Rosemount Oxymitter 5000 O2 Transmitter Owner's Manual

Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Oxygen Transmitter with Foundation
Fieldbus Communications
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.
Read all instructions prior to installing, operating, and servicing the product.
If you do not understand any of the instructions, contact your Rosemount Analytical representative for clarification.
Follow all warnings, cautions, and instructions marked on and supplied with the product.
Inform and educate your personnel in the proper installation, operation, and maintenance
of the product.
Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
To ensure proper performance, use qualified personnel to install, operate, update, program,
and maintain the product.
When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s performance,
place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in fire, electrical hazards, or improper operation.
Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent electrical shock
and personal injury.
The information contained in this document is subject to change without notice.
If a Model 275 Universal HART® Communicator is used with this unit, the software
within the Model 275 may require modification. If a software modification is required,
please contact your local Fisher-Rosemount Service Group or National Response Center at 1-800-654-7768.
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: [email protected]
http://www.processanalytic.com
HIGHLIGHTS OF CHANGES
Effective March, 1999 Rev. 1.0
Page
Summary
Page 3-1
Added note referencing appendices for fieldbus information.
Page A-5
Added Table A-4.
Page A-6
Added Table A-5.
Effective November, 1999 Rev. 1.1
Page
Summary
Pages P-12 thru
P-17
Added new Quick Start Guide.
Page 1-8
Added information on electronics operating temperatures and parts
for mounting.
Page 1-15
Removed Table 1-4, renumbered subsequent tables in Section 1.
Page 4-5
Updated Figure 4-3 to include Fault 4, A/D Comm Error.
Page 4-7
Updated Table 4-1 to include Fault 4, A/D Comm Error.
Page 4-9
Added Note to paragraph 4-5.
Page 5-6
Added new Figure 5-4 and paragraph d for Fault 4, A/D Comm Error.
Pages 5-7 thru 5-21
Updated subsequent figures and paragraphs in Section 5.
Effective April, 2001 Rev. 1.2
Page
Summary
Page 5-2
Table 5-1; changed Fault 6 Self-Clearing column data to “NO” and
Fault 8 Self-Clearing column data to “YES”.
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
TABLE OF CONTENTS
PREFACE........................................................................................................................ P-1
Definitions ........................................................................................................................ P-1
Safety Instructions .......................................................................................................... P-3
Material Safety Data Sheet.............................................................................................. P-5
Can You Use the Following Quick Start Guide ........................................................... P-13
1-0
1-1
1-2
1-3
1-4
1-5
DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1
Component Checklist Of Typical System (Package Contents) .................................. 1-1
System Overview............................................................................................................ 1-1
IMPS 4000 (Optional) .................................................................................................... 1-4
SPS 4000 (Optional)...................................................................................................... 1-6
Specifications................................................................................................................... 1-8
2-0
2-1
2-2
2-3
2-4
2-5
INSTALLATION .............................................................................................................. 2-1
Mechanical Installation ................................................................................................... 2-1
Electrical Installation (For Oxymitter 5000 Without SPS 4000)................................. 2-9
Electrical Installation (For Oxymitter 5000 With SPS 4000)..................................... 2-10
Pneumatic Installation (For Oxymitter 5000 Without SPS 4000) ............................. 2-13
Pneumatic Installation (For Oxymitter 5000 With SPS 4000) .................................. 2-14
3-0
3-1
3-2
3-3
3-4
3-5
3-6
3-7
STARTUP AND OPERATION ...................................................................................... 3-1
General ............................................................................................................................ 3-1
Logic I/O ......................................................................................................................... 3-4
Recommended Configuration......................................................................................... 3-5
Power Up ........................................................................................................................ 3-6
Start Up Oxymitter 5000 Calibration............................................................................ 3-7
IMPS 4000 Connections................................................................................................ 3-7
General ............................................................................................................................ 3-8
4-0
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
MAINTENANCE AND SERVICE .................................................................................. 4-1
Overview.......................................................................................................................... 4-1
Calibration........................................................................................................................ 4-1
LED Status Indicators.................................................................................................... 4-6
Oxymitter 5000 Removal/ Replacement........................................................................ 4-6
Electronics Replacement................................................................................................ 4-9
Entire Probe Replacement (Excluding Electronics) ................................................. 4-12
Heater Strut Replacement ........................................................................................... 4-12
Cell Replacement ......................................................................................................... 4-14
Ceramic Diffusion Element Replacement................................................................... 4-16
SPS 4000 Maintenance And Component Replacement .......................................... 4-17
5-0
5-1
5-2
5-3
5-4
5-5
TROUBLESHOOTING .................................................................................................... 5-1
General ............................................................................................................................ 5-1
Alarm Indications ............................................................................................................ 5-1
Alarm Contacts ............................................................................................................... 5-1
Identifying And Correcting Alarm Indications .............................................................. 5-2
SPS 4000 Troubleshooting.......................................................................................... 5-18
6-0
OPTIONAL ACCESSORIES........................................................................................... 6-1
Rosemount Analytical Inc.
A Division of Emerson Process Management
i
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
ii
Oxymitter 5000
7-0
RETURN OF MATERIAL ................................................................................................ 7-1
8-0
REPLACEMENT PARTS ................................................................................................ 8-1
9-0
APPENDICES ................................................................................................................. 9-1
Appendix A. Fieldbus Parameter Description.................................................................. A-1
Appendix B. Analog Input (AI) Function Block ................................................................ B-1
Appendix C. PID Function Block .....................................................................................C-1
10-0
INDEX............................................................................................................................ 10-1
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
LIST OF ILLUSTRATIONS
Figure 1.
Figure 2.
Figure 3.
Figure 1-1.
Figure 1-2.
Figure 1-3.
Figure 1-4.
Figure 1-5.
Figure 2-1.
Figure 2-2.
Figure 2-3.
Figure 2-4.
Figure 2-5.
Figure 2-6.
Figure 2-7.
Figure 2-8.
Figure 2-9.
Figure 2-10.
Figure 2-11.
Figure 2-12.
Figure 3-1.
Figure 3-2.
Figure 3-3.
Figure 3-4.
Figure 3-5.
Figure 4-1.
Figure 4-2.
Figure 4-3.
Figure 4-4.
Figure 4-5.
Figure 4-6.
Figure 4-7.
Figure 4-8.
Figure 4-9.
Figure 4-10.
Figure 4-11.
Figure 4-12.
Figure 4-13.
Figure 5-1.
Figure 5-2.
Figure 5-3.
Figure 5-4.
Figure 5-5.
Figure 5-6.
Figure 5-7.
Figure 5-8.
Figure 5-9.
Figure 5-10.
Figure 5-11.
Figure 5-12.
Rosemount Analytical Inc.
Oxymitter 5000 Installation Options..................................................................... P-12
Oxymitter 5000 with SPS 4000 Wiring Diagram.................................................. P-15
Oxymitter 5000 without SPS 4000 Wiring Diagram............................................. P-15
Typical System Package ....................................................................................... 1-0
Oxymitter 5000 Autocalibration System Options ................................................... 1-3
Oxymitter 5000 FOUNDATION Fieldbus Connections.......................................... 1-4
Typical System Installation .................................................................................... 1-5
SPS 4000............................................................................................................... 1-6
Oxymitter 5000 Installation .................................................................................... 2-2
Oxymitter 5000 Installation (with SPS 4000) ......................................................... 2-3
Oxymitter 5000 with Abrasive Shield ..................................................................... 2-4
Oxymitter 5000 Adaptor Plate Installation ............................................................. 2-5
Oxymitter 5000 Mounting Flange Installation ........................................................ 2-6
Oxymitter 5000 Bracing Installation ....................................................................... 2-7
Orienting the Optional Vee Deflector ..................................................................... 2-7
Installation with Drip Loop and Insulation Removal............................................... 2-8
Terminal Block ..................................................................................................... 2-10
SPS 4000 Electrical Connections ........................................................................ 2-12
Air Set, Plant Air Connection ............................................................................... 2-13
Oxymitter 5000 Gas Connections........................................................................ 2-14
Integral Electronics ................................................................................................ 3-1
Oxymitter 5000 Defaults ........................................................................................ 3-3
Startup and Normal Operation............................................................................... 3-6
Calibration Keys..................................................................................................... 3-7
Normal Operation................................................................................................... 3-8
Oxymitter 5000 Exploded View.............................................................................. 4-2
Membrane Keypad................................................................................................. 4-3
Inside Right Cover ................................................................................................. 4-4
Terminal Block ....................................................................................................... 4-7
Electronic Assembly............................................................................................... 4-8
J8 Connector.......................................................................................................... 4-9
Fuse Location ...................................................................................................... 4-11
Heater Strut Assembly......................................................................................... 4-13
Cell Replacement Kit ........................................................................................... 4-14
Ceramic Diffusion Element Replacement............................................................ 4-16
SPS 4000 Manifold Assembly ............................................................................. 4-18
Power Supply Board and Interface Board Connections ...................................... 4-20
Calibration Gas and Reference Air Components ................................................ 4-24
Fault 1, Open Thermocouple ................................................................................. 5-3
Fault 2, Shorted Thermocouple ............................................................................. 5-4
Fault 3, Reversed Thermocouple .......................................................................... 5-5
Fault 4, A/D Comm Error ....................................................................................... 5-6
Fault 5, Open Heater ............................................................................................. 5-7
Fault 6, High High Heater Temp ............................................................................ 5-8
Fault 7, High Case Temp....................................................................................... 5-9
Fault 8, Low Heater Temp ................................................................................... 5-10
Fault 9, High Heater Temp .................................................................................. 5-11
Fault 10, High Cell mV......................................................................................... 5-12
Fault 11, Bad Cell ................................................................................................ 5-13
Fault 12, EEPROM Corrupt ................................................................................. 5-14
A Division of Emerson Process Management
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Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Figure 5-13.
Figure 5-14.
Figure 5-15.
Figure 5-16.
Figure 8-1.
Figure 8-2.
Oxymitter 5000
Fault 13, Invalid Slope ......................................................................................... 5-15
Fault 14, Invalid Constant .................................................................................... 5-16
Fault 15, Last Calibration Failed .......................................................................... 5-17
SPS 4000 Troubleshooting Flowchart (Sheet 1 of 2) .......................................... 5-20
Cell Replacement Kit ............................................................................................. 8-4
Probe Disassembly Kit........................................................................................... 8-5
LIST OF TABLES
Table 1-1.
Table 1-2.
Table 1-3.
Table 1-4.
Table 1-5.
Table 3-1.
Table 3-2.
Table 4-1.
Table 5-1.
Table 5-2.
Table 8-1.
Table 8-2.
Table 8-3.
Table 8-4.
iv
Specifications......................................................................................................... 1-8
Product Matrix...................................................................................................... 1-10
Calibration Gas Bottles ........................................................................................ 1-11
Intelligent Multiprobe Test Gas Sequencer Versions .......................................... 1-12
Single Probe Autocalibration Sequencer Coding ................................................ 1-12
Logic I/O Configuration .......................................................................................... 3-4
Logic I/O Parameters............................................................................................. 3-5
Diagnostic/Unit Alarms .......................................................................................... 4-6
Diagnostic/Unit Alarm Fault Definitions ................................................................. 5-2
SPS 4000 Fault Finding....................................................................................... 5-19
Replacement Parts for Probe ................................................................................ 8-1
Replacement Parts for Electronics ........................................................................ 8-6
Replacement Parts for SPS 4000.......................................................................... 8-8
Replacement Parts for Calibration Gas Bottles ..................................................... 8-8
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
PREFACE
The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Oxymitter 5000 Oxygen Transmitter with Foundation Fieldbus Communications module.
Some sections may describe equipment not used in your configuration. The user should
become thoroughly familiar with the operation of this module before operating it. Read
this instruction manual completely.
DEFINITIONS
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this
publication.
Highlights an operation or maintenance
procedure, practice, condition, statement, etc. If not strictly observed, could
result in injury, death, or long-term
health hazards of personnel.
Highlights an operation or maintenance
procedure, practice, condition, statement, etc. If not strictly observed, could
result in damage to or destruction of
equipment, or loss of effectiveness.
NOTE
Highlights an essential operating procedure,
condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical
manner.
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P-1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Oxymitter 5000
OXYGEN TRANSMITTER
WITH FOUNDATION
FIELDBUS COMMUNICATIONS
NOTICE
Read this manual before working with the product. For personal and system safety, and for
optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product.
The products described in this document are NOT designed for nuclear-qualified
applications.
Using non-nuclear-qualified products in applications that require nuclear-qualified hardware
or products may cause inaccurate readings.
For information on Fisher-Rosemount nuclear-qualified products, contact your local FisherRosemount Sales Representative.
Rosemount is a registered trademark of Rosemount Inc.
Delta V, the Delta V logotype, PlantWeb, and the PlantWeb logotype are trademarks of Fisher-Rosemount.
FOUNDATION is a trademark of the Fieldbus Foundation.
Rosemount satisfies all obligations coming from legislation to harmonize the product requirements in the European Union.
P-2
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Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
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. NonEU 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 IEC245.
4. All wiring shall be suitable for use in 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 circuits 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, hazardous 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. Certain 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 following standards: EN61010-1, IEC417, and ISO3864.
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April 2001
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Oxymitter 5000
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Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
CERAMIC FIBER PRODUCTS
MATERIAL SAFETY DATA SHEET
JULY 1, 1996
SECTION I.
IDENTIFICATION
PRODUCT NAME
Ceramic Fiber Heaters, Molded Insulation Modules and Ceramic Fiber Radiant Heater Panels.
CHEMICAL FAMILY
Vitreous Aluminosilicate Fibers with Silicon Dioxide.
CHEMICAL NAME
N.A.
CHEMICAL FORMULA
N.A.
MANUFACTURER’S NAME AND ADDRESS
Watlow Columbia
2101 Pennsylvania Drive
Columbia, MO 65202
573-474-9402
573-814-1300, ext. 5170
HEALTH HAZARD SUMMARY
WARNING
•
Possible cancer hazard based on tests with laboratory animals.
•
May be irritating to skin, eyes and respiratory tract.
•
May be harmful if inhaled.
•
Cristobalite (crystalline silica) formed at high temperatures (above 1800ºF) can cause severe respiratory disease.
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IB-106-350 Rev. 1.2
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Oxymitter 5000
SECTION II.
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.): N.A.
WATER SOLUBILITY: N.A.
SECTION III.
HAZARDOUS INGREDIENTS
MATERIAL, QUANTITY, AND THRESHOLD/EXPOSURE LIMIT VALUES
Aluminosilicate (vitreous) 99+ %
CAS. No. 142844-00-06
Zirconium Silicate
Black Surface Coating**
Armorphous Silica/Silicon Dioxide
1 fiber/cc TWA
10 fibers/cc CL
0-10% 5 mg/cubic meter (TLV)
0 - 1% 5 mg/cubic meter (TLV)
0-10% 20 mppcf (6 mg/cubic meter)
PEL (OSHA 1978) 3 gm cubic meter
(Respirable dust): 10 mg/cubic meter,
Intended TLV (ACGIH 1984-85)
**Composition is a trade secret.
SECTION IV.
FLASH POINT:
FIRE AND EXPLOSION DATA
None
FLAMMABILITY LIMITS:
N.A.
EXTINGUISHING MEDIA
Use extinguishing agent suitable for type of surrounding fire.
UNUSUAL FIRE AND EXPLOSION HAZARDS / SPECIAL FIRE FIGHTING PROCEDURES
N.A.
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Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION V.
HEALTH HAZARD DATA
THRESHOLD LIMIT VALUE
(See Section III)
EFFECTS OF OVER EXPOSURE
EYE
Avoid contact with eyes. Slightly to moderately irritating. Abrasive action may cause damage to outer surface
of eye.
INHALATION
May cause respiratory tract irritation. Repeated or prolonged breathing of particles of respirable size may
cause inflammation of the lung leading to chest pain, difficult breathing, coughing and possible fibrotic change
in the lung (Pneumoconiosis). Pre-existing medical conditions may be aggravated by exposure: specifically,
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 PRODUCT
Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) 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 exposure 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 is a review of the results to date:
EPIDEMIOLOGY
At this time there are no known published reports demonstrating negative health outcomes of workers exposed
to refractory ceramic fiber (RCF). Epidemiologic investigations of RCF production workers are ongoing.
1) There is no evidence of any fibrotic lung disease (interstitial fibrosis) whatsoever on x-ray.
2) There is no evidence of any lung disease among those employees exposed to RCF that had never smoked.
3) A statistical “trend” was observed in the exposed population between the duration of exposure to RCF and a
decrease in some measures of pulmonary function. These observations are clinically insignificant. In other words,
if these observations were made on an individual employee, the results would be interpreted as being within the
normal range.
4) Pleural plaques (thickening along the chest wall) have been observed in a small number of employees who had a
long duration of employment. There are several occupational and non-occupational causes for pleural plaque. It
should be noted that plaques are not “pre-cancer” nor are they associated with any measurable effect on lung
function.
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Oxymitter 5000
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/m3, which corresponds with approximately 200, 150, 75, and 25 fibers/cc.
Animals exposed to 30 and 16 mg/m3 were observed to have developed a pleural and parenchymal fibroses;
animals exposed to 9 mg/m3 had developed a mild parenchymal fibrosis; animals exposed to the lowest dose
were found to have the response typically observed any time a material is inhaled into the deep lung. While a
statistically significant increase in lung tumors was observed following exposure to the highest dose, there was
no excess lung cancers at the other doses. Two rats exposed to 30 mg/m3 and one rat exposed to 9 mg/m3 developed masotheliomas.
The International Agency for Research on Cancer (IARC) reviewed the carcinogenicity data on man-made vitreous fibers (including ceramic fiber, glasswool, 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 if irritation persists.
INHALATION
Remove person from source of exposure and move to fresh air. Some people may be sensitive to fiber induced
irritation of the respiratory tract. If symptoms such as shortness of breath, coughing, wheezing or chest pain
develop, seek medical attention. If person experiences continued breathing difficulties, administer oxygen until medical assistance can be rendered.
INGESTION
Do not induce vomiting. Get medical attention if 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.
INCOMPATIBILITY/MATERIALS TO AVOID
Incompatible with hydrofluoric acid and concentrated alkali.
HAZARDOUS DECOMPOSITION PRODUCTS
N.A.
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Rosemount Analytical Inc.
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Instruction Manual
Oxymitter 5000
IB-106-350 Rev. 1.2
April 2001
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 sweeping if necessary. Avoid clean up procedure which may result in water pollution. (Observe Special Protection Information 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 attainable is 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 accompany binder burn-off during first heat. Use adequate ventilation or other precautions to eliminate vapors resulting from binder burn-off. Exposure to burn-off fumes may cause respiratory tract irritation,
bronchial hyper-reactivity and asthmatic response.
