic Diffusion Element Replacement 3 On systems equipped with abrasive shield remove dual dust seal gaskets 4 Use spanner wrenches from Probe 10 Allow filter to dry at room temperature ly Kit Table 7 1 h 2195 overnight 1 to 2 hours at 93 200 F 5 Put hub in vise Break out old ceramic diffusion element with chisel along ce ment line Use a 9 5 mm 3 8 in pin punch and clean fillet from the cement port 11 Wipe a heavy layer of anti seize com pound onto the threads and mating surfaces of the flame arrestor diffusion hub and probe tube 12 Assemble flame arrestor and diffusion hub with two pin spanner wrenches Torque to 14 N m 10 ft lbs Secure with hub retaining setscrew 6 Break out remaining ceramic diffusion element by tapping lightly around hub with hammer Clean grooves with pointed tool if necessary 7 Replace ceramic diffusion element us 13 On systems equipped with abrasive ing the ceramic diffusion element re shield install dust seal gaskets with placement kit in This li tO consists of a diffusion element ce ment setscrews anti seize compound and instructions 14 Re
39. comply with the warranty provisions whether claims by the purchaser are based in contract or in tort including negligence Rosemount does not warrant equipment against normal deterioration due to environment Factors such as corrosive gases and solid particulates can be detrimental and can create the need for re pair 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 3622 1 02 Instruction Manual IB 106 340CDR Original Issue January 2002 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 gas csc emersonprocess com ASIA PACIFIC Fisher Rosemount Singapore Private Ltd 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65 777 8211 F 65 777 0947 http www processanalytic com Rosemount Analytical Inc
40. cuits carrying conductors during a fault situation The circuit breaker may also include a mechanically operated isolating 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 standards 7 Where equipment or covers are marked with the symbol to the right hazard ous 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 personnel 8 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 removed by trained service personnel when power is removed from the equipment Cer tain surfaces may remain hot to the touch 9 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 follow ing standards EN61010 1 IEC417 1503864 P 2 Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 CERAMIC FIBER PRODUCTS MATERIAL SAFETY DATA SHEET JULY 1 1996 SECTION IDENTIFICATION PRODUCT NAME Ceramic Fiber Heaters Molde
41. d order the cell replacement kit Table 7 1 The cell replacement kit Figure 4 4 contains a cell and flange assembly corrugated seal setscrews socket head cap screws and anti seize compound The items are carefully pack aged to preserve precise surface finishes Do not remove items from the packaging until they are ready to be used Spanner wrenches and hex wrenches needed for this procedure are part of an available special tools kit Table 7 1 Maintenance and Service 4 5 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR PROBE TUBE NOT INCLUDED IN KIT CORRUGATED SEAL CELL AND FLANGE ASSEMBLY SOCKET HEAD CAP SCREWS CALIBRATION GAS PASSAGE 22220028 Figure 4 4 Cell Replacement Kit N C 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 427 C 800 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 a Follow the instructions in paragraph 4 3a to rem
42. d Insulation Modules and Ceramic Fiber Radiant Heater Panels CHEMICAL FAMILY Vitreous Aluminosilicate Fibers with Silicon 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 Division of Emerson Process Management P 3 Instruction Manual IB 106 340CDR Original 2002 Hazardous Area Oxymitter DR SECTION 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 LB CUBIC FOOT BOILING POINT N A VOLATILES BY WT WATER SOLUBILITY N A SECTION Ill HAZARDOUS INGREDIENTS MATERIAL QUANTITY AND THRESHOLD EXPOSURE LIMIT VALUES Aluminosilicate vitreous 99 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 1
43. de The output is proportional to the inverse logarithm of the oxygen concentration Therefore the output signal increases as the oxygen con centration of the sample gas decreases This characteristic enables the Hazardous Area Oxymitter DR to provide exceptional sensi tivity at low oxygen concentrations Description and Specifications 1 1 Instruction Manual IB 106 340CDR Original Issue January 2002 1 2 The Hazardous Area Oxymitter DR 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 analysis will in general indicate a lower per centage of oxygen The difference will be proportional to the water content of the sam pled gas stream System Configuration Hazardous Area Oxymitter DR units are 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 1 83 m 6 ft Instruction Bulletin Hazardous Area Oxymitter DR Reference Air Set pP Hazardous Area Oxymitter DR Abrasive shields are offered for applications where abrasive particulates are present Acid resistant cells are available for SO and environments By