SKIN PROTECTION
Wear gloves, hats and full body clothing to prevent 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.
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A Division of Emerson Process Management
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Instruction Manual
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Oxymitter 5000
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 caution 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. Rinse washing machine thoroughly after use. If clothing is to be laundered by
someone else, inform launderer of proper procedure. Work clothes and street clothes should be kept separate
to prevent contamination.
Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) 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/m3 (respirable dust). The ACGIH
threshold limit value (TLV) for cristobalite is 0.05 mg/m3 (respirable dust) (ACGIH 1991-92). Use NIOSH or
MSHA approved equipment when airborne exposure limits may be exceeded. The minimum respiratory protection recommended for given airborne fiber or cristobalite concentrations are:
CONCENTRATION
P-10
0-1 fiber/cc or 0-0.05 mg/m3 cristobalite
(the OSHA PEL)
Optional disposable dust respirator (e.g. 3M
9970 or equivalent).
Up to 5 fibers/cc or up to 10 times the
OSHA PEL for cristobalite
Half face, air-purifying respirator equipped
with high 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
PEL for cristobalite (2.5 mg/m3)
Full face, air-purifying respirator with high
efficiency 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. 3M W3265S with W3267 filters or
equivalent).
Greater than 25 fibers/cc or 50 times the
OSHA PEL for cristobalite (2.5 mg/m3)
Full face, positive pressure supplied air respirator (e.g. 3M 7800S with W9435 hose & W3196
low pressure regulator kit connected to clean
air supply or equivalent).
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
Oxymitter 5000
IB-106-350 Rev. 1.2
April 2001
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.
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 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.
A Division of Emerson Process Management
P-11
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
WHAT YOU NEED TO KNOW
BEFORE INSTALLING AND WIRING A ROSEMOUNT
OXYMITTER 5000 OXYGEN TRANSMITTER
1. What type of installation does your system require?
Use the following drawing, Figure 1, to identify which type of installation is required for your
Oxymitter 5000 system.
STANDARD
REFERENCE AIR
CALIBRATION GAS
OXYMITTER 5000
LINE VOLTAGE
LOGIC I/O
FIELDBUS DIGITAL SIGNAL
INTEGRAL SPS 4000 OPTION
LINE VOLTAGE
FIELDBUS DIGITAL SIGNAL
RELAY OUTPUTS, AND
REMOTE CONTACT INPUT
OXYMITTER 5000
(WITH INTEGRAL SPS 4000)
CALIBRATION GAS 1
CALIBRATION GAS 2
REFERENCE AIR
IMPS 4000 OPTION
LINE VOLTAGE
FIELDBUS DIGITAL SIGNAL
OXYMITTER 5000
LOGIC I/0
INSTR. AIR SUPPLY
CAL GAS
IMPS
4000
REFERENCE AIR
CALIBRATION GAS 1
CALIBRATION GAS 2
LINE VOLTAGE
31770001
Figure 1. Oxymitter 5000 Installation Options
P-12
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
CAN YOU USE THE FOLLOWING
QUICK START GUIDE?
Use this Quick Start Guide if ...
1. Your system requires a STANDARD or INTEGRAL SPS 4000 OPTION installation. Installation options for the Oxymitter 4000 are shown in Figure 1.
2. Your system does NOT require an IMPS 4000 OPTION installation.
3. You are familiar with the installation requirements for the Oxymitter 4000 Oxygen Transmitter. You are familiar with the installation requirements for the Oxymitter 4000 Oxygen
Transmitter with an integral SPS 4000.
If you cannot use the Quick Start Guide, turn to Section 2, Installation, in this Instruction
Bulletin.
Rosemount Analytical Inc.
A Division of Emerson Process Management
P-13
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
QUICK START GUIDE FOR OXYMITTER 5000 SYSTEMS
Before using the Quick Start Guide, please read “WHAT YOU NEED TO KNOW BEFORE
INSTALLING AND WIRING A ROSEMOUNT OXYMITTER 5000 OXYGEN TRANSMITTER” on the preceding page.
1. Install the Oxymitter 5000 in an appropriate location on the stack or duct. Refer to Section 2,
paragraph 2-1a for information on selecting a location for the Oxymitter 5000.
2. If using an SPS 4000, connect the calibration gasses to the appropriate fittings on the SPS
4000 manifold.
3. Connect reference air to the Oxymitter 5000 or SPS 4000, as applicable.
4. If using an SPS 4000, make the following wire connections as shown in Figure 2: line voltage, cal initiate-remote contact input, relay output, and fieldbus digital signal.
5. If NOT using an SPS 4000, make the following wire connections as shown in Figure 3: line
voltage, logic I/O, and fieldbus digital signal.
6. Verify the Oxymitter 5000 switch configuration is as desired. Refer to Section 3, paragraphs
3-1c, 3-1d, and 3-1e.
7. Apply power to the Oxymitter 5000, the cell heater will turn on. Allow approximately one half
hour for the cell to heat to operating temperature. Once the ramp cycle has completed and
the Oxymitter 5000 is at normal operation, proceed with step 8.
8. If using an SPS 4000, initiate a semi-automatic calibration.
9. If NOT using an SPS 4000, perform a manual calibration. Refer to the QUICK REFERENCE
GUIDE manual calibration instructions on the following pages, or Section 4, paragraph
4-2, Calibration, in this instruction bulletin.
P-14
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
5 VDC
(SELF-POWERED)
TO REMOTE
CONTACT INPUT
CONNECTION
CAL INITIATE
+
FIELDBUS
DIGITAL
SIGNAL
CONNECTION
+
-
5 - 30 VDC TO RELAY OUTPUT
CONNECTIONS
NOT USED
CAL FAIL
+
-
-
IN CAL
+
LINE IN
GROUND
-
NEUTRAL
90 - 250 VAC,
50/60 HZ LINE
VOLTAGE
INPUT
FACTORY
WIRING
TO INTERFACE
BOARD
FACTORY
WIRING TO
OXYMITTER
5000
NOT USED
GREEN
ORANGE
BLUE
RED
BROWN
YELLOW
WHITE
BLACK
FACTORY
WIRING TO
OXYMITTER
5000
FACTORY WIRING
TO INTERFACE BOARD
FACTORY WIRING
TO POWER SUPPLY
BOARD
35950001
Figure 2. Oxymitter 5000 with SPS 4000 Wiring Diagram
TERMINAL
BLOCK
AC TERMINAL
COVER
LINE VOLTAGE
(85 TO 264 VAC)
AC
L1
AC
N
+
GROUND
LUGS
-
LOGIC I/O
FIELDBUS
DIGITAL
SIGNAL
AC LINE
VOLTAGE PORT
+
FIELDBUS
-
LEFT SIDE OF
OXYMITTER 5000
SIGNAL
PORT
31770002
Figure 3. Oxymitter 5000 without SPS 4000 Wiring Diagram
Rosemount Analytical Inc.
A Division of Emerson Process Management
P-15
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
QUICK REFERENCE GUIDE
OXYMITTER 5000 OXYGEN TRANSMITTER
Performing a Manual Calibration
1. Place the control loop in manual.
2. Press the CAL key. The CAL LED will light solid.
3. Apply the first calibration gas.
4. Press the CAL key. When the unit has taken the readings using the first calibration gas, the
CAL LED will flash continuously.
5. Remove the first calibration gas and apply the second calibration gas.
6. Push the CAL key. The CAL LED will light solid. When the unit has taken the readings using
the second calibration gas, the CAL LED will flash a two-pattern flash or a three-pattern
flash. A two-pattern flash equals a valid calibration,
three-pattern flash equals an invalid calibration.
7. Remove the second calibration gas and cap off the calibration gas port.
8. Press the CAL key. The CAL LED will be lit solid as the unit purges. When the purge is
complete, the CAL LED will turn off.
9. If the calibration was valid, the DIAGNOSTIC ALARMS LEDs indicate normal operation. If
the new calibration values are not within the parameters, the DIAGNOSTIC ALARMS LEDs
will indicate an alarm.
10. Place the control loop in automatic.
P-16
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
HART COMMUNICATOR
FAST KEY SEQUENCES
Perform Calibration
2
3
1
O2 Upper Range Value
1
3
Trim Analog Output
2
4
3
1
1
Analog Output Lower Range Value
3
Toggle Analog Output Tracking
2
2
2
2
View O2 Value
2
1
1
1
View Analog Output
1
2
1
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: [email protected]
World Wide Web: www.processanalytic.com
Rosemount Analytical Inc.
A Division of Emerson Process Management
P-17
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 1
1
2
6
3
5
4
1.
2.
3.
4.
5.
6.
28550004
Instruction Bulletin
IMPS 4000 Intelligent Multiprobe Test Gas Sequencer (Optional)
Oxymitter 5000 with Integral Electronics
SPS 4000 Single Probe Autocalibration Sequencer (Optional) - (Shown with reference air option)
Adaptor Plate with Mounting Hardware and Gasket
Reference Air Set (used if SPS 4000 without reference air option or IMPS 4000 not supplied)
Figure 1-1. Typical System Package
1-0
Description and Specifications
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1-1
COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
A typical Rosemount Oxymitter 5000 Oxygen
Transmitter should contain the items shown in
Figure 1-1. Record the part number, serial number, and order number for each component of
your system in the table located on the first
page of this manual.
Use the product matrix in Table 1-1 at the end
of this section to compare your order number
against your unit. The first part of the matrix defines the model. The last part defines the various options and features of the Oxymitter 5000.
Ensure the features and options specified by
your order number are on or included with the
unit.
1-2
SYSTEM OVERVIEW
a. Scope
This Instruction Bulletin is designed to supply details needed to install, start up, operate, and maintain the Oxymitter 5000.
Integral signal conditioning electronics outputs a digital FOUNDATION fieldbus signal
representing an O2 value and provides a
membrane keypad for setup, calibration,
and diagnostics. This same information,
plus additional details, can be accessed via
fieldbus digital communications.
b. FOUNDATION fieldbus Technology
FOUNDATION fieldbus is an all digital, serial, two-way communication system that
interconnects field equipment such as sensors, actuators, and controllers. Fieldbus is
a Local Area Network (LAN) for instruments
used in both process and manufacturing
automation with built-in capacity to distribute the control application across the network. The fieldbus environment is the base
level group of digital networks in the hierarchy of planet networks.
Rosemount Analytical Inc.
A Division of Emerson Process Management
The fieldbus retains the desirable features
of the 4-20 mA analog system, including a
standardized physical interface to the wire,
bus powered devices on a single wire, and
intrinsic safety options, and enables additional capabilities, such as:
•
•
•
•
•
Increased capabilities due to full digital
communications
Reduced wiring and wire terminations
due to multiple devices on one set of
wires
Increased selection of suppliers due to
interoperability
Reduced loading on control room
equipment with the distribution of some
control and input/ output functions to
field devices
Speed options for process control and
manufacturing applications
c. System Description
The Oxymitter 5000 is designed to measure
the net concentration of oxygen in an industrial process; i.e., the oxygen remaining
after all fuels have been oxidized. The
probe is permanently positioned within an
exhaust duct or stack and performs its task
without the use of a sampling system.
The equipment measures oxygen percentage by reading the voltage developed
across a heated electrochemical cell, which
consists of a small yttria-stabilized, zirconia
disc. Both sides of the disc are coated with
porous metal electrodes. When operated at
the proper temperature, the millivolt output
voltage of the cell is given by the following
Nernst equation:
EMF = KT log10(P1/P2) + C
Where:
1. P2 is the partial pressure of the oxygen
in the measured gas on one side of the
cell.
2. P1 is the partial pressure of the oxygen
in the reference air on the opposite side
of the cell.
Description and Specifications
1-1
1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
3. T is the absolute temperature.
4. C is the cell constant.
5. K is an arithmetic constant.
NOTE
For best results, use clean, dry, instrument air (20.95% oxygen) as the
reference air.
When the cell is at operating temperature
and there are unequal oxygen concentrations across the cell, oxygen ions will travel
from the high oxygen partial pressure side
to the low oxygen partial pressure side of
the cell. The resulting logarithmic output
voltage is approximately 50 mV per decade.
The output is proportional to the inverse
logarithm of the oxygen concentration.
Therefore, the output signal increases as
the oxygen concentration of the sample gas
decreases. This characteristic enables the
Oxymitter 5000 to provide exceptional sensitivity at low oxygen concentrations.
The Oxymitter 5000 measures net oxygen
concentration in the presence of all the
products of combustion, including water vapor. Therefore, it may be considered an
analysis on a “wet” basis. In comparison
with older methods, such as the portable
apparatus, which provides an analysis on a
“dry” gas basis, the “wet” analysis will, in
general, indicate a lower percentage of
oxygen. The difference will be proportional
to the water content of the sampled gas
stream.
d. System Configuration
Oxymitter 5000 units are available in five
length options, giving the user the flexibility
to use an in situ penetration appropriate to
the size of the stack or duct. The options on
length are 18 in. (457 mm), 3 ft (0.91 m), 6 ft
(1.83 m), 9 ft (2.7 m), or 12 ft (3.66 m).
The integral electronics control probe temperature and provide an output that represents the measured oxygen concentration.
The power supply can accept voltages of
90-250 VAC and 50/60 Hz; therefore, no
setup procedures are required. The oxygen
sensing cell is maintained at a constant
1-2
Description and Specifications
temperature by modulating the duty cycle of
the probe heater portion of the integral
electronics. The integral electronics accepts
millivolt signals generated by the sensing
cell and produces the outputs to be used by
remotely connected devices. The output is a
FOUNDATION fieldbus digital communication signal.
Two calibration gas sequencers are available to the Oxymitter 5000: the IMPS 4000
and the SPS 4000 (Figure 1-2).
Systems with multiprobe applications may
employ an optional IMPS 4000 Intelligent
Multiprobe Test Gas Sequencer. The IMPS
4000 provides automatic calibration gas sequencing for up to four Oxymitter 5000 units
and accommodates autocalibrations based
on the CALIBRATION RECOMMENDED
signal from the Oxymitter 5000, a timed interval set up via fieldbus or the IMPS 4000,
or when a calibration request is initiated.
For systems with one or two Oxymitter 5000
units per combustion process, an optional
SPS 4000 Single Probe Autocalibration Sequencer can be used with each Oxymitter
5000 to provide automatic calibration gas
sequencing. The SPS 4000 can be
mounted directly to the Oxymitter 5000 or in
a remote location if space is limited. The
sequencer performs autocalibrations based
on the CALIBRATION RECOMMENDED
signal from the Oxymitter 5000, a timed interval set up in fieldbus, or whenever a calibration request is initiated.
e. System Features
1. The CALIBRATION RECOMMENDED
feature detects when the sensing cell is
likely out of limits. This may eliminate
the need to calibrate on a “time since
last cal” basis.
2. The cell output voltage and sensitivity
increase as the oxygen concentration
decreases.
3. Membrane keypad and FOUNDATION
fieldbus communication are standard.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
7. The integral electronics are adaptable
for line voltages from 90-250 VAC;
therefore, no configuration is
necessary.
8. The Oxymitter 5000 membrane keypad
is available in five languages:
English
French
German
Italian
Spanish
9. An operator can calibrate and diagnostically troubleshoot the Oxymitter 5000
in one of three ways:
(a) Membrane Keypad. The membrane keypad, housed within the
right side of the electronics housing, provides fault indication by
way of flashing LEDs. Calibration
can be performed from the membrane keypad.
Figure 1-2. Oxymitter 5000 Autocalibration System
Options
4. Field replaceable cell, heater, thermocouple, and diffusion element.
5. The Oxymitter 5000 is constructed of
rugged 316 L stainless steel for all
wetted parts.
6. Integral electronics eliminates traditional wiring between probe and
electronics.
Rosemount Analytical Inc.
A Division of Emerson Process Management
(b) FOUNDATION fieldbus Interface.
The Oxymitter 5000’s output carries a signal containing the oxygen
level encoded in digital format.
This digital output can also be
used to communicate with the
Oxymitter and access all of the
Oxymitter’s status information.
(c) Optional IMPS 4000. The Programmable Logic Controller (PLC)
in the IMPS 4000 provides fault indications using flashing LEDs and
LCD display messages. Refer to
the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for more
information.
Description and Specifications
1-3
1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
f.
Oxymitter 5000
Handling the Oxymitter 5000
A source of instrument air is optional at the
Oxymitter 5000 for reference air use. Since
the unit is equipped with an in-place calibration feature, provisions can be made to
permanently connect calibration gas tanks
to the Oxymitter 5000.
It is important that printed circuit
boards and integrated circuits are
handled only when adequate antistatic
precautions have been taken to prevent possible equipment damage.
If the calibration gas bottles will be permanently connected, a check valve is required
next to the calibration fittings on the integral
electronics. This check valve is to prevent
breathing of the calibration gas line and
subsequent flue gas condensation and corrosion. The check valve is in addition to the
stop valve in the calibration gas kit or the
solenoid valves in the IMPS 4000 or SPS
4000.
The Oxymitter 5000 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.
NOTE
g. System Considerations
The integral electronics is rated NEMA
4X (IP66) and is capable of operation
at temperatures up to 149°F (65°C).
Prior to installing your Oxymitter 5000,
make sure you have all the components
necessary to make the system installation.
Ensure all the components are properly integrated to make the system functional.
After verifying that you have all the components, select mounting locations and determine how each component will be placed in
terms of available line voltage, ambient
temperatures, environmental considerations, convenience, and serviceability.
Figure 1-3 shows a typical system wiring. A
typical system installation is illustrated in
Figure 1-4.
Retain the packaging in which the
Oxymitter 5000 arrived from the factory in case any components are to be
shipped to another site. This packaging has been designed to protect the
product.
1-3
IMPS 4000 (OPTIONAL)
Information on the IMPS 4000 is available in the
IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin.
FIELDBUS DIGITAL
SIGNAL
OXYMITTER 5000
WITH INTEGRAL ELECTRONICS
2 CALIBRATION GAS LINES
BY CUSTOMER
[300 FT (90 M) MAX]
LINE VOLTAGE
FIELDBUS COMPUTER
TERMINAL
28550005
Figure 1-3. Oxymitter 5000 FOUNDATION Fieldbus Connections
1-4
Description and Specifications
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
STANDARD
GASES
DUCT
STACK
OXYMITTER
5000
ADAPTOR
PLATE
LINE
VOLTAGE
INSTRUMENT
AIR SUPPLY
(REFERENCE AIR)
FLOWMETER
LOGIC I/O
FIELDBUS
DIGITAL
SIGNAL
PRESSURE
REGULATOR
GASES
CALIBRATION
GAS
IMPS 4000 OPTION
DUCT
STACK
ADAPTOR
PLATE
CALIBRATION
GAS
OXYMITTER
5000
CA
CA LIB
INS
LIB RA
RA TIO SU T. A
P IR
TIO N
N GASPLY
GA
S 2
1
LINE
VOLTAGE
SPS 4000 OPTION
(WITH REFERENCE AIR OPTION)
FIELDBUS
DIGITAL
SIGNAL
LOGIC I/O
REFERENCE
AIR
GASES
IMPS 4000
DUCT
STACK
OXYMITTER
5000
ADAPTOR
PLATE
CALIBRATION GAS 1
(HIGH CALIBRATION GAS)
INSTRUMENT
AIR SUPPLY
CALIBRATION GAS 2
(LOW CALIBRATION GAS)
LINE
VOLTAGE
FIELDBUS DIGITAL SIGNAL,
RELAY OUTPUTS, AND
REMOTE CONTACT INPUT
35950002
Figure 1-4. Typical System Installation
Rosemount Analytical Inc.
A Division of Emerson Process Management
Description and Specifications
1-5
1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
FRONT VIEW
REFERENCE AIR
PRESSURE
REGULATOR
(OPTIONAL)
CALIBRATION GAS
FLOWMETER
NOTE: MANIFOLD COVER IS
REMOVED TO SHOW
INTERNAL COMPONENTS.
REFERENCE GAS
FLOWMETER
ALSO, BOARD COMPONENTS
ARE NOT SHOWN FOR
CLARITY.
REAR VIEW (OF MANIFOLD ONLY)
INTERFACE
BOARD
CALIBRATION GAS 1
(HIGH CALIBRATION GAS)
SOLENOID
PRESSURE
SWITCH
TERMINAL
COVER
MANIFOLD
POWER
SUPPLY BOARD
CALIBRATION GAS 2
(LOW CALIBRATION GAS)
SOLENOID
26170001
Figure 1-5. SPS 4000
1-4
SPS 4000 (OPTIONAL)
The SPS 4000 Single Probe Autocalibration
Sequencer provides the capability of performing
automatic, timed or on demand, calibrations of a
single Oxymitter 5000 without sending a technician to the installation site.
a. Mounting
location if space is limited. In addition, the
integrally mounted SPS 4000 can be configured for a horizontally or vertically
mounted Oxymitter 5000 (Figure 2-2). The
information in this instruction bulletin will
cover the integrally mounted units only. For
information on remote mounted units, refer
to the SPS 4000 Single Probe Autocalibration Sequencer Instruction Bulletin.
The SPS 4000 can be mounted either directly to an Oxymitter 5000 or at a remote
1-6
Description and Specifications
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
b. Components (Figure 1-5)
The SPS 4000 consists of a manifold and a
calibration gas flowmeter. The manifold provides electrical feedthroughs and calibration
gas ports to route power and signal connections and calibration gases to and from the
sequencer. In addition, the manifold houses
two calibration gas solenoids that sequence
the gases to the Oxymitter 5000, a pressure
switch that detects low calibration gas pressure, and two PC boards. A terminal strip
housed within the terminal cover provides
convenient access for all user connections.
Components optional to the SPS 4000 include a reference air flowmeter and pressure regulator. The reference air flowmeter
indicates the flow rate of reference air continuously flowing to the Oxymitter 5000. The
reference air pressure regulator ensures the
instrument air (reference air) flowing to the
Oxymitter 5000 is at a constant pressure [20
psi (138 kPa)]. The regulator also has a filter to remove particulates in the reference
Rosemount Analytical Inc.
A Division of Emerson Process Management
air and a drain valve to bleed the moisture
that collects in the filter bowl.
Brass fittings and Teflon tubing are standard. Stainless steel fittings and tubing are
optional. Also, disposable calibration gas
bottles are available as an option or can be
purchased through a local supplier.
c. Operation
The SPS 4000 works in conjunction with the
Oxymitter 5000’s CALIBRATION RECOMMENDED feature to perform an autocalibration. This feature automatically performs a gasless calibration check every
hour on the Oxymitter 5000. If a calibration
is recommended and its contact output signal is set for “handshaking” with the sequencer, the Oxymitter 5000 sends a signal
to the sequencer. The sequencer automatically performs a calibration upon receiving
the signal. Thus, no human interface is required for the automatic calibration to take
place.
Description and Specifications
1-7
1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
1-5
Oxymitter 5000
SPECIFICATIONS
Table 1-1. Specifications
Oxymitter 5000
O2 Range:
Standard ..............................................................
Accuracy ....................................................................
System Response to Calibration Gas ........................
Temperature Limits:
Process ...............................................................
Electronics ...........................................................
0 to 10% O2
0 to 25% O2
0 to 40% O2 (via FOUNDATION fieldbus)
±0.75% of reading or 0.05% O2, whichever is greater
Initial response in less than 3 seconds T90 in less than
8 seconds
32° to 1300°F (0° to 704°C) up to 2400°F (1300°C) with
optional accessories
-40° to 185°F (-40° to 85°C)
Operating temperature of electronics inside of instrument housing, as measured by a HART communicator
or Rosemount Asset Management Solutions software.
Probe Lengths ...........................................................
18 in. (457 mm)
3 ft (0.91 m)
6 ft (1.83 m)
9 ft (2.74 m)
12 ft (3.66 m)
Mounting and Mounting Position ...............................
Vertical or horizontal
Spool pieces are available, P/N 3D39761G02, to offset
transmitter housing from hot ductwork.
Materials:
Probe ...................................................................
Electronics Enclosure ..........................................
Wetted or welded parts - 316L stainless steel
Non-wetted parts - 304 stainless steel, low-copper aluminum
Low-copper aluminum
Calibration ..................................................................
Manual, semi-automatic, or automatic
Calibration Gas Mixtures Recommended ..................
0.4% O2, Balance N2
8% O2, Balance N2
Calibration Gas Flow .................................................
5 scfh (2.5 l/m)
Reference Air .............................................................
2 scfh (1 l/m), clean, dry, instrument-quality air
(20.95% O2), regulated to 5 psi (34 kPa)
Electronics .................................................................
NEMA 4X, IP66 with fitting and pipe on reference exhaust port to clear dry atmosphere
Electronic Noise .........................................................
Meets EN 50082-2 Generic Immunity Std. Part II.
Includes EN 61000-4-2 for Electrostatic Discharge
4 KV contact, 8 KV in air
Includes IEC 801-4 for fast transients; 2 KV on power
supply and control lines
Line Voltage ...............................................................
90-250 VAC, 50/60 Hz. No configuration necessary
3/4 in. - 14 NPT conduit port
1-8
Description and Specifications
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 1-1. Specifications (Continued)
Signals:
Digital Output .......................................................
Logic I/O ..............................................................
FOUNDATION fieldbus compatible
Two-terminal logic contact configurable as either an
alarm output or as a bi-directional calibration handshake signal to IMPS 4000 or SPS 4000
Self-powered (+5 V), in series with 340 ohms
Conduit ports — 3/4 in.-14 NPT (one threaded hole for
both analog output and logic I/O)
Power Requirements:
Probe Heater .......................................................
Electronics ...........................................................
Maximum .............................................................
175 W nominal
10 W nominal
500 W
SPS 4000
Mounting ....................................................................
Integral to Oxymitter 5000
Remote from Oxymitter 5000
Materials of Construction:
Manifold/Electronics Enclosure ...........................
Mounting Brackets ..............................................
Pneumatic Fittings ...............................................
Pneumatic Tubing ...............................................
Assembly Hardware ............................................
Aluminum
316 stainless steel (SS)
1/8 in. brass NPT (SS optional)
1/4 in. Teflon (SS optional)
Galvanized and stainless steel
Humidity Range .........................................................
100% relative humidity
Ambient Temperature Range ....................................
-40° to 149°F (-40° to 65°C)
Electrical Classification ..............................................
NEMA 4X (IP56)
Explosion-Proof Option (both pending) .....................
CENELEC EExd IIB + H2
(Class 1, Div. 1, Group B,C,D)
Electrical Feedthroughs .............................................
1/2 in. NPT
Input Power ................................................................
90 to 250 VAC, 50/60 Hz
Power Consumption ..................................................
5 VA maximum
External Electrical Noise ............................................
EN 50 082-2, includes 4 KV electrostatic discharge
Handshake Signal
to/from Oxymitter 5000 (self-powered) ...............
5 V (5 mA maximum)
Cal Initiate Contact Input from Control Room ............
5 VDC (self-powered)
Relay Outputs to Control Room .................................
5 to 30 VDC, Form A (SPST)
(one “In-Cal”, one “Cal Failed”)
Cabling Distance between
SPS 4000 and Oxymitter 5000 ............................
Maximum 1000 ft (303 m)
Piping Distance between SPS 4000
and Oxymitter 5000 .............................................
Maximum 300 ft (91 m)
Approximate Shipping Weight ...................................
10 lbs (4.5 kg)
Fisher-Rosemount has satisfied all obligations coming from the European legislation to harmonize
the product requirements in Europe.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Description and Specifications
1-9
1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 1-2. Product Matrix
OXT5A
Oxymitter 5000 In Situ Oxygen Transmitter
Oxygen Transmitter - Instruction Book
Code
1
2
3
4
5
6
7
8
9
Sensing Probe Type
ANSI (N. American Std.) Probe with Ceramic Diffuser
ANSI Probe with Flame Arrestor and Ceramic Diffuser
ANSI Probe with Snubber Diffuser
DIN (European Std.) Probe with Ceramic Diffuser
DIN Probe with Flame Arrestor and Snubber Diffuser
DIN Probe with Snubber Diffuser
JIS (Japanese Std.) Probe with Ceramic Diffuser
JIS Probe with Flame Arrestor and Ceramic Diffuser
JIS Probe with Snubber Diffuser
Code
0
1
2
3
4
5
6
7
8
9
Probe Assembly
18 in. (457 mm) Probe
18 in. (457 mm) Probe with Abrasive Shield(1)
3 ft (0.91 m) Probe
3 ft (0.91 m) Probe with Abrasive Shield(1)
6 ft (1.83 m) Probe
6 ft (1.83 m) Probe with Abrasive Shield(1)
9 ft (2.74 m) Probe
9 ft (2.74 m) Probe with Abrasive Shield(1)
12 ft (3.66 m) Probe(1)
12 ft (3.66 m) Probe with Abrasive Shield(1)
Code
0
1
2
3
4
5
Mounting Hardware - Stack Side
No Mounting Hardware (“0” must be chosen under “Mounting Hardware - Probe Side” below)
New Installation - Square weld plate with studs
Mounting to Model 218 Mounting Plate (with Model 218 Shield Removed)
Mounting to Existing Model 218 Support Shield
Mounting to Other Mounting(2)
Mounting to Model 132 Adaptor Plate
Code
0
1
2
4
5
7
8
Mounting Hardware - Probe Side
No Mounting Hardware
Probe Only (ANSI) (N. American Std.)
New Bypass or Abrasive Shield (ANSI)
Probe Only (DIN) (European Std.)
New Bypass or Abrasive Shield (DIN)
Probe Only (JIS) (Japanese Std.)
New Bypass or Abrasive Shield (JIS)
Code
11
12
Electronics Housing & Filtered Customer Termination - NEMA 4X, IP66
Standard Filtered Termination
Transient Protected Filtered Termination
Code
1
OXT5A
1-10
3
2
1
Description and Specifications
1
11
1
Communications
FOUNDATION fieldbus with Membrane Keypad
(Cont’d)
Rosemount Analytical Inc.
Example
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 1-2. Product Matrix (Continued)
Cont'd
Code
1
2
3
4
5
Language
English
German
French
Spanish
Italian
Code
00
Filtered Customer Termination
Specified as Part of Electronics Housing
Code
00
01
02
XX
Cont’d
1
00
Calibration Accessories
No Hardware
Calibration Gas Flowmeter and Reference Air Set
Intelligent Multiprobe Sequencer (Refer to Table 1-4)
Single Probe Sequencer – mounted to Oxymitter 5000 (Refer to Table 1-5)
XX
Example
NOTES:
(1)
Recommended usages: High velocity particulates in flue stream, installation within 11.5 ft (3.5 m) of soot blowers or heavy salt cake buildup.
Applications: Pulverized coal, recovery boilers, lime kiln. Regardless of application, abrasive shields with support brackets are recommended
for 9 ft (2.74 m) and 12 ft (3.66 m) probe installations, particularly horizontal installations.
(2)
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.
Table 1-3. Calibration Gas Bottles
PART
NUMBER
DESCRIPTION
1A99119G01
Two disposable calibration gas bottles — 0.4%
and 8% O2, balance nitrogen — 550 liters each,
includes bottle rack*
1A99119G02
Two flow regulators for calibration gas bottles
*Calibration gas bottles cannot be shipped via airfreight.
When the bottles are used with “CALIBRATION RECOMMENDED”
features, the bottles should provide 2 to 3 years of calibrations in normal
service.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Description and Specifications
1-11
1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 1-4. Intelligent Multiprobe Test Gas Sequencer Versions
PART
NUMBER
NUMBER
OF OXYMITTER
5000 UNITS
DESCRIPTION
3D39695G01
IMPS
1
3D39695G02
IMPS
2
3D39695G03
IMPS
3
3D39695G04
IMPS
4
3D39695G05
IMPS w/115 V Heater
1
3D39695G06
IMPS w/115 V Heater
2
3D39695G07
IMPS w/115 V Heater
3
3D39695G08
IMPS w/115 V Heater
4
3D39695G09
IMPS w/220 V Heater
1
3D39695G10
IMPS w/220 V Heater
2
3D39695G11
IMPS w/220 V Heater
3
3D39695G12
IMPS w/220 V Heater
4
Table 1-5. Single Probe Autocalibration Sequencer Coding
REF AIR
SET
CODE
NO
03
X
04
05
X
X
10
1-12
Description and Specifications
X
X
X
ST
STEEL
HOR
X
X
X
X
X
08
09
BRASS/
TEFLON
X
06
07
YES
OXYMITTER
5000
MOUNTING
FITTINGS/
TUBING
X
X
X
X
VERT
X
X
X
X
X
X
X
X
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 2
INSTALLATION
2
Before installing this equipment, read
the “Safety instructions for the wiring
and installation of this apparatus” at
the front of this Instruction Bulletin.
Failure to follow the safety instructions could result in serious injury or
death.
2-1
MECHANICAL INSTALLATION
either make the necessary repairs or
install the Oxymitter 5000 upstream of
any leakage.
3. Ensure the area is clear of internal and
external obstructions that will interfere
with installation and maintenance access to the membrane keypad. Allow
adequate clearance for removal of the
Oxymitter 5000 (Figure 2-1 or
Figure 2-2).
a. Selecting Location
1. The location of the Oxymitter 5000 in
the stack or flue is most important for
maximum accuracy in the oxygen
analyzing process. The Oxymitter 5000
must be positioned so the gas it measures is representative of the process.
Best results are normally obtained if
the Oxymitter 5000 is positioned near
the center of the duct (40 to 60% insertion). Longer ducts may require several
Oxymitter 5000 units since the O2 can
vary due to stratification. A point too
near the wall of the duct, or the inside
radius of a bend, may not provide a
representative sample because of the
very low flow conditions. The sensing
point should be selected so the process gas temperature falls within a
range of 32° to 1300°F (0° to 704°C).
Figure 2-1 through Figure 2-6 provide
mechanical installation references. The
ambient temperature of the integral
electronics housing must not exceed
149°F (65°C).
2. Check the flue or stack for holes and
air leakage. The presence of this condition will substantially affect the accuracy of the oxygen reading. Therefore,
Rosemount Analytical Inc.
A Division of Emerson Process Management
Do not allow the temperature of the
Oxymitter 5000 integral electronics to
exceed 149°F (65°C) or damage to the
unit may result.
b. Installation
1. Ensure all components are available to
install the Oxymitter 5000. If equipped
with the optional ceramic diffusor element, ensure it is not damaged.
2. The Oxymitter 5000 may be installed
intact as it is received.
NOTE
An abrasive shield is recommended
for high velocity particulates in the
flue stream (such as those in coalfired boilers, kilns, and recovery boilers). Vertical and horizontal brace
clamps are provided for 9 ft and 12 ft
(2.75 m and 3.66 m) probes to provide
mechanical support for the Oxymitter
5000. Refer to Figure 2-6.
3. Weld or bolt adaptor plate (Figure 2-5)
onto the duct.
Installation
2-1
FLANGE
DIA
HOLE
DIA
(4) HOLES
EQ SP
ON BC
Rosemount Analytical Inc.
5.71
(145)
5.12
(130)
BOTTOM VIEW
12.50 (318)
DIM "B"
REMOVAL ENVELOPE
T
4.75
(121)
WHE N
CI R
CU
IT
12
(305)
R
500 VA
5 Amps
COVER REMOVAL & ACCESS
6.52
(166)
REF AIR
ANSI 1/4 (6.35) TUBE
DIN 6 mm TUBE
JIS 6 mm TUBE
CAL GAS
SMART FAMILY
HART TM
IG
HT
WH E N
CI R
CU
VE ATM
OS I
O
PL WA RN I NG - SPH
EX -
REF.
GAS
121.8
(3094)
157.8
(4008)
106
(2692)
142
(3607)
9 FT
12 FT
3 FT
85.8
(2179)
49.8
(1265)
34
(864)
18 IN.
70
(1778)
31.8
(808)
16
(406)
6 FT
DIM "B"
DIM "A"
PROBE
TABLE 2 INSTALLATION/REMOVAL
ELEC CONN
3/4 NPT
IT
IB-106-350 Rev. 1.2
April 2001
2.89
(73)
1.55
(39)
12
(305)
Rosemount Analytical Inc.
Orrville, OH 44667-0901
800-433-6076
T
TABLE 1 MOUNTING FLANGE
DIN
JIS
ANSI
4512C17H01 4512C19H01 4512C18H01
6.10
6.00
7.28
(155)
(185)
(153)
0.75
0.59
0.71
(15)
(18)
(20)
P
6.02 (153)
T
R
TM
OXYMITTER 4000
SERIAL NO.
TAG NO.
VOLTS: 85-264 VAC WATTS:
48-62 Hz
OUTPUT: 4-20 mA
LINE FUSE:
P
WITH
STANDARD
SNUBBER
DIFFUSER
4.77 (121)
CAL.