44. e A broken diffusion element will cause a slower response to calibration 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 7 1 Replacement Procedure 1 Follow the instructions in paragraph 4 3a to remove the Hazardous Area Oxymitter DR from the stack or duct 2 Loosen setscrews using hex wrench from Probe Disassembly Kit and remove vee deflec tor Inspect setscrews If damaged re place with stainless setscrews coated with anti seize compound Maintenance and Service 4 7 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR M5 0 8 x 5 mm LOCKING SET SCREW CAUTION USE 2 5 mm HEX KEY Do not get cement on ceramic diffu A sion element except where it touches the hub Any cement on ceramic diffu CERAMIC sion element blocks airflow through p ED element Wiping wet cement off of ce ramic only forces cement into pores 2 Also do not get any cement onto the USE flame arrestor element FLAME gf N HEX KEY ARRESTER A lt d 9 Thoroughly mix cement and insert tip CEMENT of squeeze bottle into cement port Tilt PORT d bottle and squeeze while simultane ously turning ceramic diffusion element into seat Do not get any cement on upper part of ceramic diffusion ele ment Ensure complete penetration of cement around 3 grooves in hu
45. e flange NOTE To maintain CE compliance ensure a good connection exists between the mounting plate studs or earthing screws on termination housing and earth 8 Ensure the Hazardous Area Oxymitter DR is properly earthed by way of both internal and external points 9 If insulation is being removed to access the duct work for Hazardous Area Oxymitter DR mounting make sure the insulation is replaced afterward 2 6 10 Ensure the installation does not obscure the messages on either housing cover 2 2 ELECTRICAL INSTALLATION All wiring must conform to local and national codes Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue January 2002 WARNING Disconnect and lock out power before connecting the unit to the power supply N 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 WARNING To 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 mea
46. e 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 in a sturdy box with sufficient shock absorbing material to ensure that no additional damage will occur during shipping c In a cover letter describe completely 1 The symptoms from which it was de termined 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 Division of Emerson Process Management 5 Complete shipping instructions for re turn of equipment 6 Reference the return authorization number d Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Rosemount Re turn 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 wit
47. e less nega tive by 10 x 0 242 or 2 42 mV making the adjusted nominal 319 9 Mv TPS PIN 2 PSC Adjust potentiometer M110 1 to read 322 3 millivolts nominal Remove voltmeter leads Remove jumper wire TP1 M110 1 PIN 7 PSC P0019 Figure 2 9 Temperature Controller Card Calibration Points 2 10 Installation Rosemount Analytical Inc Division of Emerson Process Management Hazardous Area Oxymitter DR c WESTINGHOUSE MODEL 218A ELEC TRONICS SETUP Before beginning operation it is important that the probe heater setpoint of the existing electronics be changed to support the Haz ardous Area Oxymitter DR probe To con vert the Model 218A Digital Electronics Package for use with the DR probe an EPROM change is necessary Remove Main PCB and check back of board to iden tify unit as G02 or G04 The replacement EPROM needed is as identified below 4 United Kingdom 1M03192G02 1M02982G02 EPROM Instruction Manual IB 106 340CDR Original Issue January 2002 NOTE The replacement EPROM when using a multiprobe averager unit is 1M02982G10 To replace the EPROM proceed as follows 1 Shut off and lock out power to the electronics package Open electronics enclosure On the Main PCB Figure 2 10 loc
48. e oxygen reading Therefore either make the necessary repairs or install the Hazardous Area Oxymitter DR upstream of any leak age Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance low adequate clearance for removal of the Hazardous Area Oxymitter DR Figure 2 1 b Installation 1 2 Ensure all components are available to install the Hazardous Area Oxymitter DR If equipped with the optional ce ramic diffusion element ensure it is not damaged The Hazardous Area Oxymitter DR may be installed intact as it is received NOTE An abrasive shield is recommended for high velocity particulate in the flue stream such as those in coal fired boilers kilns and recovery boilers 3 Weld or bolt adapter plate Figure 2 4 onto the duct Installation 2 1 Q31ON 5 SSI INN SASSHLNAYVd S3HONI HLIM SYALAWITIN SNOISNAWIG 35910002 3unss3ud LON ANY 1 SIF 8 NIG ISNV OL GSYNLOVANNVW S3SNV ld qQ3OVd 1V 14 ASSHL S31ON SS3OOV TVAOW3H E Hazardous Area Oxymitter DR
49. e 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 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 airborne 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 critically 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 equip ment when airborne exposure limits may be exceeded The minimum respiratory protection recommended for given air borne fiber or cristobalite concentrations are CONCENTRATION 0 1 fiber cc or 0 0 05 mg m cristobalite Optional disposable dust respirator e g 3M 9970 the OSHA PEL or equivalent Up to 5 fibers cc or
50. ement 36210017 1 Signal connecting cable 2 Heater connecting cable 3 Electronic assembly 4 Screw Figure A 1 Component Replacement Appendices 1 Instruction Manual Appendix A January 2002 Hazardous Area Oxymitter DR Inthe left side of the termination housing VAC 50 60 Hz for the Oxymitter The re place the new termination designation la terminations may be inside the old elec bels over the labels on the existing terminal tronics housing which will function as a block After placing the new labels the ter simple junction box Alternatively the old minal block should appear as shown in electronics may be removed and replaced with a smaller junction box The existing wiring from the Oxymitter to the Place the round error blink code and cali electronics may be reused However the bration instructions label on the inside of the wires will be carrying new signals as noted right housing cover by the new labels The 4 20 mA wires must be removed from the old electronics and re m Install both housing covers terminated to the wires carrying the 4 20 mA signal to the control room n Refer to the instruction bulletin provided with your upgrade kit IB 106 340C for The wires carrying the heater power must startup and diagnostic information be converted to carry AC power 90 250 TERMINAL BLOC
51. es may cause respiratory tract irritation bronchial hyper reactivity and asth matic response SKIN PROTECTION Wear gloves hats and full body clothing to prevent skin contact Use separate lockers for work clothes to prevent fiber transfer to street clothes Wash work clothes separately from other clothing and rinse washing machine 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 Division of Emerson Process Management P 7 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 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 described in this MSDS must be strictly followed In particular when handling refractory ceramic fiber in any application special cau tion should be taken to avoid unnecessary cutting and tearing of the material to minimize generation of airborne dust It is recommended that full body clothing be worn to reduce the potential for skin irritation Washable or disposable clothing may be used Do not take unwashed work clothing home Work clothes should be washed separately from other clothing Rins
52. ffusion as sembly includes a set of baf fles between the cell and the stack gases This keeps 816 C 1500 F cell tempera 1 4 Description and Specifications Hazardous Area Oxymitter DR 36220005 Figure 1 3 Flame Arrestor Diffusion Assembly tures 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 Flame Arrestor Snubber Diffusion Assembly The snubber diffusion assembly Figure 1 is satisfactory for most applications This element is also available with a dust seal for use with an abrasive shield 36220006 Figure 1 4 Flame Arrestor Snubber Diffusion Assembly Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 ON INSIDE BREAK FOR SMOOTH ROUNDED EDGE ON BOTH ENDS OF CHAMFER 45 MIN p lt SKIN CUT FACE FOR 90 0 75 THRU 4 PLS EQ SP ON 4 75 B C NOTES N WELD ON BOTH SIDES WITH EXPANDING CHILL BLOCK 2 BEFORE WELDING BUTT ITEM 2 OR 4 WITH ITEM 1 AS SHOWN 745 DIA A 7 50 DIA B C REF Figure 1 5 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 abrasive flow stream Rosemou
53. h 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 6 1 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 6 2 Return of Material Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 SECTION 7 REPLACEMENT PARTS Table 7 1 Replacement Parts for Probe 3D39496G06 V Strut Assembly 18 in 3D39496G07 V Strut Assembly 3 ft 3D39496G08 V Strut Assembly 6 ft 3534B56G04 Contact and Thermocouple Assembly 18 in 3534856605 Contact and Thermocouple Assembly 3 ft 3534B56G06 Contact and Thermocouple Assembly 6 ft 7 1 3535B44G01 Cell Replacement Kit 18 in 7 1 3535B44G02 Cell Replacement Kit 3 ft 7 1 3535B44G03 Cell Replacement Kit 6 ft 7 1 3535B44G04 Cell Replacement Kit No Inconel and Platinum Pad Assembly 7 2 1L03825G01 Probe Disassembly Kit 1U05677G04 F A Diffuser Hub Assembly Snubber Diffusor 1005677606 F A Diffuser Hub Assembly For use with Abrasive Shield 6292A74G02 Ceramic Diffusion Element Replacement Kit 1N04966H02 Abrasive Shield Assembly 3 ft 1N04966H03 Abrasive Shield Assembly 6 ft 1M03241H01 90 Elbow for Bypass 4507C26G07 Bypass Gas Pickup Tube 3 ft