GAS
IG
H
VE ATM
OS I
O
PL WA RN I NG - SPH
EX -
INSULATE IF EXPOSED TO
AMBIENT WEATHER CONDITIONS
KEE
DIM "A"
3535B18H02
3535B46H01
3535B45H01
NOTE: ALL DIMENSIONS ARE IN
INCHES WITH MILLIMETERS
IN PARENTHESES.
KEE
ADD TO DIM “A”
FOR PROBE WITH
CERAMIC DIFFUSER
AND FLAME
ARRESTOR
3.80(96)
ADD TO DIM “A”
FOR PROBE
WITH CERAMIC
DIFFUSER
5.14(131)
2.27 (58)
DIA MAX
ANSI
JIS
DIN
.062 THK GASKET
-
IN
I VE
IN
-
Installation
I VE
2-2
E
ER
AL
E
ER
AL
PROCESS FLOW MUST BE IN
THIS DIRECTION WITH RESPECT
TO DEFLECTOR 3534B48G01
Instruction Manual
Oxymitter 5000
26170013
Figure 2-1. Oxymitter 5000 Installation
A Division of Emerson Process Management
Instruction Manual
Oxymitter 5000
IB-106-350 Rev. 1.2
April 2001
2
Figure 2-2. Oxymitter 5000 Installation (with SPS 4000)
Rosemount Analytical Inc.
A Division of Emerson Process Management
Installation
2-3
DIM "A"
DIFFUSER/DUST SEAL ASSY
Rosemount Analytical Inc.
12 FT
9 FT
(8) HOLES
EQ SP
ON BC
7.50
(190)
7.48
(190)
TABLE 4 ABRASIVE SHIELD
JIS
ANSI
FLANGE
9.00
9.25
FLANGE
(229)
(235)
DIA
0.75
0.75
HOLE
(19)
(19)
DIA
7.48
(190)
-3D39003
DIN
9.25
(235)
0.94
(24)
IG
HT
WHE N
C
CI R
U
VE ATM
OS I
O
PL WA RN I NG - SPH
EX -
CAL GAS*
REF AIR
ANSI 1/4 IN. TUBE
ANSI 6 mm TUBE
ANSI 6 mm TUBE
*ADD CHECK VALVE IN CAL GAS LINE
3/4 NPT ELECTRICAL CONNECTION
IT
IB-106-350 Rev. 1.2
April 2001
6 FT
3 FT
DIM "B"
50.5
(1283)
86.5
(2197)
122.5
(3112)
158.5
(4026)
CAL.
GAS
12.50
(318)
T
DIM "A"
31
(787)
67
(1702)
103
(2616)
139
(3531)
4.77
(121) 6.02
(153)
DIM "B"
REMOVAL ENVELOPE
P
PROBE
3.6 (91) DIA NOMINAL
7.00
(178)
KE E
INSTALLATION/REMOVAL TABLE
DEFLECTOR ASSY
0.2
(5)
SNUBBER/DUST SEAL
ASSEMBLY
3.9
(99)
NOTE: ALL DIMENSIONS ARE IN
INCHES WITH MILLIMETERS
IN PARENTHESES.
IN
-
Installation
I VE
2-4
E
ER
AL
NOTES:
1. THESE FLAT FACED FLANGES ARE MANUFACTURED TO ANSI, DIN, & JIS BOLT PATTERNS;
AND ARE NOT PRESSURE RATED.
Instruction Manual
Oxymitter 5000
26170014
Figure 2-3. Oxymitter 5000 with Abrasive Shield
A Division of Emerson Process Management
Rosemount Analytical Inc.
A Division of Emerson Process Management
B
C
45o
A
4 STUDS,
LOCKWASHERS AND
NUTS EQUALLY
SPACED ON
C DIA B.C.
ADAPTOR PLATE FOR 3, 6, 9,
AND 12 FT ABRASIVE SHIELD
INSTALLATIONS. SEE SHEET 2.
A
B
CROSSHATCHED AREA IN 4
CORNERS MAY BE USED TO
PROVIDE ADDITIONAL HOLES FOR
FIELD BOLTING OF PLATE TO
OUTSIDE WALL SURFACE.
A
C
22.5o
*PART NUMBERS FOR ADAPTOR PLATES INCLUDE
ATTACHING HARDWARE.
7.48
(190)
7.50
(191)
"D"
DIA
ABRASIVE SHIELD
FLANGE O.D.
8 THREADED HOLES
EQUALLY SPACED ON
D DIA B.C.
7.894
(200)
(M-20 x 2.5)
4.92
(125)
9.25
(235)
JIS
(P/N 3535B58G04)
Oxymitter 5000
ADAPTOR PLATE
FOR OXYMITTER 5000
INSTALLATION. SEE
SHEET 1.
2.500 DIA
(63.5)
NOTE: DIMENSIONS ARE
IN INCHES WITH
MILLIMETERS IN
PARENTHESES.
A
*PART NUMBERS FOR ADAPTOR PLATES INCLUDE
ATTACHING HARDWARE.
(M-16 x 2)
0.625-11
5.118
(130)
5.708
(145)
4.75
(121)
"C"
DIA
9.25
(235)
"C"
THREAD
(M-12 x 1.75)
(M-16 x 2)
0.625-11
"B"
THREAD
9.00
(229)
DIN
(P/N 3535B58G06)
3.94
(100)
"B"
DIA
6.50
(165)
7.5
(191)
6.00
(153)
"A"
ANSI
(P/N 3535B58G02)
4.75
(121)
"A"
JIS
(P/N 4512C35G01)
DIN
(P/N 4512C36G01)
DIMENSIONS
IN.
(mm)
TABLE VI. ADAPTOR PLATE* DIMENSIONS FOR OXYMITTER 5000
WITH ABRASIVE SHIELD
ANSI
(P/N 4512C34G01)
DIMENSIONS
IN.
(mm)
TABLE V. ADAPTOR PLATE* DIMENSIONS FOR OXYMITTER 5000
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
2
28550035
Figure 2-4. Oxymitter 5000 Adaptor Plate Installation
Installation
2-5
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
INSTALLATION FOR METAL
WALL STACK OR DUCT
CONSTRUCTION
INSTALLATION FOR MASONRY
WALL STACK CONSTRUCTION
0.50 [13]
0.50 [13]
BOLT ADAPTOR
PLATE TO OUTSIDE
WALL SURFACE
FIELD WELD
PIPE TO
ADAPTOR PLATE
3.75 [95]
MIN DIA HOLE
IN WALL
MTG HOLES
SHOWN
ROTATED
o
45 OUT OF
TRUE POSITION
STACK OR DUCT
METAL WALL
MTG HOLES
SHOWN ROTATED
o
45 OUT OF
TRUE POSITION
PIPE 4.00 SCHED 40
PIPE SLEEVE (NOT
BY ROSEMOUNT)
LENGTH BY CUSTOMER
JOINT MUST
BE AIRTIGHT
WELD OR BOLT ADAPTOR
PLATE TO METAL WALL
OF STACK OR DUCT.
JOINT MUST BE AIRTIGHT.
4.50 [114]
O.D. REF
MASONRY
STACK WALL
OUTSIDE WALL
SURFACE
NOTE:
ALL MASONRY STACK WORK AND JOINTS EXCEPT
ADAPTOR PLATE NOT FURNISHED BY ROSEMOUNT.
BOLT ADAPTOR
PLATE TO OUTSIDE
WALL SURFACE
FIELD WELD
PIPE TO
ADAPTOR PLATE
3.50 [89]
O.D. REF
2.50 [63.5]
MIN DIA HOLE
IN WALL
STACK OR DUCT
METAL WALL
WELD OR BOLT ADAPTOR
PLATE TO METAL WALL
OF STACK OR DUCT.
JOINT MUST BE AIRTIGHT.
PIPE 3.00 SCHED 40
PIPE SLEEVE (NOT
BY ROSEMOUNT)
LENGTH BY CUSTOMER
JOINT MUST
BE AIRTIGHT
MASONRY
STACK WALL
OUTSIDE WALL
SURFACE
NOTE:
DIMENSIONS IN INCHES WITH
MILLIMETERS IN PARENTHESES.
22220022
Figure 2-5. Oxymitter 5000 Mounting Flange Installation
2-6
Installation
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
BRACE BARS
(NOT BY ROSEMOUNT)
NOTE: DIMENSIONS IN INCHES WITH
MILLIMETERS IN PARETHESES.
2.00
(51)
60o MAX
2
}
1.00
(25)
o
30 MIN
VERTICAL BRACE CLAMP ASSY.
BY ROSEMOUNT
HORIZONTAL BRACE CLAMP ASSY.
(BOTH BRACE CLAMP ASSEMBLIES ARE THE SAME.
INSTALLATION AND LOCATION OF CLAMP ASSEMBLIES
AND BRACE BARS TO BE DONE IN FIELD.)
2 HOLES - 0.625
(16) DIA FOR
0.50 (12) DIA
BOLT
5.62
(143)
ABRASIVE SHIELD
4.12
(105)
4.12
(105)
0.375
(10)
1.00
(25) MAX
5.62
(143)
36.00 (914)
NOTE: BRACING IS FOR VERTICAL AND HORIZONTAL OXYMITTER 4000
INSTALLATION. EXTERNAL BRACING REQUIRED FOR 9 FT AND 12 FT
(2.75 M AND 3.66 M) PROBES AS SHOWN ABOVE.
26170034
Figure 2-6. Oxymitter 5000 Bracing Installation
4. If using the optional ceramic diffusor
element, the vee deflector must be correctly oriented. Before inserting the
Oxymitter 5000, check the direction of
flow of the gas in the duct. Orient the
vee deflector so the apex points upstream toward the flow (Figure 2-7).
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
system cable drops vertically from the
Oxymitter 5000 and the conduit is
routed below the level of the electronics housing. This drip loop minimizes
the possibility that moisture will damage the electronics (Figure 2-8).
Rosemount Analytical Inc.
A Division of Emerson Process Management
GAS FLOW
DIRECTION
VEE
DEFLECTOR
APEX
DIFFUSION
ELEMENT
SETSCREW
FILTER
VEE
DEFLECTOR
22220020
Figure 2-7. Orienting the Optional Vee Deflector
Installation
2-7
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
-
IVE
-
KEE
IG
HT
WHE N
CI R
CU
VE ATM
O
OS I
PL WARN I NG - SPH
EX -
AL
E
ER
FIELDBUS
DIGITAL
SIGNAL
IT
LINE
VOLTAGE
T
IN
REPLACE INSULATION
AFTER INSTALLING
OXYMITTER 5000
DRIP
LOOP
CAL.
GAS
P
INSULATION
ADAPTOR
PLATE
STACK OR DUCT
METAL WALL
28550007
Figure 2-8. Installation with Drip Loop and Insulation Removal
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 Oxymitter
5000 slides into the 15° forcing cone in
the abrasive shield.
NOTE
If process temperatures will exceed
392°F (200°C), use anti-seize compound on stud threads to ease future
removal of Oxymitter 5000.
7. Insert probe through the opening in the
mounting flange and bolt the unit to the
flange. When probe lengths selected
2-8
Installation
are 9 or 12 ft (2.74 or 3.66 m), special
brackets are supplied to provide additional support for the probe inside the
flue or stack (Figure 2-6).
Uninsulated stacks or ducts may
cause ambient temperatures around
the electronics to exceed 149°F (65°C),
which may cause overheating damage
to the electronics.
8. If insulation is being removed to access
the duct work for Oxymitter 5000
mounting, make sure the insulation is
replaced afterward (Figure 2-8).
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
2-2
ELECTRICAL INSTALLATION (FOR OXYMITTER 5000 WITHOUT SPS 4000)
All wiring must conform to local and national
codes.
Disconnect and lock out power before
connecting the unit to the power
supply.
Install all protective equipment covers
and safety ground leads after installation. Failure to install covers and
ground leads could result in serious
injury or death.
To meet the Safety Requirements of
IEC 1010 (EC requirement), and ensure
safe operation of this equipment, connection to the main electrical power
supply must be made through a circuit
breaker (min 10 A) which will disconnect all current-carrying conductors
during a fault situation. This circuit
breaker should also include a mechanically operated isolating switch. If
not, then another external means of
disconnecting the supply from the
equipment should be located close by.
Circuit breakers or switches must
comply with a recognized standard
such as IEC 947.
NOTE
To maintain CE compliance, ensure a
good connection exists between the
mounting flange bolts and earth.
a. Remove screw (36, Figure 4-1), gasket (37),
and cover lock (38). Remove terminal block
cover (31).
Rosemount Analytical Inc.
A Division of Emerson Process Management
b. Connect Line Voltage
Connect the line, or L1, wire to the L1 terminal and the neutral, or L2 wire, to the N
terminal (Figure 2-9). The Oxymitter 5000
automatically will configure itself for 90-250
VAC line voltage and 50/60 Hz. The power
supply requires no setup.
c. Connect fieldbus Digital Signal and
Logic I/O/ Calibration Handshake Leads
(Figure 2-9).
1. Fieldbus Digital Signal. The fieldbus
digital signal carries the O2 value. This
digital signal can also be used to communicate with the Oxymitter.
2. Logic I/O/Calibration Handshake. The
output can either be an alarm or provide the handshaking to interface with
an IMPS 4000. For more information,
refer to paragraph 5-3 and the IMPS
4000 Intelligent Multiprobe Test Gas
Sequencer Instruction Bulletin.
3. If autocalibration is not utilized, a
common bi-directional logic contact is
provided for any of the diagnostic
alarms listed in Table 5-1. The assignment of alarms which can actuate this
contact can be modified to one of
seven additional groupings listed in
Table 3-1.
The logic contact is self-powered, +5
VDC, 340 ohm series resistance. An
interposing relay will be required if this
contact is to be utilized to annunciate a
higher voltage device, such as a light
or horn, and may also be required for
certain DCS input cards. A Potter &
Brumfield R10S-E1Y1-J1.0K 3.2 MA
DC or an equal interposing relay will be
mounted where the contact wires terminate in the control/relay room.
d. Install terminal block cover (31, Figure 4-1)
and secure with cover lock (38), gasket
(37), and screw (36).
Installation
2-9
2
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Figure 2-9. Terminal Block
2-3
ELECTRICAL INSTALLATION (FOR OXYMITTER 5000 WITH SPS 4000)
All wiring must conform to local and national
codes.
To meet the Safety Requirements of
IEC 1010 (EC requirement), and ensure
safe operation of this equipment, connection to the main electrical power
supply must be made through a circuit
breaker (min 10 A) which will disconnect all current-carrying conductors
during a fault situation. This circuit
breaker should also include a mechanically operated isolating switch. If
not, then another external means of
disconnecting the supply from the
equipment should be located close by.
Circuit breakers or switches must
comply with a recognized standard
such as IEC 947.
Install all protective equipment covers
and safety ground leads after installation. Failure to install covers and
ground leads could result in serious
injury or death.
2-10
Installation
Disconnect and lock out power before
connecting the unit to the power
supply.
a. Autocalibration Connections
Autocalibration systems will inject gases
into the probe and make electronic adjustments with no operator attention required.
The SPS 4000 provides solenoid valves and
circuitry for calibrating a single Oxymitter
5000 unit.
The SPS 4000 autocalibration system utilizes the Oxymitter 5000’s bidirectional logic
contact as a “handshake” signal; therefore,
this signal is not available for alarming
purposes.
The following contacts are provided through
the autocalibration system:
1. One contact closure per probe from the
control room to the SPS 4000 for “calibration initiate”.
2. One contact output per probe from
SPS 4000 to the control room for “in
calibration” notification.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
Oxymitter 5000
3. One contact per probe from SPS 4000
to the control room for “calibration
failed” notification, which includes output from pressure switch indicating “cal
gas bottles empty”.
NOTE
The fieldbus digital signal can be configured to respond normally during
any calibration, or can be configured
to hold the last O2 value upon the initiation of calibration. Factory default is
for the fieldbus signal to operate normally throughout calibration. Holding
the last O2 value may be useful if several probes are being averaged for the
purpose of automatic control. Unless
several probes are being averaged,
always place any control loops using
the O2 signal into manual prior to
calibrating.
b. Other Electrical Connections
IB-106-350 Rev. 1.2
April 2001
2. Connect Line Voltage. Route the line
voltage leads into the manifold through
the 1/2 in. line voltage conduit fitting
(Figure 2-2) and out through the bottom of the manifold. Connect the LINE
IN and NEUTRAL leads to terminals L
and N, respectively, as shown in Figure
2-10. Also, be sure to connect the
ground wire to the ground lug. The unit
automatically will configure itself for 90
to 250 VAC line voltage and 50/60 Hz.
The power supply requires no setup.
3. Connect Remote Contact Input Wiring.
To set up the SPS 4000 to initiate a
calibration from a remote location,
route the 5 VDC calibration initiate
contact input leads through the 1/2 in.
NPT signal conduit port (Figure 2-2)
and out through the bottom of the
manifold. Connect the (+) and (-) CAL
INITIATE leads to terminals 1 and 2,
respectively, as shown in Figure 2-10.
1. Remove screws (26, Figure 4-1) securing terminal cover (27). Remove the
cover to expose terminal strip (25).
Rosemount Analytical Inc.
A Division of Emerson Process Management
Installation
2-11
2
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
5 VDC
(SELF-POWERED)
TO REMOTE
CONTACT INPUT
CONNECTION
CAL INITIATE
+
-
FIELDBUS
DIGITAL
SIGNAL
CONNECTION
+
5 - 30 VDC TO RELAY OUTPUT
CONNECTIONS
NOT USED
CAL FAIL
+
-
-
LINE IN
IN CAL
+
GROUND
-
NEUTRAL
90 - 250 VAC,
50/60 HZ LINE
VOLTAGE
INPUT
FACTORY
WIRING
TO INTERFACE
BOARD
FACTORY
WIRING TO
OXYMITTER
5000
NOT USED
GREEN
ORANGE
BLUE
RED
BROWN
YELLOW
WHITE
BLACK
FACTORY
WIRING TO
OXYMITTER
5000
FACTORY WIRING
TO INTERFACE BOARD
FACTORY WIRING
TO POWER SUPPLY
BOARD
28550009
Figure 2-10. SPS 4000 Electrical Connections
2-12
Installation
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
2
Figure 2-11. Air Set, Plant Air Connection
4. Connect Relay Output Wiring. Relay
connections are available to signal
when the Oxymitter 5000 is in calibration or when calibration failed. Relay
outputs can be connected to either indicator lights or a computer interface.
The relay contacts are capable of handling a 5 to 30 VDC maximum power
source. The cabling requirement is
1000 ft (303 m) maximum. Route the
relay output leads through the 1/2 in.