54. inal connection and tighten the cover 4 4 screw 4 Install left housing cover 10 and ensure it is tight Se cure the cover using cover lock 11 captive washer 13 and screw 12 5 Connect the calibration gas and in strument air lines to the Hazardous Area Oxymitter DR Rosemount Analytical Inc A Division of Emerson Process Management 6 Turn the calibration gases at the cylinders and turn on instrument air 7 Restore power to the system 1 N C Opening the termination housing will cause the loss of ALL hazardous per mits Opening the termination 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 TERMINAL BLOCK REPLACEMENT Refer to Figure 4 2 land perform the following procedure to replace the terminal block a Loosen the mounting screws on the termi nal block and carefully lift the block out of the housing Maintenance and Service 4 3 Instruction Manual IB 106 340CDR Original Issue January 2002 4 5 4 4 b 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 con duit ports and should not be able to rotate c Tighten the three mounting screws and en sure the termi
55. install vee deflector orienting apex toward gas flow Apply anti seize com pound to setscrews and tighten with 8 Test fit replacement ceramic diffusion hex wrench element to be sure seat is clean 15 Reinstall probe on stack flange 4 8 Maintenance and Service Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 4 9 TERMINATION HOUSING WIRING HEATER BLACK Under normal circumstances the right termina tion housing should not need to be removed J HEATER BLACK This side of the housing contains only two jumper wires that connect the connectors from df OXYGEN CELL the integral electrical barrier to pins in the ORANGE housing wall If these jumpers should become disconnected or need to be replaced use the YELLOW diagram in Figure 4 6 to connect the jumpers THERMOCOUPLE ED R A OXYGEN CELL GREEN 36210011 Figure 4 6 Termination Housing Connections Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Service 4 9 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 4 10 Maintenance and Service Rosemount Analytical Inc Division of Emerson Process Management Hazardous Area Oxymitter DR 5 1 1 Rosemount Analytical Inc SECTION 5 TROUBLESHOOTING 1 N C I
56. l rockwool and slagwool in 1987 IARC classified ceramic fiber fibrous glasswool and mineral wool rockwool and slagwool as possible human carcinogens Group 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 1f 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 medi cal 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 POLYMERIZATION CONDITIONS TO AVOID N A P 6 Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 INCOMPATIBILITY MATERIALS TO AVOID
57. lve is to prevent breathing of the calibration gas line and subsequent flue gas condensation and corrosion Upgrading the Hazardous Area Oxymitter DR The Hazardous Area Oxymitter DR can be easily upgraded to a full Oxymitter 4000 or 5000 This provides an economi cal upgrade path for users looking to pre serve their probe investment upon the eventual failure of the signal conditioning electronics Upgrading the Hazardous Area Oxymitter DR to a full Oxymitter 4000 or 5000 requires only the addition of a small electronics package to the exist ing termination housing of the Hazardous Area Oxymitter DR probe The converted unit will be a full Oxymitter 4000 or 5000 Oxygen Transmitter with the capability of providing a 4 20 mA oxygen signal with out the need for an external signal condi tioning electronics package HART or Fieldbus communications are provided with the Oxymitter electronics See Ap pendix A for upgrade information 1 3 PROBE OPTIONS a Abrasive Shield Assembly The abrasive shield assembly is a stainless steel tube that surrounds the probe assembly The shield protects against particle abrasion and condensa tions provides a guide for ease of insertion and 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 Flame Arrestor Ceramic Diffusion Assembly The flame arrestor ceramic di
58. nal block is secure in the housing i N C Opening the termination housing will cause the loss of ALL hazardous per mits Opening the termination 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 ENTIRE PROBE REPLACEMENT Do not attempt to replace the probe until all other possibilities for poor performance have been considered If probe replacement is needed see Table 7 1 part numbers a Follow the instructions in paragraph 4 3a to remove the Hazardous Area Oxymitter DR from the stack or duct b Remove four screws 15 and washers 14 Separate the electrical con nectors between the heater strut assembly and the electrical barriers on the termination housing The probe and termination housing can now be separated c When installing the new probe make sure that o ring 27 is in good condition Con nect the two electrical connectors between the heater strut and the electrical barrier on the termination housing Make sure the conduit port of the termination housing is on the same side as the CAL and REF gas ports d Install the four washers 14 and screws 15 and tighten Maintenance and Service Hazardous Area Oxymitter DR 4 6 Rosemount Analytical Inc e Replace the housing cover 20 and en
59. ns 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 Hazardous Area Oxymitter DR and probe abrasive shield are heavy Use proper lifting and carrying procedures to avoid personal injury a Remove screw 11 Figure 4 1 captive washer 13 and cover lock 12 Remove left housing cover 10 Installation 2 7 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR TERMINAL BLOCK HEATER POWER PORT HEATER POWER SIGNAL SIGNAL LEFT SIDE OF PORT OXYMITTER DR Figure 2 7 Terminal Block GROUND LUGS TYPEK THERMOCOUPLE SIGNAL OXYGEN b Connect Heater Power Instrument Air Reference Air 68 95 kPag 10 psig minimum 1551 38 kPag 225 psig maxi Connect the heater power lines to the two mum at 56 6 L hr 2 scfh maximum less than terminals indicated in Figure 2 7 40 parts per million total hydrocarbons Regu lator outlet pressure should be set at 35 kPa c Connect O and Heater Thermocouple 5 psi Signals 1 Oxygen Signal Connect the oxygen NOTE signal lines from the signal conditioning Upon completing installation make electronics to the terminals shown in sure that the Hazardous Area Oxymit Figure 2 7 ter
60. nstall 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 OVERVIEW Troubleshooting for the oxygen analyzer system is broken down to the main component level In addition to the information in this section instruc tion bulletins for individual models also discuss troubleshooting For Models 218 225 and 132 analog refer to IB 106 101 For Model 218A refer to IB 106 101A For Model TC200 refer to IB 107 020 For Model 132 digital refer to IB 106 106A For Yokogawa YEW ZA8C Converter refer to original converter documentation 5 2 Instruction Manual IB 106 340CDR Original Issue January 2002 PROBE TROUBLESHOOTING a Probe Faults Listed below are the five symptoms of probe failure 1 The system does not respond to changes in the oxygen concentration The system responds to oxygen changes but does not give the correct indication The system does not give an accept able indication of the value of the oxy gen test gas being applied during cali bration The probe takes a long time to return to flue gas value after the calibration gas is turned off The probe heater temperature is un stable b Symptoms able 5 1 provides a guide to fault finding for the above symptoms Table 5 1 Fault Finding SYMPTOM No response to oxy gen concentration change when Heater is
61. nt Analytical Inc Division of Emerson Process Management Description and Specifications 1 5 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR 1 4 SPECIFICATIONS Hazardous Area Certifications CENELEC EEXd IIB H2 CSA Class Division 1 Groups B C D Prope Lengths oxi Resp ex u uu 18 in 457 mm 3 ft 0 91 m 6 ft 1 83 m Temperature Limits in Process Measurement Area 0 to 704 C 32 to 1300 F up to 1300 C 2400 F with optional accessories Resolution Sensitivity 0 01 transmitted signal Sensing Cell Repeatability 0 75 of reading or 0 05 System Response to Calibration Gas Initial response in less than 3 seconds T90 in less than 8 seconds Resolution Sensitivity 0 01 of O value Mounting and Mounting Position Vertical or horizontal Materials mico UPS Wetted or welded parts 316L stainless steel Non wetted parts 304 stainless steel low copper aluminum Termination Housing Low copper aluminum Calibration Gas Mixtures Recommended 0 4 Os Balance N gt 8 O gt Balance Calibration Gas Flow 2 5 5 scfh Optional Reference Air