NPT signal conduit port (Figure 2-2)
and out through the bottom of the
manifold. Connect the (+) and (-) CAL
FAIL leads and the (+) and (-) IN CAL
leads to terminals 7, 8, 9, and 10, respectively, as shown in Figure 2-10.
5. Connect fieldbus Digital Signal Wiring.
Route the signal wiring into the manifold through the 1/2 in. NPT signal
conduit port (Figure 2-2) and out
Rosemount Analytical Inc.
A Division of Emerson Process Management
through the bottom of the manifold.
Connect the (+) and (-) signal leads to
terminals 3 and 4, respectively, as
shown in Figure 2-10.
6. Once all connections are made, install
terminal cover (27, Figure 4-11) and
secure with screws (26).
2-4
PNEUMATIC INSTALLATION (FOR OXYMITTER 5000 WITHOUT SPS 4000)
a. Reference Air Package
After the Oxymitter 5000 is installed, connect the reference air set to the Oxymitter
5000. The reference air set should be installed in accordance with Figure 2-11.
Instrument Air (Reference Air): 10 psig
(68.95 kPag) minimum, 225 psig (1551.38
kPag) maximum at 2 scfh (56.6 L/hr) maximum; less than 40 parts-per-million total
Installation
2-13
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
a. Calibration Gas Connections
hydrocarbons. Regulator outlet pressure
should be set at 5 psi (35 kPa). Reference
air can be supplied by the reference air set
of the IMPS 4000.
Locate the 1/4 in. calibration gas fittings on
the SPS 4000 manifold (Figure 2-2). Connect O2 calibration gas 1 (high calibration
gas) to the HIGH CAL-GAS IN fitting and O2
calibration gas 2 (low calibration gas) to the
LOW CAL GAS IN fitting. Ensure the calibration gas pressure is set at 20 psi (138
kPa).
If using an IMPS 4000, refer to the IMPS
4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for the proper
reference air connections.
b. Reference Air Connection (Optional)
Do not use 100% nitrogen as a low gas
(zero gas). It is suggested that gas for
the low (zero) be between 0.4% and
2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40
parts per million. Failure to use proper
gases will result in erroneous readings.
If the reference air option (which includes
the reference air flowmeter, pressure regulator, and necessary tubing and fittings) is
used, connect the instrument air to the 1/4
in. fitting on the reference air pressure
regulator (Figure 2-2). The pressure regulator is factory set at 20 psi (138 kPa). Readjust by turning the knob on the top of the
regulator to obtain the desired pressure.
b. Calibration Gas
Two calibration gas concentrations are used
with the Oxymitter 5000, Low Gas - 0.4% O2
and High Gas - 8% O2. See Figure 2-12 for
the Oxymitter 5000 connections.
2-5
If the SPS 4000 does not have the reference air option, connect the reference air to
the Oxymitter 5000 as instructed in paragraph 2-4.
PNEUMATIC INSTALLATION (FOR OXYMITTER 5000 WITH SPS 4000)
Do not use 100% nitrogen as a low gas
(zero gas). It is suggested that gas for
the low (zero) be between 0.4% and
2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40
parts per million. Failure to use proper
gases will result in erroneous readings.
Figure 2-12. Oxymitter 5000 Gas Connections
!
NOTE
Upon completing installation, make sure that the Oxymitter 5000 is turned on and operating
prior to firing up the combustion process. Damage can result from having a cold Oxymitter
5000 exposed to the process gases.
During outages, and if possible, leave all Oxymitter 5000 units running to prevent condensation and premature aging from thermal cycling.
If the ducts will be washed down during outage, MAKE SURE to power down the Oxymitter
5000 units and remove them from the wash area.
2-14
Installation
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 3
STARTUP AND OPERATION
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.
NOTE
Refer to Appendices A, B, and C for
fieldbus information concerning the
Oxymitter 5000.
3-1
GENERAL
a. Verify Mechanical Installation
Ensure the Oxymitter 5000 is installed correctly (Section 2, INSTALLATION).
b. Verify Terminal Block Wiring
1. Remove screw (36, Figure 4-1), gasket
(37), and cover lock (38) that secure
the terminal block cover. Remove the
cover to expose the terminal block
(Figure 3-1).
2. Check the terminal block wiring. Be
sure the power, fieldbus signal, and
logic outputs are properly connected
and secure.
3
3. Install the housing cover on the terminal block and secure with cover lock
(38, Figure 4-1), gasket (37), and
screw (36).
4. For an Oxymitter 5000 with an integrally mounted SPS 4000, remove
screws (26, Figure 4-11) and terminal
cover (27). Check that the power and
signal terminations are properly connected to terminal strip (25) and secure
according to instructions in Section 2,
INSTALLATION.
5. Install terminal cover (27) and secure
with screws (26).
Figure 3-1. Integral Electronics
Rosemount Analytical Inc.
A Division of Emerson Process Management
Startup and Operation
3-1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
c. Verify Oxymitter 5000 Configuration
(Figure 3-2)
Located on the microprocessor board, the
top board, is a switch that controls the
simulate enable status of the Oxymitter
5000. To allow the Oxymitter to be placed in
simulation mode, place position two of SW2
in the ON position. Once the Oxymitter has
been set to the simulate mode, switch position two of SW2 to the OFF position to remove the Oxymitter from simulate mode.
Note that SW2 does not actually place the
Oxymitter in simulate mode, it only allows
the Oxymitter to be placed into simulate
mode through the fieldbus interface.
Positions 1, 3, and 4 of SW 2 are not used,
and should remain in the OFF position.
Typically, the probe’s sensing cell,
which is in direct contact with the process gases, is heated to approximately
1357°F (736°C), and the external temperature of the probe body may exceed 842°F (450°C). If operating
conditions also contain high oxygen
levels and combustible gases, the
Oxymitter 5000 may self-ignite.
d. O2 Range
The O2 range of the Oxmitter is set through
the fieldbus interface using the AI block.
3-2
Startup and Operation
Oxymitter 5000
Refer to Appendix A for more information on
using the AI block.
e. Once the cell is up to operating temperature, the O2 percentage can be read:
1. Access TP5 and TP6 next to the membrane keypad. Attach a multimeter
across TP5 and TP6. The calibration
and process gases can now be monitored. Pressing the INC or DEC once
will cause the output to switch from the
process gas to the calibration gas.
Pressing INC or DEC a second time
will increase or decrease the calibration gas parameter. If the keys have
been inactive for one minute, the output reverts to the process gas. When a
calibration has been initiated, the value
at TP5 and TP6 is the % O2 seen by
the cell. Oxygen levels, as seen on the
multimeter, are:
8.0% O2 = 8.0 VDC
0.4% O2 = 0.4 VDC
NOTE
The maximum reading available at TP5
and TP6 is 30 VDC. While the Oxymitter will measure oxygen concentrations up to 40%, the test point output
will reach a maximum of 30 VDC at a
30% oxygen concentration.
2. FOUNDATION fieldbus.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SIMULATE
ENABLE
NOT USED
NOT USED
OFF
ON
NOT USED
NOT USED
NOT USED
NOT USED
DEFAULT
POSITION
(EX-FACTORY)
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
3
1
2
3
4
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
J1
TP1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
O2 CELL mV +
O2 CELL mV HEATER T/C +
HEATER T/C -
CAL
TEST GAS +
PROCESS % O2
TP5
TP6
28550011
Figure 3-2. Oxymitter 5000 Defaults
Rosemount Analytical Inc.
A Division of Emerson Process Management
Startup and Operation
3-3
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
3-2
Oxymitter 5000
LOGIC I/O
Of the ten modes in Table 3-1, modes 0
through 7 are the alarm modes. The factory
default is mode 5 for Oxymitter 5000 units
without an IMPS 4000 or SPS 4000. In this
mode, the output will signal when a unit
alarm or a CALIBRATION RECOMMENDED indication occurs.
This two-terminal logic contact can be configured either as a solid-state relay-activated alarm
or as a bi-directional calibration handshake signal to an IMPS 4000 or SPS 4000. The configuration of this signal depends on the setting of
the IO_PIN_MODE parameter via fieldbus. The
different modes available are described in Table
3-1. The IO_PIN_MODE and IO_PIN_STATE
parameters are described in Table 3-2.
b. Calibration Handshake Signal
If using an optional IMPS 4000 or SPS
4000, the logic I/O must be configured for
calibration handshaking. Of the ten modes
in Table 3-1, only modes 8 and 9 are configured for calibration handshaking. For an
Oxymitter 5000 with an IMPS 4000 or an
SPS 4000, the factory sets the default to
mode 8. In this mode, the logic I/O will be
used to communicate between the Oxymitter 5000 and sequencer and to signal the
sequencer when a CALIBRATION RECOMMENDATION indication occurs.
a. Alarm
When configured as an alarm, this signal
alerts you to an out-of-spec condition. The
output is 5 V in series with a 340 ohm resistor. For optimum performance, Rosemount recommends connecting the output
to a Potter & Bromfield 3.2 mA DC relay
(P/N R10S-E1Y1-J1.0K).
Table 3-1. Logic I/O Configuration
Mode
Configuration
0
The unit is not configured for any alarm condition.
1
The unit is configured for a Unit Alarm.
2
The unit is configured for Low O2.
3
The unit is configured for both a Unit Alarm and Low O2.
4
The unit is configured for a High AC Impedance/CALIBRATION RECOMMENDED.
5*
The unit is configured for both a Unit Alarm and a High AC Impedance/CALIBRATION
RECOMMENDED.
6
The unit is configured for both a Low O2 and High AC Impedance/CALIBRATION
RECOMMENDED.
7
The unit is configured for a Unit Alarm, a Low O2, and a High AC Impedance/CALIBRATION
RECOMMENDED.
8**
The unit is configured for a calibration handshake with IMPS 4000 or SPS 4000. CALIBRATION
RECOMMENDED will initiate the calibration cycle.
9
The unit is configured for a calibration handshake. CALIBRATION RECOMMENDED will not
initiate the calibration cycle with the IMPS 4000 or SPS 4000.
*The default condition for an Oxymitter 5000 without an IMPS 4000 or SPS 4000.
**The default condition for an Oxymitter 5000 with an IMPS 4000 or SPS 4000.
3-4
Startup and Operation
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 3-2. Logic I/O Parameters
Parameter
Definition
Range
Parameter
Number
IO_PIN_MODE
This parameter represents the operating mode of
the discrete IO pin of the transmitter.
1-10
40
IO_PIN_STATE
This parameter represents the current state of the
transmitter’s discrete IO pin. 0=FALSE, 1=TRUE.
0-1
41
3
3-3
RECOMMENDED CONFIGURATION
4000, consider wiring some or all associated alarm contacts.
a. Fieldbus Signal Upon Critical Alarm
When a critical alarm occurs which causes
the O2 reading to become unstable or unreliable, the Oxymitter will flag the O2 reading.
All further O2 readings will be flagged as Out
Of Service until the problem has been corrected.
If the O2 measurement is being utilized as
part of an automatic control loop, the loop
should be placed in manual upon this failure
event, or other appropriate action should be
taken.
b. Calibration
Rosemount recommends utilizing an autocalibration system, actuated by the “calibration recommended” diagnostic. New O2
cells may operate for more than a year, but
older cells may require recalibration every
few weeks as they near the end of their life.
This strategy ensures that the O2 reading is
always accurate, and eliminates many unnecessary calibrations based on calendar
days or weeks since previous calibration.
When utilizing the SPS 4000 or the IMPS
Rosemount Analytical Inc.
A Division of Emerson Process Management
1. CALIBRATION INITIATE. Contact
from the control room to an SPS 4000
or IMPS 4000 (one per probe) provides
the ability to manually initiate a calibration at any time from the control room.
Note that calibrations can also be initiated via fieldbus or from the keypad on
the Oxymitter 5000.
2. IN CALIBRATION. One contact per
probe provides notification to the control room that the “calibration recommended” diagnostic has initiated an
automatic calibration through the SPS
4000 or IMPS 4000. If the O2 signal is
being utilized in an automatic control
loop, this contact should be utilized to
place the control loop into manual during calibration.
3. CALIBRATION FAILED. One contact
per probe from and SPS 4000 or IMPS
4000 to the control room for notification
that the calibration procedure failed.
Grouped with this alarm is an output
from a pressure switch that indicates
when the calibration gas bottles are
empty.
Startup and Operation
3-5
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
3-4
Oxymitter 5000
POWER UP
top to the bottom, one at a time. After the
bottom LED turns on, the sequence starts
again at the top with the HEATER T/C LED
(Figure 3-3).
a. Startup Display
When power is applied to the probe, the cell
heater turns on. It takes approximately one
half hour for the cell to heat to operating
temperature. This condition is indicated by
the top four LEDs (DIAGNOSTIC ALARMS)
on the membrane keypad (Figure 3-3).
Starting with the CALIBRATION LED, the
LEDs light in ascending order until all four
LEDs are on. At this point, all four turn off
and the cycle starts again. This ramp cycle
continues until the cell is up to operating
temperature.
1. Error. If there is an error condition at
startup, one of the diagnostics LEDs
will be blinking. Refer to Section 5,
TROUBLESHOOTING, to determine
the cause of the error. Clear the error,
cycle power, and the operating display
should return.
2. Keypad. The five membrane keys on
the membrane keypad are only used
during calibration to adjust the high and
low gas and to initiate the calibration
sequence (Figure 3-4).
b. Operating Display
The ramp cycle turns into a cycle where the
diagnostic LEDs light in sequence from the
HEATER T/C
HEATER
O2 CELL
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
CALIBRATION
ON
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
TP1
J1
1
2
3
4
1
2
3
4
TP2
LIGHTING SEQUENCE DURING NORMAL OPERATION
TP3
TP4
CAL
RED
YEL
GRN
ORG
TEST
POINTS
HEATER T/C
HEATER
TEST GAS +
PROCESS % O2
TP5
O2 CELL
TP6
CALIBRATION
1
2
3
4
1
2
3
LIGHTING SEQUENCE DURING WARM-UP
4
28550012
Figure 3-3. Startup and Normal Operation
3-6
Startup and Operation
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
3-5
START UP OXYMITTER 5000
CALIBRATION
Refer to Section 4, MAINTENANCE AND
SERVICE, for calibration instructions.
DIAGNOSTIC
ALARMS
HEATER T/C
HEATER
02 CELL
CALIBRATION
3-6
CALIBRATION REQUIRED
TEST
POINTS
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
02 CELL mV
02 CELL mv
HEATER T/C
HEATER T/C
+
+
-
IMPS 4000 CONNECTIONS
See the IMPS 4000 Intelligent Multiprobe Test
Gas Sequencer Instruction Bulletin for wiring
and pneumatic connections.
CAL
TEST GAS +
PROCESS % 02
Figure 3-4. Calibration Keys
Rosemount Analytical Inc.
A Division of Emerson Process Management
Startup and Operation
3-7
3
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
3-7
Oxymitter 5000
GENERAL
3. TEST POINTS. Test points 1 through
6 will allow you to monitor with a multimeter: the heater thermocouple, O2
cell millivolt, and the process O2.
a. Overview
Ensure the Oxymitter 5000 is at normal operation. The diagnostic LEDs will display the
operating cycle. All other LEDs should be
off (Figure 3-5).
(a) TP1 and TP2 monitor the oxygen
cell millivolt output which equates
to the percentage of oxygen present.
1. DIAGNOSTIC ALARM LEDS. If there
is an error in the system, one of these
LEDs will flash various blink codes
(Section 5, TROUBLESHOOTING). In
the case of multiple errors, only one
will be displayed based on a priority
system. Correct the problem and cycle
power. The operating display will return
or the next error will be displayed. The
alarms are:
(b) TP3 and TP4 monitor the heater
thermocouple.
(c) TP5 and TP6 monitor the process
gas or the calibration gas parameter. The maximum reading
available from these test points is
30 VDC. This corresponds to 30%
oxygen concentrations.
HEATER T/C
HEATER
O2 CELL
CALIBRATION
4. CAL LED. The CAL LED is on steady
or flashing during calibration. Further
information is available in Section 4,
MAINTENANCE AND SERVICE.
2. CALIBRATION RECOMMENDED
LED. Turns on when the system determines a calibration is recommended.
HEATER T/C
HEATER
SW2
ON
DIAGNOSTIC
ALARMS
HEATER T/C
HEATER
O2 CELL
CALIBRATION
O2 CELL
CALIBRATION
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
TP1
J1
TP2
TP3
TP4
1
RED
YEL
GRN
ORG
TEST
POINTS
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
2
3
4
1
2
3
4
LIGHTING SEQUENCE DURING NORMAL OPERATION
CAL
CAL LED
TEST GAS +
PROCESS % O2
TP5
TP6
28550013
Figure 3-5. Normal Operation
3-8
Startup and Operation
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
5. Keys.
cell. Oxygen levels, as seen on the
multimeter, are:
(a) INC and DEC. The INC and DEC
keys are used to set the values of
the calibration gases. Attach a
multimeter across TP5 and TP6.
The calibration and process gases
can now be monitored. Pressing
the INC or DEC once will cause the
output to switch from the process
gas to the calibration gas.
Pressing INC or DEC a second
time will increase or decrease the
calibration gas parameter. If the
keys have been inactive for one
minute, the output reverts to the
process gas. When a calibration
has been initiated, the value at TP5
and TP6 is the % O2 seen by the
Rosemount Analytical Inc.
A Division of Emerson Process Management
8.0% O2 = 8.0 volts DC
0.4% O2 = 0.4 volts DC
(b) CAL. The CAL key can:
1
Initiate a calibration.
2
Sequence through calibration.
3
Abort the calibration.
b. Model 751 Remote Powered Loop LCD
Display (Optional)
Refer to Remote Powered Loop LCD manual for calibration and operation.
Startup and Operation
3-9
3
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
3-10
Startup and Operation
Oxymitter 5000
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 4
MAINTENANCE AND SERVICE
4-1
OVERVIEW
This section identifies the calibration methods
available and provides the procedures to maintain and service the Oxymitter 5000 and optional integrally mounted SPS 4000.
Install all protective equipment covers
and safety ground leads after equipment repair or service. Failure to install covers and ground leads could
result in serious injury or death.
Change the diffusion element when the
calibration gas flowmeter reads slightly
lower during calibration or when the response time to the process flue gases becomes very slow. Each time the diffusion
element is changed, reset the calibration
gas flowmeter to 5 scfh and calibrate the
Oxymitter 5000. To change the diffusion
element, refer to paragraph 4-8.
b. Three types of calibration methods are
available: automatic, semiautomatic, and
manual.
4
NOTE
4-2
CALIBRATION
a. During a calibration, two calibration gases
with known O2 concentrations are applied to
the Oxymitter 5000. Slope and constant
values calculated from the two calibration
gases determine if the Oxymitter 5000 is
correctly measuring the net concentration of
O2 in the industrial process.