62. on can be found in IB 106 101A For Westinghouse Model TC200 refer to paragraph Additional information can be found in IB 107 020 For Westinghouse Model 132 digital refer to paragraph Additional information can be found in IB 106 106A For Rosemount World Class 3000 refer to paragraph Additional information can be found in IB 106 300NF X For Yokogawa Model ZA8C refer to para graph Installation 2 9 Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 b WESTINGHOUSE MODELS 218 225 AND 132 ANALOG ELECTRONICS SETUP Before beginning operation it is important that the probe heater setpoint of the existing electronics be changed to support the Haz ardous Area Oxymitter DR In Situ Oxygen Probe The setpoint adjustment procedure required for Models 218 225 and 132 analog electronics is as follows 1 Open electronics enclosure 2 On temperature controller card Figure 2 9 connect jumper wire from TP3 to either Pin 2 or Pin 7 3 Set voltmeter to read DC millivolts MV 4 Attach voltmeter with positive lead on TP1 and negative on either Pin 2 or 7 NOTE The voltage given above is for an am bient machinery space temperature of 25 C 77 F For each degree of am bient temperature above or below 25 C 77 F add or subtract 0 242 mV from the nominal Example at 31 C 87 F the nominal voltage of 322 3 Mv should be increased mad
63. ove the Hazardous Area Oxymitter DR from the stack or duct Maintenance and Service CAUTION The flame arrestor and flame arrestor hub are among the critical compo nents of this type of protection b If the probe uses the standard diffusion element use a spanner wrench to remove the diffusion element NOTE To determine if the diffusion element needs to be replaced refer to para graph c If equipped with the optional ceramic diffu sion assembly remove and discard the setscrews and remove the vee deflector Figure 4 5 Use spanner wrenches from the probe disassembly kit Table 7 1 to turn the hub free from the retainer Inspect the diffusion element If damaged replace the element d Loosen the four socket head cap screws from the cell and flange assembly and re move the assembly and the corrugated seal The cell flange has a notch that may be used to gently pry the flange away from the probe Note that the contact pad inside of the probe will sometimes fuse to the oxy gen 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 assembly The cell and contact pad should separate If the contact pad stays fused to the cell a new contact thermocouple assembly must be in stalled Disconnect the cell and the thermo couple wires at the probe electronics and withdraw the cell with the wires still attached e Remo
64. paratus at the front of this Instruction Bulletin Failure to follow safety instructions could result in serious injury or death MECHANICAL INSTALLATION If the probe will be installed into an existing lo cation proceed to paragraph a Selecting Location 1 3 The location of the Hazardous Area Oxymitter DR in the stack or flue is most important for maximum accuracy in the oxygen analyzing process The Hazardous Area Oxymitter DR must be positioned so the gas it measures is representative of the process Best re sults are normally obtained if the Haz ardous Area Oxymitter DR is positioned near the center of the duct 40 60 insertion Longer ducts may require several Haz ardous Area Oxymitter DR units since the Os 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 be cause of the very low flow conditions A Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue January 2002 The sensing point should be selected so the process gas temperature falls within a range of 0 to 704 C 32 to 1300 F Figure 2 1 through provide mechanical installation refer ences The ambient temperature of the termination housing must not exceed 65 C 149 F Ducts and stacks that operate under negative pressure will draw air in through any holes or torn seals sub stantially affecting th
65. pass and probe mounting jacket options are available for process temperatures above 1300 F 705 C d System Features 1 The cell output voltage and sensitivity increase as the oxygen concentration decreases 2 Field replaceable cell heater thermo couple and diffusion element 3 The Hazardous Area Oxymitter DR is constructed of rugged 316L stainless steel for all wetted parts 36220001 Adapter Plate with Mounting Hardware and Gasket Figure 1 1 Typical System Package Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter DR e Handling the Hazardous Area Oxymitter DR CAUTION The Hazardous Area Oxymitter DR is designed for industrial applications Treat each component of the system with care to avoid physical damage Some probe components are made from ceramics which are susceptible to shock when mishandled f System Considerations Prior to installing your Hazardous Area Oxymitter DR make sure you have all the components necessary to make the system installation Ensure all the components are properly integrated to make the system functional NOTE Retain the packaging in which the Hazardous Area Oxymitter DR arrived from the factory in case any compo nents are to be shipped to another 4 20 mA OXYMITTER DR AC POWER 4 5 Rn O Or Loney l EXISTING SIGNAL Z CONDITIONING 5
66. r N Lb 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 OVERVIEW This section identifies the calibration methods available and provides the procedures to main tain and service the Hazardous Area Oxymitter DR CALIBRATION The Hazardous Area Oxymitter DR should be calibrated when commissioned Under normal circumstances the probe will not require fre quent calibration When calibration is required follow the procedure described in the Instruction Bulletin applicable to your electronics package WARNING It is recommended that the Hazardous Area Oxymitter DR be removed from the stack for all service activities Wear heat resistant gloves and cloth ing to remove probe from stack Nor mal operating temperature of diffusor and vee deflector are approximately 316 to 472 C 600 to 800 F The unit should be allowed to cool and be taken to a clean work area Failure to comply may cause severe burns A Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue January 2002 WARNING Disconnect and lock out power before working on any electrical components There is voltage up to 115 VAC HAZARDOUS AREA OXYMITTER DR REPLACEMENT a Remove 1 2 Turn off power to the system Shut off the calibration gases at the
67. r up system Installation Rosemount Analytical Inc cess membrane keyboard Put controller in PAR parameter mode by depressing LOCK A 0902 INC ACK in sequence Depress ACK pushbutton to clear display Press NUM pushbutton Using INC DEC buttons dis play parameter 125 Press VAL button Using INC DEC buttons change parameter 125 value to 15 4 Press ENT to save new value A Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 EPROMS U11 AND U12 U11 U12 m DIS AMI A OO 21 99 gi 1 2 C D C P0021 Figure 2 11 Main PCB Model TC200 EPROM Replacement Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 13 Instruction Manual IB 106 340CDR Original Issue January 2002 e WESTINGHOUSE MODEL 132 DIGITAL ELECTRONICS SETUP
68. sure it is tight f Follow the instructions in paragraph H 3b to install the Hazardous Area Oxymitter DR into the stack or duct HEATER STRUT REPLACEMENT This paragraph covers heater strut replacement Do not attempt to replace the heater strut until all other possibilities for poor performance have been considered If heater strut replacement is needed order a replacement heater strut Table 7 1 WARNING 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 800 F 427 C This can cause severe burns a Follow the instructions in paragraph 4 3a to remove the Hazardous Area Oxymitter DR from the stack or duct b Remove four screws 15 and washers 14 Separate the electrical con nectors between the heater strut assembly and the electrical barriers on the termination housing The probe and termination housing can now be separated c Once the probe and termination housing are separated spring tension releases and the heater strut moves up Carefully remove the CAL and REF gas silicon tubes by pulling them off the CAL and REF gas ports Pull the silicon tubes off the CAL and REF gas lines d Remove pressure clamp 28 e Remove tube nuts 26 and capillary breather tubes 23 from the CAL REF and VENT ports A Division of Emerson Process Management Instruction Manual IB 106 34
69. to electronics Cell mV satisfactory both at junction box and input to electronics failure of electronics Calibration error Calibration error Air ingress into duct Failure of electronics Blocked port Diffusion element cracked broken or missing Plugged diffusion ele ment Hazardous Area Oxymitter DR REMEDY See Recorder Instruction Manual Replace cell or return probe to Rosemount Check out cable con nection Check electronics pack age Recalibrate recorder or indicator Reference Re corder Instruction Man ual Recalibrate system Re place cell if necessary otop air leaks or resite probe Check electronics pack age Clean port If the flue gas is condensing in the test gas line insulate the back of the probe Make sure that the test gas line is capped between calibrations or a check valve is installed Replace diffusion ele ment Change diffusion ele ment or snubber diffu sion element Change heater to proper voltage A Division of Emerson Process Management Hazardous Area Oxymitter DR SECTION 6 Instruction Manual IB 106 340CDR Original Issue January 2002 RETURN OF MATERIAL EQUIPMENT RETURN If factory repair of defective equipment is re quired 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 complet
70. ty that moisture will damage the electrical connections Figure 2 6 ROSEMOUNT REPLACE INSULATION N AFTER INSTALLING HAZARDOUS AREA OXYMITTER DR Hazardous Area Oxymitter DR GAS FLOW DIRECTION VEE DEFLECTOR APEX DIFFUSION ELEMENT SETSCREW K VEE DEFLECTOR 22220020 Figure 2 5 Orienting the Optional Vee Deflector OXYGEN n THERMOCOUPLE C SIGNAL LINE VOLTAGE MI INSULATION DRIP LOOP ADAPTER PLATE STACK OR DUCT METAL WALL 36210007 Figure 2 6 Installation with Drip Loop and Insulation Removal 2 6 Installation Rosemount Analytical Inc A Division of Emerson Process Management Hazardous Area Oxymitter DR 6 If the system has an abrasive shield check the dust seal gaskets The joints in the two gaskets must be staggered 180 Also make sure the gaskets are in the hub grooves as the Hazardous Area Oxymitter DR slides into the 15 chamfer in the abrasive shield NOTE If process temperatures will exceed 200 C 392 F use anti seize com pound on stud threads to ease future removal of Oxymitter DR 7 Insert probe through the opening in the mounting flange and bolt the unit to th