Before calibrating the Oxymitter 5000, verify
that the calibration gas parameters are correct by setting the gas concentrations used
when calibrating the unit (See paragraph
3-7a.5) and by setting the calibration gas
flowmeter.
The calibration gas flowmeter regulates the
calibration gas flow and must be set to 5
scfh. However, only adjust the flowmeter to
5 scfh after placing a new diffusion element
on the end of the Oxymitter 5000. Adjusting
the flowmeter at any other time can pressurize the cell and bias the calibration.
In applications with a heavy dust loading,
the O2 probe diffusion element may become
plugged over time, causing a slower speed
of response. The best way to detect a
plugged diffusion element is to note the time
it takes the Oxymitter 5000 to return to the
normal process reading after the last calibration gas is removed and the calibration
gas line is blocked off. A plugged element
also can be indicated by a slightly lower
reading on the flowmeter.
Rosemount Analytical Inc.
A Division of Emerson Process Management
A calibration can be aborted any time
during the process by pressing the
CAL key (Figure 4-2) on the Oxymitter
5000 keypad three times in a three
second interval or via FOUNDATION
fieldbus or an IMPS 4000. An aborted
calibration will retain the values of the
previous good calibration.
1. Automatic Calibration. Automatic calibrations require no operator action.
However, the calibration gases must
be permanently piped to the Oxymitter
5000, an SPS 4000 or IMPS 4000
must be installed to sequence the
gases, and the Oxymitter 5000’s logic
I/O must be set to mode 8 via fieldbus
using the IO_PIN_MODE parameter so
the sequencer and Oxymitter 5000 can
communicate.
Depending on your system setup, an
automatic calibration can be initiated
by the following methods:
(a) The Oxymitter 5000’s CALIBRATION RECOMMENDED alarm signals that a calibration is required.
(b) Enter a time to next calibration using the TIME_TO_NEXT_CAL parameter via fieldbus. Calibrations
will then occur regularly at this
interval.
Maintenance and Service
4-1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
30
26
29
27
28
25
36
37
Note: The Electronic Assembly, item 12,
consists of items 13 through 24.
31
24
12
21
22
38
23
20
17
38
14
13
37
36
15
DIAG
CA
NO
AL STIC
AR
MS
LIBR
AT
HE
AT
ER
HE T/C
CA 02 ATER
N RE LIBR CELL
AT
CO
IO
N
MM
EN
DE
02
D
CE
02 LL
HE CELL mV
+
AT
HE ER mv
AT T/ ER C +
INC
T/C
-
IO
TE
PO ST
INTS
INC
HIGH
GA
S
DE
C
LO
W
GA
S
DE
C
CA
L
TE
ST
PR GAS
OCE
+
% SS
02 -
19
18
7
11
16
6
10
Note: Not all parts shown.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Heater Strut Assembly
Diffusion Assembly (Snubber)
Retainer Screw
Cell and Flange Assembly
Corrugated Seal
Probe Tube Assembly
Screw
Tube Connector
Gas Port
O-ring
Right Housing Cover
Electronic Assembly
Screw
Membrane Keypad
Snap Connector
Captive Screw
Microprocessor Board
Screw
Washer
Fieldbus Output Board
Fieldbus Isolator Board
Fuse Cap
Fuse
Power Supply Board
Electronic Housing
Screw
5
32
9
4
3
2
8
1
33
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
34
35
Lock Washer
Cable Clamp
Terminal Block
Captive Screw
Left Housing Cover
Silicon Tube
Tube Clamp
Screw
Washer
Screw
Gasket
Cover Lock
28550001
Figure 4-1. Oxymitter 5000 Exploded View
4-2
Maintenance and Service
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
DIAGNOSTIC
ALARMS
IMPS 4000 must be installed to sequence the gases, and the Oxymitter
5000’s logic I/O must be set to mode 8
or 9 via fieldbus so the sequencer and
Oxymitter 5000 can communicate.
HEATER T/C
HEATER
O2 CELL
CALIBRATION
Depending on your system setup, a
semi-automatic calibration can be initiated by the following methods:
CALIBRATION RECOMMENDED
TEST
POINTS
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
(a) Oxymitter 5000. Press the CAL
key on the Oxymitter 5000 keypad.
(b) IMPS 4000. Use the IMPS 4000
keypad to change the InitCalX parameter of the CHANGE PRESETS display mode from 0000 to
0001. Refer to the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer Instruction Bulletin for
more information.
CAL
TEST GAS +
PROCESS % O2
22220067
Figure 4-2. Membrane Keypad
(c) If using an IMPS 4000, enter a time
interval via the IMPS 4000 keypad
that will initiate an automatic calibration at a scheduled time interval
(in hours). To set the CalIntvX parameter of the CHANGE PRESETS display mode, refer to the
IMPS 4000 Intelligent Multiprobe
Test Gas Sequencer Instruction
Bulletin for more information.
Once an automatic calibration is
initiated, by any of the methods
previously described, the Oxymitter
5000’s CALIBRATION RECOMMENDED alarm signals an IMPS
4000 or SPS 4000 to initiate a calibration. The sequencer sends an
“in cal” signal to the control room
so that any automatic control loops
can be placed in manual. Then, the
sequencer begins to sequence the
calibration gases.
2. Semi-Automatic Calibration. Semiautomatic calibrations only require operator initiation. However, the calibration gases must be permanently piped
to the Oxymitter 5000, an SPS 4000 or
Rosemount Analytical Inc.
A Division of Emerson Process Management
(c) FOUNDATION fieldbus. Use fieldbus to perform the O2 CAL method.
(d) Remote Contact. Initiate a calibration from a remote location via the
remote contact input connection
provided by an IMPS 4000 or SPS
4000. Refer to the documentation
available for the control system in
use for more information.
Once a semi-automatic calibration is
initiated, by any of the methods previously described, the Oxymitter 5000’s
CALIBRATION RECOMMENDED
alarm signals an IMPS 4000 or SPS
4000 to initiate a calibration. The sequencer sends an “in cal” signal to the
control room so that any automatic
control loops can be placed in manual.
Then, the sequencer begins to sequence the calibration gases.
3. Manual Calibration. Manual calibrations must be performed at the Oxymitter 5000 site and require operator
intervention throughout the process.
Manual calibration instructions can also
be found, in condensed form, on the
inside of the right electronics housing
cover (Figure 4-3).
Maintenance and Service
4-3
4
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
MANUAL
CALIBRATION
ALARMS
LED
FLASHES
STATUS
1
HEATER T/C
OPEN
2
SHORTED
3
REVERSED
A/D COMM
ERROR
OPEN
HIGH HIGH
TEMP
HIGH CASE
TEMP
LOW TEMP
4
1
2
3
HEATER
4
5
HIGH TEMP
OPEN
1
3
O2 CELL
4
1
CALIBRATION
2
3
BAD
EPROM
CORRUPT
INVALID SLOPE
INVALID
CONSTANT
LAST CAL
FAILED
CONTROL LOOP
* PLACE
IN MANUAL
IF CAL LED ON
* GO TO STEP 2
1 PUSH CAL
CAL LED ON
2 PUSH CAL
CAL LED FLASH
3 APPLY TG1
PUSH CAL
CAL LED ON SOLID
WAIT FOR FLASH
5 REMOVE TG1 & APPLY TG2
4
PUSH CAL
CAL LED ON SOLID
WAIT FOR FLASH
2 FLASH-VALID CAL
3 FLASH-INVALID CAL
7 REMOVE TG2
PUSH CAL
CAL LED ON FOR
8
PURGE TIME
CAL LED OFF
6
SW2 DIP SWITCH
NOT USED
OFF
NOT USED
NOT USED
NOT USED
ON
NOT USED
NOT USED
31770003
Figure 4-3. Inside Right Cover
display the percentage of
oxygen seen by the cell.
Use the following procedure to perform
a manual calibration:
2
(c) If performing a manual calibration
with CALIBRATION RECOMMENDED LED off and the CAL
LED off, start at step 1.
Push the CAL key. The CALIBRATION RECOMMENDED
LED will turn off and the CAL
LED will flash continuously.
The flashing LED indicates
that the Oxymitter 5000 is
ready to accept the first calibration gas.
3
(d) If performing a manual calibration
with CALIBRATION RECOMMENDED LED on and the CAL
LED on, start at step 2.
Apply the first calibration gas.
(Electronics will abort the calibration if step 4 is not done
within 30 minutes).
4
Push the CAL key; the CAL
LED will be on solid. A timer is
activated to allow the calibration gas adequate time to flow
(default time of five minutes).
When the timer times out, the
Oxymitter 5000 has taken the
readings using the first calibration gas and the CAL LED
(a) Place control loop in manual.
(b) Verify the calibration gas parameters are correct per paragraph
4-2a.
1
4-4
Push the CAL key. The CALIBRATION RECOMMENDED
LED will come on and the
CAL LED will be on solid. If a
multimeter is attached across
TP5 and TP6, the reading will
Maintenance and Service
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
Oxymitter 5000
will flash continuously. The
flashing indicates the Oxymitter 5000 is ready to take
readings using the second
calibration gas.
5
Remove the first calibration
gas and apply the second
calibration gas. (Electronics
will abort the calibration if step
6 is not done within 30 minutes).
6
Push the CAL key; the CAL
LED will be on solid. The timer
is activated for the second
calibration gas flow. When the
timer times out, the CAL LED
will flash a 2 pattern flash or a
3 pattern flash (2 pattern flash
equals a valid calibration, 3
pattern flash equals an invalid
calibration).
If the slope or the constant is
out of specification, a diagnostic alarm LED will be
flashing. The diagnostic alarm
will remain active until the
purge cycle is over. If the
three pattern flash occurs
without a diagnostic alarm, the
calibration gases could be the
same or the calibration gas
was not turned on.
The CAL LED flashing indicates the calibration is done.
(See Section 5, TROUBLESHOOTING, for an explanation of the 2 pattern and 3
pattern flashes).
7
Remove the second calibration gas and cap off the calibration gas port.
8
Push the CAL key; the CAL
LED will be on solid as the
unit purges. (Default purge
time is three minutes). When
the purge is complete, the
CAL LED will turn off.
Rosemount Analytical Inc.
A Division of Emerson Process Management
IB-106-350 Rev. 1.2
April 2001
If the calibration was valid, the DIAGNOSTIC ALARMS LEDs will indicate normal operation. If the new
calibration values, slope or constant, is not within the parameters,
the DIAGNOSTIC ALARMS LED
will indicate an alarm. (See Section
5, TROUBLESHOOTING, for alarm
codes). If the calibration was invalid, the Oxymitter 5000 will return to
normal operation, as it was before
a calibration was initiated, and the
parameters will not be updated.
(e) Place control loop in automatic.
4
c. FOUNDATION fieldbus O2 CAL
METHOD
To perform a calibration using FOUNDATION fieldbus, use the following procedure.
1. From the computer running the fieldbus
control program, run the O2 Cal
Method.
Failure to remove the Oxymitter 5000
from automatic control loops prior to
performing this procedure may result
in a dangerous operating condition.
2. In the first O2 CAL screen, a “Loop
should be removed from automatic
control” warning appears. Remove the
Oxymitter 5000 from any automatic
control loops to avoid a potentially
dangerous operating condition and
press OK.
3. From this point, follow the on-screen
prompts to complete the calibration
procedure. When a step is complete,
select Proceed to Next Step and press
the Next button.
4. During the wait periods, such as during
a purge, the Time Remaining display
may be updated by selecting Update
and pressing the Next button.
Maintenance and Service
4-5
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
4-3
Oxymitter 5000
LED STATUS INDICATORS
It is recommended that the Oxymitter
5000 be removed from the stack for all
service activities. The unit should be
allowed to cool and be taken to a clean
work area. Failure to comply may
cause severe burns.
a. Diagnostic/Unit Alarms
Table 4-1 lists the types and status of
alarms that will be encountered. (See
Section 5, TROUBLESHOOTING, for a detailed description of each fault).
b. When the electronics determines a calibration is recommended, the CALIBRATION
RECOMMENDED LED is on solid.
c. The CAL LED turns on when a calibration is
recommended and is on during the calibration process. During calibration, the CAL
LED can be flashing, which would indicate
operator action is requested, or on solid,
which indicates calculations and measurements are in progress.
Table 4-1. Diagnostic/Unit Alarms
LED
HEATER T/C
HEATER
STATUS
FAULT
1
2
3
4
OPEN
SHORTED
REVERSED
A/D COMM
ERROR
OPEN
HIGH HIGH
TEMP
HIGH CASE
TEMP
LOW TEMP
HIGH TEMP
HIGH mV
BAD
EEPROM
CORRUPT
INVALID
SLOPE
INVALID
CONSTANT
LAST
CALIBRATION
FAILED
1
2
3
4
O2 CELL
CALIBRATION
3
4
5
1
3
4
1
2
3
4-6
Maintenance and Service
4-4
OXYMITTER 5000 REMOVAL/
REPLACEMENT
a. Oxymitter 5000 (without Integrally
Mounted SPS 4000)
1. Remove.
FLASHES
1
2
Disconnect and lock out power before
working on any electrical components.
There is voltage up to 115 VAC.
5
6
7
8
9
10
11
12
13
14
15
(a) Turn off power to the system.
(b) Shut off the calibration gases at the
cylinders and the instrument air.
(c) Disconnect the calibration gas and
instrument air lines from the Oxymitter 5000.
(d) While facing the Oxymitter 5000
and looking at the Rosemount label, remove screw (36, Figure 4-1),
gasket (37) and cover lock (38) securing left housing cover (31). Remove the cover to expose the
terminal block Figure 4-4.
(e) Loosen the screw on the AC terminal cover and slide the cover back
to access the neutral and line terminals. Loosen the AC line and
neutral terminal screws and remove the leads. Loosen the ground
lug screws and remove the leads.
Slide the line power leads out of
the AC line voltage port.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
(f) Loosen the logic I/O and the fieldbus signal terminal screws. Remove the leads from the terminals
and slide the wires out of the signal
port.
(g) Remove insulation to access the
mounting bolts. Unbolt the Oxymitter 5000 from the stack and take
it to a clean work area.
(h) Allow the unit to cool to a comfortable working temperature.
2. Replace.
(a) Bolt the Oxymitter 5000 to the
stack and install insulation.
(b) Insert the logic I/O and fieldbus
signal leads in the signal port and
connect to the logic I/O and fieldbus digital signal screw terminals
(Figure 4-4).
(c) Insert the power leads in the AC
line voltage port and connect to the
AC line screw terminals. Connect
the line, or L1, wire to the L1 terminal, and the neutral, or L2, wire to
the N terminal. Slide the AC terminal cover over the terminal connection and tighten the cover
screw.
(d) Install left housing cover (31,
Figure 4-1) and ensure it is tight.
Secure the cover using cover lock
(38), gasket (37), and screw (36).
(e) Connect the calibration gas and instrument air lines to the Oxymitter
5000.
(f) Turn on the calibration gases at the
cylinders and turn on instrument
air.
(g) Restore power to the system.
Figure 4-4. Terminal Block
Rosemount Analytical Inc.
A Division of Emerson Process Management
Maintenance and Service
4-7
4
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
b. Oxymitter 5000 (with Integrally Mounted
SPS 4000)
wired LINE IN and NEUTRAL
leads to terminals L and N (Figure
2-10). Also, remove the customerwired ground lead from the ground
lug. Remove the leads from the
terminal strip and slide them from
the manifold through the line voltage conduit port.
1. Remove.
(a) Turn off power to the system.
(b) Shut off the calibration gases at the
cylinders and the instrument air.
(c) Disconnect the instrument air and
calibration gas lines from the SPS
4000. If the instrument air does not
flow through the SPS 4000, disconnect the instrument air directly
at the Oxymitter 5000.
(d) Remove the screws securing the
terminal cover to the SPS 4000
manifold. Remove the terminal
cover to expose the terminal strip.
(e) Tag all customer-wired leads that
are connected to the terminal strip
before removing.
(f) On the terminal strip, loosen the
screws securing the customer-
(g) Next, loosen the screws of remote
contact input terminals 1 and 2;
fieldbus digital signal terminals 3
and 4; and relay output terminals 7,
8, 9, and 10. Remove the leads
from the terminal strip and slide
them from the manifold through the
signal conduit port.
(h) Remove insulation to access the
mounting bolts. Unbolt the Oxymitter 5000/SPS 4000 assembly
from the stack and take the entire
assembly to a clean work area.
(i) Allow the unit to cool to a comfortable working temperature.
Figure 4-5. Electronic Assembly
4-8
Maintenance and Service
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Oxymitter 5000/SPS 4000 assembly,
follow the instructions in paragraph 44b.1.
2. Replace.
(a) Bolt the Oxymitter 5000/SPS 4000
assembly to the stack and install
insulation.
2. Remove the right housing cover uncovering the electronic assembly
(Figure 4-5).
(b) Follow the instructions in paragraph 2-3 to connect the line voltage and signal leads to an
Oxymitter 5000/ SPS 4000
assembly.
3. Depress and remove the J1 (cell and
T/C) connector from the J1 socket.
Loosen the three captive mounting
screws on the microprocessor board
(top board).
(c) Follow the instructions in paragraph 2-5 to connect the calibration
gases and instrument air to an
Oxymitter 5000/SPS 4000 assembly. Turn on the calibration gases
at the cylinders and turn on instrument air.
4. The J8 connector (heater leads) can be
accessed by moving the J1 connector
leads out of the slot on the microprocessor board and sliding the electronic
assembly partially out of the housing
(Figure 4-6).
(d) Restore power to the system.
4-5
5. Squeeze the J8 connector on the sides
and carefully remove. The electronic
assembly can now be completely removed from the housing.
ELECTRONICS REPLACEMENT
Each of the following procedures details how to
remove and replace a specific electronic component of the Oxymitter 5000.
6. Remove the four screws (7, Figure 4-1)
from the probe finned housing. The
probe and the electronic housing can
now be separated.
NOTE
Recalibration is required whenever
electronic cards or sensing cell is
replaced.
1
+
a. Entire Electronics Replacement (with
Housing).
POWER
SUPPLY
BOARD
+
NOTE
J8
1
+
+
9G
A Division of Emerson Process Management
+
61
Rosemount Analytical Inc.
+
39
1. Follow the instructions in paragraph
4-4a.1 to remove the Oxymitter 5000
from the stack or duct. If removing an
+
5A
250VAC
TIME LAG
3D
Only perform this procedure on Oxymitter 5000 units without integrally
mounted SPS 4000 units. If it is necessary to replace the entire electronics
on an Oxymitter 5000/ SPS 4000 assembly, contact Rosemount for further
instructions.