71. up to 10 times the Half face air purifying respirator equipped with high OSHA PEL for cristobalite efficiency particulate air HEPA filter cartridges e g 3M 6000 series with 2040 filter or equivalent Up to 25 fibers cc or 50 times the OSHA Full face air purifying respirator with high efficiency PEL for cristobalite 2 5 mg m particulate air HEPA filter cartridges 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 Greater than 25 fibers cc or 50 times the Full face positive pressure supplied air respirator OSHA PEL for cristobalite 2 5 mg m 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 8 Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 Insulation surface should be lightly sprayed with water before removal to suppress airborne dust As water evaporates 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
72. ve four screws 15 and washers 14 f Separate the electrical connectors between the heater strut and the termination hous ing Rosemount Analytical Inc Division of Emerson Process Management Hazardous Area Oxymitter DR If the contact assembly is damaged replace the strut or the contact pad Instructions for replacing the contact pad are in the cell re placement kit h Remove and discard the corrugated seal Clean the mating faces of the probe tube and retainer Remove burrs and raised surfaces with a block of wood and crocus cloth Clean the threads on the retainer and hub I Ruba small amount of anti seize compound on both sides of the new corrugated seal Assemble the cell and flange assembly cor rugated seal and probe tube Make sure the calibration tube lines up with the cali bration gas passage in each component Apply a small amount of anti seize com pound to the screw threads and use the screws to secure assembly Torque to 4 35 in lbs k Install the termination housing per the instructions in paragraph 4 5 steps through anti seize compound to the threads of the cell assembly hub and setscrews Re install the hub on the cell assembly Using pin spanner wrenches torque to 14 N m 10 ft lbs If applicable reinstall the vee de flector orienting apex toward gas flow Se cure with the setscrews and anti seize compound Torque to 2 8 N m 25 in lbs
73. xymitter DR LIST OF ILLUSTRATIONS Figure 1 1 Figure 1 2 LIST OF TABLES Product Matrix Calibration Components Fault Findina Replacement Parts for Probe i Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual IB 106 340CDR Original Issue Hazardous Area Oxymitter DR January 2002 PREFACE The purpose of this manual is to provide information concerning the components func tions installation and maintenance of the Hazardous Area Oxymitter DR Some sections may describe equipment not used in your configuration The user should become thoroughly familiar with the operation of this module before operating it Read this instruction manual completely DEFINITIONS The following definitions apply to WARNINGS CAUTIONS and NOTES found throughout this publication 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 Z WARNING REFER TO INSTRUCTION BULL
74. y salt cake buildup Applications Pulverized coal recovery boilers lime kiln Where possible specify SPS number otherwise provide details of the existing mounting plate as follows Plate with studs Bolt circle diameter number and arrangement of studs stud thread stud height above mounting plate Plate without studs Bolt circle diameter number and arrangement of holes thread depth of stud mounting plate with accessories Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 7 Instruction Manual IB 106 340CDR Original Issue January 2002 Hazardous Area Oxymitter DR Table 1 2 Calibration Components Part Number Description 1A99119G01 Two disposable calibration gas bottles 0 4 and 8 balance nitrogen 550 liters each 1A99119G02 Two flow regulators for calibration gas bottles 1A99119G03 Bottle rack Calibration gas bottles cannot be shipped via airfreight 1 8 Description and Specifications Rosemount Analytical Inc Division of Emerson Process Management Hazardous Area Oxymitter DR 2 1 Rosemount Analytical Inc SECTION 2 INSTALLATION 1 N Lb C The Hazardous Area Oxymitter DR and probe abrasive shield are heavy Use proper lifting and carrying procedures to avoid personal injury N C Before installing this equipment read the Safety instructions for the wiring and installation of this ap

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