RE
V
22220061
Figure 4-6. J8 Connector
Maintenance and Service
4-9
4
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
7. When reinstalling or replacing the
electronic housing, make sure that oring (10) is in good condition. Place the
J1 and J8 connectors in the hole on the
flat side of the electronic housing.
8. Hold the J1 and J8 connectors out and
to the probe side of the electronic
housing. Make sure that the conduit
port of the electronic housing is on the
same side as the CAL and REF gas
ports. Replace the four screws and
tighten.
9. Reconnect the J8 connector to the
power supply board. Make sure the
connector is secure.
10. Holding the J1 connector leads, slide
the electronic assembly the rest of the
way into the housing. Align the electronic assembly so that it fits flush on
the pins. To ensure that it is flush, gently try to rotate the electronics. If the
electronics rotates, repeat the
alignment.
11. Reconnect the J1 connector to the microprocessor board. Ensure the connector is secure and tighten the three
captive screws on the microprocessor
board (top board).
12. Replace the housing cover and ensure
it is tight.
13. Follow the instructions in paragraph
4-4a.2 to install the Oxymitter 5000 into
the stack or duct. If installing an Oxymitter 5000/SPS 4000 assembly, follow
the instructions in paragraph 4-4b.2.
4-10
Maintenance and Service
Oxymitter 5000
b. Electronic Assembly Replacement
(Figure 4-5).
1. Remove the right housing cover uncovering the electronic assembly.
2. Depress and remove the J1 (cell and
T/C) connector from the J1 socket.
Loosen the three captive mounting
screws on the microprocessor board
(top board).
3. The J8 connector (heater leads) can be
accessed by moving the J1 connector
leads out of the slot on the microprocessor board and sliding the electronic
assembly partially out of the housing
(Figure 4-6).
4. Squeeze the J8 connector on the sides
and carefully remove. The electronic
assembly can now be completely removed from the housing.
5. Reconnect the J8 connector to the
power supply board. Make sure the
connector is secure.
6. Holding the J1 connector leads, slide
the electronic assembly the rest of the
way into the housing. Align the electronic assembly so that it fits flush on
the pins. To ensure that it is flush, gently try to rotate the electronics. If the
electronics rotates, repeat the
alignment.
7. Reconnect the J1 connector to the microprocessor board. Ensure the connector is secure and tighten the three
captive screws on the microprocessor
board (top board).
8. Replace the housing cover and ensure
it is tight.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
c. Terminal Block Replacement
(Figure 4-4).
1. Loosen the mounting screws on the
terminal block and carefully lift the
block out of the housing.
1
POWER
SUPPLY
BOARD
+
+
+
2. Depress and remove the J1 (cell and
T/C) connector from the J1 socket.
Loosen the three captive mounting
screws on the microprocessor board
(top board).
3. The J8 connector (heater leads) can be
accessed by moving the J1 connector
leads out of the slot on the microprocessor board and sliding the electronic
assembly partially out of the housing
(Figure 4-6).
4. Squeeze the J8 connector on the sides
and carefully remove. The electronic
assembly can now be completely removed from the housing.
Rosemount Analytical Inc.
A Division of Emerson Process Management
+
+
9G
1. Remove the right housing cover uncovering the electronic assembly.
FUSE
61
d. Fuse Replacement (Figure 4-5).
+
1
39
3. Tighten the three mounting screws and
ensure the terminal block is secure in
the housing.
+
3D
2. Carefully align the new terminal block
on the pins so that it sits flat in the
housing. The round end of the terminal
block should be on the opposite side of
the housing conduit ports and should
not be able to rotate.
5A
250VAC
TIME LAG
RE
V
22220058
Figure 4-7. Fuse Location
5. Completely remove the three mounting
screws on the microprocessor board.
6. Turn the electronic assembly over so
that you are looking at the bottom of
the power supply printed circuit board.
Gently depress the two white posts one
at a time. Carefully separate the power
supply board from the microprocessor
board.
7. Remove the fuse and replace it with a
new one (Figure 4-7).
8. Align the white posts with the post
holes on the power supply board and
the pin connector on the power supply
board with the connector port on the
back of the microprocessor board.
Gently push the boards together until
the white posts snap in place. Ensure
the assembly is secure by gently trying
to separate the boards.
Maintenance and Service
4-11
4
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
9. Reconnect connector J8 to the power
supply board. Make sure the connector
is secure.
10. Holding the J1 connector leads, slide
the electronic assembly the rest of the
way into the housing. Align the electronic assembly so that it fits flush on
the pins. To ensure that it is flush, gently try to rotate the electronics. If the
electronics rotates, repeat the
alignment.
11. Reconnect the J1 connector to the microprocessor board. Ensure the connector is secure and tighten the three
captive screws on the microprocessor
board (top board).
Oxymitter 5000
4-7
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 8-1).
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.
NOTE
12. Replace the housing cover and ensure
that it is tight.
4-6
ENTIRE PROBE REPLACEMENT
(EXCLUDING ELECTRONICS)
Do not attempt to replace the probe until all
other possibilities for poor performance have
been considered. If probe replacement is
needed, see Table 8-1 for part numbers.
a. Follow the instructions in paragraph 4-4a.1
to remove the Oxymitter 5000 from the
stack or duct. If removing an Oxymitter 5000
with an integrally mounted SPS 4000, follow
the instructions in paragraph 4-4b.1.
b. Separate the probe and the electronics
housing per paragraph 4-5a, steps 2
through 6.
c. Reinstall electronics on the new probe per
paragraph 4-5a, steps 7 through 13.
4-12
Maintenance and Service
If the Oxymitter 5000 has an integrally
mounted SPS 4000, it is not necessary
to remove the sequencer when replacing the heater strut.
a. Follow the instructions in paragraph 4-4a.1
to remove the Oxymitter 5000 from the
stack or duct. If removing an Oxymitter
5000/SPS 4000 assembly, follow the instructions in paragraph 4-4b.1.
b. Remove entire electronics per paragraph
4-5a, steps 2 through 6.
NOTE
If the Oxymitter 5000 is equipped with
an integrally mounted SPS 4000 and
installed in corrosive conditions,
stainless steel gas tubes are used instead of silicon or Teflon tubes.
c. 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.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
WIRE
LOOP
V-DEFLECTOR
CERAMIC SUPPORT ROD
CERAMIC
DIFFUSER
ASSEMBLY
CELL FLANGE
4
HEATER
22220050
Figure 4-8. Heater Strut Assembly
d. Loosen, but do not remove, the three
screws (34, Figure 4-1) on the strut in the
finned housing. The spring tension should
release and the strut moves up.
g. Push down on the back plate of the strut to
make sure you have spring tension and
then tighten the three screws on the back
plate.
e. Grasp the wire loop and carefully slide the
strut out of the probe tube (Figure 4-8).
h. Replace the CAL and REF gas silicon
tubes.
f.
i.
Install the entire electronics per paragraph
4-5a, steps 7 through 13.
j.
Follow the instructions in paragraph 4-4a.2
to install the Oxymitter 5000 into the stack
or duct. If installing an Oxymitter 5000/SPS
4000 assembly, follow the instructions in
paragraph 4-4b.2.
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 calibration gas line. When the hole and the calibration gas line are aligned correctly, the
strut will slide in the rest of the way.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Maintenance and Service
4-13
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
PROBE TUBE
(NOT INCLUDED
IN KIT)
CORRUGATED
SEAL
CELL AND
FLANGE
ASSEMBLY
SOCKET HEAD
CAP SCREWS
CALIBRATION GAS
PASSAGE
Use heat-resistant gloves and clothing
when removing the probe. Do not attempt to work on these components
until they have cooled to room temperature. Probe components can be as
hot as 800°F (427°C). This can cause
severe burns.
Disconnect and lock out power before
working on any electrical components.
There is voltage of up to 115 VAC.
22220028
Figure 4-9. Cell Replacement Kit
4-8
CELL REPLACEMENT
This paragraph covers oxygen sensing cell replacement. Do not attempt to replace the cell
until all other possibilities for poor performance
have been considered. If cell replacement is
needed, order the cell replacement kit
(Table 8-1).
The cell replacement kit (Figure 4-9) contains a
cell and flange assembly, corrugated seal,
setscrews, socket head cap screws, and antiseize compound. The items are carefully packaged to preserve precise surface finishes. Do
not remove items from the packaging until they
are ready to be used. Spanner wrenches and
hex wrenches needed for this procedure are
part of an available special tools kit (Table 8-1).
4-14
Maintenance and Service
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 4-4a.1
to remove the Oxymitter 5000 from the
stack or duct. If removing an Oxymitter
5000/SPS 4000 assembly, follow the instructions in paragraph 4-4b.1.
b. If the probe uses the standard diffusion
element, use a spanner wrench to remove
the diffusion element.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
NOTE
To determine if the diffusion element
needs to be replaced, refer to paragraph 4-2.
c. If equipped with the optional ceramic diffusor assembly, remove and discard the
setscrews and remove the vee deflector
(Figure 4-10). Use spanner wrenches from
the probe disassembly kit (Table 8-1), 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 remove 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 oxygen sensing cell. If the cell is fused to the
contact pad, push the cell assembly back
into the probe (against spring pressure) and
quickly twist the cell assembly. The cell and
contact pad should separate. If the contact
pad stays fused to the cell, a new contact/thermocouple assembly must be installed. Disconnect the cell and the
thermocouple wires at the probe electronics
and withdraw the cell with the wires still
attached.
e. Remove entire electronics per paragraph
4-5b, steps 2 through 6.
f.
If the contact assembly is damaged, replace
the strut or the contact pad. Instructions for
replacing the contact pad are in the cell replacement kit.
g. 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.
Rosemount Analytical Inc.
A Division of Emerson Process Management
h. Rub a small amount of anti-seize compound
on both sides of the new corrugated seal.
i.
Assemble the cell and flange assembly, corrugated seal, and probe tube. Make sure
the calibration tube lines up with the calibration gas passage in each component. Apply
a small amount of anti-seize compound to
the screw threads and use the screws to
secure assembly. Torque to 35 in-lbs (4
N·m).
j.
Install the entire electronics per paragraph
4-5a, steps 7 through 13.
k. Apply anti-seize compound to the threads of
the cell assembly, hub, and setscrews. Reinstall the hub on the cell assembly. Using
pin spanner wrenches, torque to 10 ft-lbs
(14 N·m). If applicable, reinstall the vee deflector, orienting apex toward gas flow. Secure with the setscrews and anti-seize
compound. Torque to 25 in-lbs (2.8 N·m).
l.
On systems equipped with an abrasive
shield, install the dust seal gaskets, with
joints 180° apart.
m. Reinstall the probe and gasket on the stack
flange.
n. Follow the instructions in paragraph 4-4a.2
to install the Oxymitter 5000 into the stack
or duct. If installing an Oxymitter 5000/SPS
4000 assembly, follow the instructions in
paragraph 4-4b.2. 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.
o. Turn on power and monitor thermocouple
output. It should stabilize at 29.3+0.2 mV.
Set reference air flow at 2 scfh (56.6 l/hr).
After the Oxymitter 5000 stabilizes, calibrate
the unit. If new components have been installed, repeat calibration after 24 hours of
operation.
Maintenance and Service
4-15
4
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
PIN
WRENCH
RETAINER
OPTIONAL CERAMIC
DIFFUSION ELEMENT
Hex wrenches needed to remove setscrews
and socket head screws in the following
procedure are available as part of a Probe
Disassembly Kit, Table 8-1.
b. Replacement Procedure
SETSCREW
1. Follow the instructions in paragraph
4-4a to remove the Hazardous Area
Oxymitter 5000 from the stack or duct.
HUB
CEMENT
PORT
CEMENT
FILLET
VEE
DEFLECTOR
22220029
4-9
Figure 4-10. Ceramic Diffusion Element
Replacement
3. On systems equipped with abrasive
shield, remove dual dust seal gaskets.
CERAMIC DIFFUSION ELEMENT
REPLACEMENT
4. Use spanner wrenches from Probe
Disassembly Kit, Table 8-1, to turn hub
free from retainer.
NOTE
This refers to ceramic diffuser element
only.
a. General
The diffusion element protects the cell from
particles in process gases. It does not normally need to be replaced because the vee
deflector protects it from particulate erosion.
In severe environments, the filter may be
broken or subject to excessive erosion. Examine the ceramic diffusion element whenever 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 response. A broken diffusion element will
cause a slower response to calibration gas.
4-16
2. Loosen setscrews, Figure 4-10, using
hex wrench from Probe Disassembly
Kit, Table 8-1, and remove vee deflector. Inspect setscrews. If damaged, replace with stainless setscrews coated
with anti-seize compound.
Maintenance and Service
5. Put hub in vise. Break out old ceramic
diffusion element with chisel along cement line. Use a 3/8 in. (9.5 mm) pin
punch and clean fillet from the cement
port.
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 using the ceramic diffusion element replacement kit in Table 8-1. This
consists of a diffusion element, cement, setscrews, anti-seize compound, and instructions.
8. Test fit replacement ceramic diffusion
element to be sure seat is clean.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Do not get cement on ceramic diffusion element except where it touches
the hub. Any cement on ceramic diffusion element blocks airflow through
element. Wiping wet cement off of ceramic only forces cement into pores.
Also, do not get any cement onto the
flame arrester element.
9. Thoroughly mix cement and insert tip
of squeeze bottle into cement port. Tilt
bottle and squeeze while simultaneously turning ceramic diffusion element
into seat. Do not get any cement on
upper part of ceramic diffusion element. Ensure complete penetration of
cement around 3 grooves in hub. Cement should extrude from opposite
hole. Wipe excess material back into
holes and wipe top fillet of cement to
form a uniform fillet. (A cotton swab is
useful for this.) Clean any excess cement from hub with water.
10. Allow filter to dry at room temperature
overnight or 1 to 2 hours at 200°F
(93°C).
11. Wipe a heavy layer of anti-seize compound onto the threads and mating
surfaces of the flame arrester, diffusion
hub, and probe tube.
12. Assemble flame arrester and diffusion
hub with two pin spanner wrenches.
Torque to 10 ft-lbs (14 N·m). Secure
with hub retaining setscrew.
13. On systems equipped with abrasive
shield, install dust seal gaskets with
joints 180° apart.
14. Reinstall vee deflector, orienting apex
toward gas flow. Apply anti-seize compound to setscrews and tighten with
hex wrench.
15. Reinstall probe on stack flange.
Rosemount Analytical Inc.
A Division of Emerson Process Management
4-10 SPS 4000 MAINTENANCE AND
COMPONENT REPLACEMENT
These paragraphs describe SPS 4000 maintenance and component replacement procedures.
Replacement parts referenced are available
from Rosemount. Refer to Section 8, REPLACEMENT PARTS, for part numbers and ordering information.
Install all protective equipment covers
and safety ground leads after equipment repair or service. Failure to install covers and ground leads could
result in serious injury or death.
4
a. Fuse Replacement
The SPS 4000 has a fuse (17, Figure 4-11)
on the power supply board (18). Refer to
Table 8-3 for replacement fuse specifications. Perform the following procedure to
check or replace the fuse.
Disconnect and lock out power before
working on any electrical components.
1. Turn off power to the system.
2. Remove screw (7, Figure 4-11) securing manifold cover lock (6) and remove
the lock.
3. Remove manifold cover (14).
4. Remove fuseholder (16) by pushing in
the top and turning 1/4 turn counterclockwise. Remove fuse (17).
5. After checking or replacing fuse (17),
install fuseholder (16) by pushing in the
top and turning 1/4 turn clockwise.
6. Install manifold cover (14), and secure
with manifold cover lock (6) and screw
(7).
Maintenance and Service
4-17
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Oxymitter 5000
Screw
Attaching Bracket
Bushing
Bushing Gasket
Manifold
Manifold Cover Lock
Screw
O-Ring
Spacer
Screw
Screw
Pressure Switch
Calibration Gas 2 Solenoid
Manifold Cover
Cover O-Ring
Fuseholder
Fuse
Power Supply Board
Interface Board
Calibration Gas 1 Solenoid
Washer
Stop Nut
Ground Nut
Terminal Base
Terminal Strip
Screw
Terminal Cover
Terminal Cover Gasket
Screw
Screw
1
2
3
3
27
28
29
4
30
4
26
20
25
24
19
23
22
18
15
16
21
17
5
14
8
11
9
10
6
7
13
12
Figure 4-11. SPS 4000 Manifold Assembly
4-18
Maintenance and Service
Rosemount Analytical Inc.
26170023
A Division of Emerson Process Management
Instruction Manual
Oxymitter 5000
b. Board Replacement
Perform the following procedure to replace
power supply board (18, Figure 4-11) or interface board (19).
Disconnect and lock out power before
working on any electrical components.
IB-106-350 Rev. 1.2
April 2001
See Figure 4-12. If removing the interface board, remove the CAL INITIATE
leads from connector J3, CAL FAIL
and IN CAL leads from connector J4,
and logic I/O handshake connection
from connector J5.
8. Remove stop nuts (22, Figure 4-11),
washers (21), and screws (10) securing power supply board (18) and interface board (19) to spacers (9).
1. Turn off power to the system.
9. Carefully separate boards (18 and 19).
2. Remove screw (7) securing manifold
cover lock (6) and remove the lock.
3. Remove manifold cover (14).
4. Remove two screws (11) attaching
spacers (9) to manifold (5).
5. Being careful not to disconnect the
board wiring, carefully lift power supply
board (18) and interface board (19)
from manifold (5) and set aside. Do not
lose o-rings (8) from the bottom of
spacers (9).
6. Tag all leads on the board to be replaced to simplify installation.
7. See Figure 4-12. If removing the power
supply board, remove the line voltage
input leads from connector J7. Also,
unplug calibration gas 1 solenoid leads
from connector J5, calibration gas 2
solenoid leads from connector J4, and
pressure switch leads from connector
J2.
Rosemount Analytical Inc.
A Division of Emerson Process Management
10. Connect replacement board to board
(18 or 19).
11. Install screws (10), washers (21), and
stop nuts (22) to secure power supply
board (18) and interface board (19) to
spacers (9).
12. Install all applicable leads in the appropriate locations on the power supply
board or interface board as shown in
Figure 4-12.
13. Install power supply board (18, Figure
4-11) and interface board (19) into
manifold (5). Align spacers (9) with the
mounting holes on the manifold and
secure with screws (11). Ensure orings (8) are installed between the
spacers and the manifold surface.
14. Install manifold cover (14) and secure
with manifold cover lock (6) and screw
(7).
Maintenance and Service
4-19
4
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Figure 4-12. Power Supply Board and Interface Board Connections
4-20
Maintenance and Service
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
Oxymitter 5000
IB-106-350 Rev. 1.2
April 2001
c. Solenoid Replacement
The SPS 4000 manifold has a calibration
gas 1 (high calibration gas) solenoid (20,
Figure 4-11) and a calibration gas 2 (low
calibration gas) solenoid (13).
Disconnect and lock out power before
working on any electrical components.
1. Turn off power to the system.
2. Shut off the calibration gases at the
cylinders.
3. Remove screw (7) securing manifold
cover lock (6) and remove the lock.
4. Remove manifold cover (14).
5. Remove two screws (11) attaching
spacers (9) to manifold (5).
6. Being careful not to disconnect the
board wiring, carefully lift the board and
spacer assembly from manifold (5) and
set aside. Do not lose o-rings (8) from
the bottom of spacers (9).
7. Tag and unplug solenoid (13 or 20)
leads from power supply board (18).
Refer to Figure 4-12. Calibration gas 1
solenoid wires connect to connector
J5, and calibration gas 2 solenoid wires
connect to connector J4.
8. Remove the top nut of solenoid (13 or
20, Figure 4-11) securing the coil assembly and washer to the base. Remove the coil assembly, including the
leads, and washer. Place a 13/16 in.
deep socket over the solenoid base
and remove.
Rosemount Analytical Inc.
A Division of Emerson Process Management
When installing a solenoid, do not
over-tighten. Damage to the solenoid
may occur.
9. Install the new solenoid base. Be
careful not to overtighten. Install the
new washer and coil assembly and secure with the top nut. Connect the
leads to the proper connector on power
supply board (18). Refer to Figure 4-12
if necessary.
10. Carefully install the board and spacer
assembly into manifold (5, Figure 4-11)
by aligning spacers (9) with the
mounting holes on the manifold and
securing with screws (11). Ensure orings (8) are installed between the
spacers and the manifold surface.
11. Install manifold cover (14), and secure
with manifold cover lock (6) and screw
(7).
12. Turn on the calibration gases at the
cylinders.
d. Pressure Switch Replacement
Use the following procedure to replace
pressure switch (12, Figure 4-11).
1. Turn off power to the system.
2. Shut off the calibration gases at the
cylinders.
3. Remove screw (7) securing manifold
cover lock (6) and remove the lock.
4. Remove manifold cover (14).
5. Remove two screws (11) attaching
spacers (9) to manifold (5).
Maintenance and Service
4-21
4
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
6. Being careful not to disconnect the
board wiring, carefully lift the board and
spacer assembly from manifold (5) and
set aside. Do not lose o-rings (8) from
the bottom of spacers (9).
7. Tag and remove the leads from pressure switch (12).
8. Place a 1-1/16 in. 6-point socket over
pressure switch (12) and remove.
When installing the pressure switch,
do not overtighten. Damage to the solenoid may occur.
Oxymitter 5000
factory set to 20 psi (138 kPa). Adjust
using the knob on top of the pressure
regulator if necessary.
Do not use fingers to release valve
stem. The valve may release air at
high pressures and cause injury.
2. Condensation Drain. To drain excess
moisture from the filter bowl of reference air pressure regulator (8), use a
screwdriver or comparable tool to periodically release valve stem on the
bottom of the regulator.
g. Flowmeter Adjustments.
9. Install new pressure switch (12). Be
careful not to overtighten. Connect the
leads to the proper terminals on the
pressure switch.
10. Carefully install the board and spacer
assembly into manifold (5) by aligning
spacers (9) with the mounting holes on
the manifold and securing with screws
(11). Ensure o-rings (8) are installed
between the spacers and the manifold
surface.
11. Install manifold cover (14), and secure
with manifold cover lock (6) and screw
(7).
12. Turn on the calibration gases at the
cylinders.
e. Check Valve Replacement
Check valve (19, Figure 4-13) may stick or
become plugged over time. Replace when
necessary. If condensation deposits are
noted upon removal, consider insulating the
check valve.
f.
Pressure Regulator (Optional) Maintenance
1. Pressure Adjustments. Reference air
pressure regulator (8, Figure 4-13) is
4-22
Maintenance and Service
1. Calibration Gas Flowmeter. Calibration
gas flowmeter (17, Figure 4-13) regulates the calibration gas flow and must
be set to 5 scfh. However, only adjust
the flowmeter to 5 scfh after placing a
new diffusion element on the end of the
Oxymitter 5000. Adjusting the flowmeter at any other time can pressurize the
cell and bias the calibration.
2. In applications with a heavy dust loading, the O2 probe diffusion element
may become plugged over time, causing a slower speed of response. The
best way to detect a plugged diffusion
element is to note the time it takes the
Oxymitter 5000 to return to the normal
process reading after the last calibration gas is removed and the calibration
gas line is blocked off. A plugged element also can be indicated by a slightly
lower reading on the flowmeter.
Change the diffusion element when the
calibration gas flowmeter reads slightly
lower during calibration or when the response time to the process flue gases
becomes very slow. Each time the diffusion element is changed, reset the
calibration gas flowmeter to 5 scfh and
calibrate the Oxymitter 5000. For more
information on changing the diffusion
element, refer to paragraph 4-8.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
Oxymitter 5000
3. Reference Air Flowmeter (Optional).
Reference air flowmeter (16, Figure
4-13) regulates the reference air and
must be set to 2 scfh. Adjust the flow
with the knob on the bottom of the reference air flowmeter when necessary.
h. Flowmeter Replacement
Use this procedure to replace either reference air flowmeter (16, Figure 4-13) or calibration gas flowmeter (17).
1. Turn off power to the system.
2. Shut off the calibration gases at the
cylinders.
3. Loosen, but do not remove, four
screws (13) securing flowmeter bracket
(25) to the manifold.
4. Flex the bottom of flowmeter bracket
(25) downward and away to disengage
and remove from the manifold.
IB-106-350 Rev. 1.2
April 2001
7. Remove flowmeter (16 or 17), with installed fittings, from flowmeter bracket
(25).
8. For reference air flowmeter (16), remove elbow street fittings (14 and 22).
It is not necessary to remove fittings
(10 and 23) from the street fittings.
For calibration gas flowmeter (17), remove elbow fittings (15 and 21).
9. Apply pipe thread sealant to the
threads of top fittings (22 or 21) and
bottom fittings (14 or 15) and install fittings into new flowmeter (16 or 17).
10. Position flowmeter (16 or 17) into
flowmeter bracket (25) and secure with
bracket (5) and screw (6).
11. For reference air flowmeter (16), connect tubing (11) to elbow fitting (10)
and install pressure regulator (9). Also,
connect tubing (24) to straight fitting
(23).
5. For reference air flowmeter (16), remove pressure regulator (8) by disconnecting tubing (11) from elbow fitting
(10). Also, disconnect tubing (24) from
straight fitting (23).
For calibration gas flowmeter (17),
connect tubing (2) to elbow fitting (15)
and connect tubing (18) to elbow fitting
(21).
For calibration gas flowmeter (17), disconnect tubing (18) at elbow fitting
(21). Also, disconnect gas tubing (2)
from elbow fitting (15).
12. Slide the top slots of flowmeter bracket
(25) onto screws (13). Flex the bottom
of the bracket downward and toward
the manifold to engage the bottom
bracket slots and screws. Tighten
screws.
6. Remove screws (6) and bracket (5) securing flowmeter (16 or 17) to flowmeter bracket (25).
Rosemount Analytical Inc.
A Division of Emerson Process Management
13. Turn on the calibration gases at the
cylinders.
Maintenance and Service
4-23
4
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
NOTE: A STANDARD SPS 4000 IS EQUIPPED WITH
TEFLON TUBING AND BRASS FITTINGS. OPTIONAL
STAINLESS STEEL TUBING AND FITTINGS ARE ALSO
AVAILABLE. REFER TO SECTION VIII, REPLACEMENT
PARTS, FOR ORDERING INFORMATION.
1
2
20
3
4
24
25
19
5
6
23
21
18
22
7
2
(REF.)
15
12
14
8
9
11
13
17
16
1.
2.
3.
4.
5.
6.
7.
8.
10
Elbow Fitting
Tubing
Straight Fitting
Elbow Fitting
Bracket
Screw
Conduit Fitting
Reference Air Pressure
Regulator (Optional)
9.
10.
11.
12.
13.
14.
15.
16.
17.
Straight Fitting (Optional)
Elbow Fitting (Optional)
Tubing (Optional)
Elbow Fitting (Optional)
Screw
Elbow Street Fitting (Optional)
Elbow Fitting
Reference Air Flowmeter (Optional)
Calibration Gas Flowmeter
26170012
18.
19.
20.
21.
22.
23.
24.
25.
Tubing
Check Valve
Flare Fitting
Elbow Fitting
Elbow Street Fitting (Optional)
Straight Fitting (Optional)
Tubing
Flowmeter Bracket
Figure 4-13. Calibration Gas and Reference Air Components
4-24
Maintenance and Service
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 5
TROUBLESHOOTING
Before troubleshooting the system, ensure
all ICs are fully seated.
Install all protective equipment covers
and safety ground leads after troubleshooting. Failure to install covers and
ground leads could result in serious
injury or death.
5-1
d. Electrostatic Discharge
Electrostatic discharge can damage the ICs
used in the electronics. Before removing or
handling the processor board or the ICs,
ensure you are at ground potential.
GENERAL
The troubleshooting section describes how to
identify and isolate faults that may develop in
the Oxymitter 5000. Also, additional troubleshooting information is provided in paragraph
5-5 for those units with the optional SPS 4000.
When troubleshooting the Oxymitter 5000, reference the following information.
5-2
The majority of the fault conditions for the Oxymitter 5000 will be indicated by one of the four
LEDs referred to as diagnostic, or unit, alarms
on the operator’s keypad. An LED will flash a
code that will correspond to an error message.
Only one LED will blink at a time. An alarm code
guide is provided inside the screw cover for the
electronics. All alarm indications will be available via fieldbus. When the error is corrected
and/or power is cycled, the diagnostic alarms
will clear or the next error on the priority list will
appear.
a. Grounding
It is essential that adequate grounding precautions are taken when installing the system. Thoroughly check both the probe and
electronics to ensure the grounding quality
has not degraded during fault finding. The
system provides facilities for 100% effective
grounding and the total elimination of
ground loops.
b. Electrical Noise
The Oxymitter 5000 has been designed to
operate in the type of environment normally
found in a boiler room or control room.
Noise suppression circuits are employed on
all field terminations and main inputs. When
fault finding, evaluate the electrical noise
being generated in the immediate circuitry
of a faulty system. Also, ensure all cable
shields are connected to earth.
c. Loose Integrated Circuits
The Oxymitter 5000 uses a microprocessor
and supporting integrated circuits (IC). If the
electronics are handled roughly during installation or located where subjected to severe vibration, the ICs could work loose.
Rosemount Analytical Inc.
A Division of Emerson Process Management
ALARM INDICATIONS
5-3
ALARM CONTACTS
a. If autocalibration is not utilized, a common
bi-directional logic contact is provided for
any of the diagnostic alarms listed in Table
5-1. The assignment of alarms which can
actuate this contact can be modified to one
of seven additional groupings listed in Table
8-1.
The logic contact is self-powered, +5 VDC,
340 ohm series resistance. An interposing
relay will be required if this contact is to be
utilized to annunciate a higher voltage device, such as a light or horn, and may also
be required for certain DCS input cards. A
Potter & Brumfield R10S-E1Y1-J1.0K 3.2
MA DC or an equal interposing relay will be
mounted where the contact wires terminate
in the control/relay room.
b. If autocalibration systems are utilized, the
bidirectional logic contact is utilized as a
Troubleshooting
5-1
5
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
2. Additional IMPS Alarm Contacts.
“handshake” signal between the autocalibration system (SPS 4000 or IMPS 4000)
and is unavailable for alarming purposes.
The following additional contacts are provided through the autocalibration systems:
(a) One contact per IMPS 4000 for
“low calibration gas flowing”.
1. SPS 4000 and IMPS 4000, 1-4
probes.
(a) One contact closure per probe
from the control room to the SPS
4000 or IMPS 4000 for “calibration
initiate”.
(b) One contact per IMPS 4000 for
“high calibration gas flowing”.
5-4
IDENTIFYING AND CORRECTING ALARM
INDICATIONS
Faults in the Oxymitter 5000 are indicated using
the four diagnostic, or unit, alarms. The pattern
of repeating blinks will define the problem. A
condensed table of the errors and the corresponding blink codes can be found on the inside
right cover of the electronics housing. Table 5-1
also identifies the blink code and fault status of
each LED as well as the output of the fieldbus
digital signal line and a fault number that corresponds to the troubleshooting instructions provided in this section.
(b) One contact output per probe from
SPS 4000 or IMPS 4000 to the
control room for “in calibration” notification.
(c) Once contact output per probe
from the SPS 4000 or IMPS 4000
to the control room for “calibration
failed” notification. (Includes output
from pressure switch indicating “cal
gas bottles empty”.)
Table 5-1. Diagnostic/Unit Alarm Fault Definitions
LED
HEATER T/C
HEATER
O2 CELL
CALIBRATION
FLASHES
STATUS
PV STATUS
FAULT
SELF-CLEARING
1
2
3
4
1
2
3
4
5
1
3
4
1
2
3
**
OPEN
SHORTED
REVERSED
A/D COMM ERROR
OPEN
HIGH HIGH TEMP
HIGH CASE TEMP
LOW TEMP
HIGH TEMP
HIGH mV
BAD
EEPROM CORRUPT
INVALID SLOPE
INVALID CONSTANT
LAST CALIBRATION FAILED
CALIBRATION RECOMMENDED
BAD
BAD
BAD
BAD
BAD
BAD
BAD
BAD
BAD
BAD
UNCERTAIN
BAD
UNCERTAIN
UNCERTAIN
UNCERTAIN
GOOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
NO
YES
YES
YES
YES
*Critical alarm conditions will render the O2 measurement as unusable, and any of these events will cause
the PV values to be tagged Out of Service. Alarms which are not “self-clearing” will require recycling of
power to the electronics.
** The CALIBRATION RECOMMENDED alarm flashes the Calibration Recommended alarm LED on the operator’s keypad.
5-2
Troubleshooting
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
a. Fault 1, Open Thermocouple
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The HEATER T/C LED flashes once,
pauses for three seconds, and repeats (Figure 5-1).
1. Check connector J1. Ensure the connector is properly seated.
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
J1
TP1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
3. Remove power. Disconnect J1. Measure continuity across the red and yellow thermocouple leads.
CAL
TEST GAS +
PROCESS % O2
2. Using a multimeter, measure TP3+ to
TP4-. If the reading is 1.2 VDC ±0.1
VDC, the thermocouple is open.
TP5
TP6
4. The measurement should read approximately 1 ohm.
28550014
5. If the thermocouple is open, see paragraph 4-7, Heater Strut Replacement.
5
Figure 5-1. Fault 1, Open Thermocouple
Rosemount Analytical Inc.
A Division of Emerson Process Management
Troubleshooting
5-3
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
b. Fault 2, Shorted Thermocouple
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The HEATER T/C LED flashes twice,
pauses for three seconds, and repeats (Figure 5-2).
1. Using a multimeter, measure across
TP3+ and TP4-.
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
TP1
J1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
CAL
TEST GAS +
PROCESS % O2
2. If the reading is 0 ±0.5 mV, then a
shorted thermocouple is likely.
3. Remove power and disconnect J1.
4. Measure from TP3+ to TP4-. The
reading should be approximately 20
Kohms.
TP5
TP6
28550015
5. If so, the short is not on the PC board.
See paragraph 4-7, Heater Strut Replacement.
Figure 5-2. Fault 2, Shorted Thermocouple
5-4
Troubleshooting
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
c. Fault 3, Reversed Thermocouple
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The HEATER T/C LED flashes three times,
pauses for three seconds, and repeats (Figure 5-3).
1. Using a multimeter, measure TP3+ to
TP4-.
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
TP1
J1
2. If the reading is negative, the thermocouple wiring is reversed.
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
CAL
TEST GAS +
PROCESS % O2
3. Check red and yellow wires in the J1
connector for the proper placement.
4. If the wiring is correct, the fault is in the
PC board. See paragraph 4-5b, Electronic Assembly Replacement.
TP5
TP6
28550016
Figure 5-3. Fault 3, Reversed Thermocouple
Rosemount Analytical Inc.
A Division of Emerson Process Management
5
Troubleshooting
5-5
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
d. Fault 4, A/D Comm Error
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The HEATER T/C LED flashes four times,
pauses for three seconds, and repeats (Figure 5-4).
1. Call the factory for assistance.
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
J1
TP1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
O2 CELL mV +
O2 CELL mV HEATER T/C +
HEATER T/C -
CAL
TEST GAS +
PROCESS % O2
TP5
TP6
29770006
Figure 5-4. Fault 4, A/D Comm Error
5-6
Troubleshooting
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
e. Fault 5, Open Heater
The HEATER LED flashes once, pauses for
three seconds, and repeats (Figure 5-5).
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
1. Remove power. Remove the electronic
assembly per paragraph 4-5b, Electronic Assembly Replacement.
ON
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
TP1
J1
2. Using a multimeter, measure across
the heater connector J8.
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
CAL
TEST GAS +
PROCESS % O2
TP5
3. The measurement should be approximately 72 ohms. If the heater is open,
see paragraph 4-7, Heater Strut Replacement.
TP6
28550017
Figure 5-5. Fault 5, Open Heater
Rosemount Analytical Inc.
A Division of Emerson Process Management
5
Troubleshooting
5-7
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
f.
Fault 6, High High Heater Temp
The HEATER LED flashes twice, pauses for
three seconds, and repeats (Figure 5-6).
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
TP1
J1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
2. The triac and the temperature control
may be at fault.
3. Remove power. Allow Oxymitter 5000
to cool for five minutes. Restore power.
CAL
TEST GAS +
PROCESS % O2
1. The high high heater temp alarm will
activate when the thermocouple produces a voltage of 37.1 mV
(1652°F/900°C).
TP5
TP6
4. If the condition repeats, replace the
electronic assembly per paragraph 45b, Electronic Assembly Replacement.
28550018
Figure 5-6. Fault 6, High High Heater Temp
5-8
Troubleshooting
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
g. Fault 7, High Case Temp
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The HEATER LED flashes three times,
pauses for three seconds, and repeats (Figure 5-7).
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
J1
TP1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
CAL
TEST GAS +
PROCESS % O2
TP5
TP6
28550019
Figure 5-7. Fault 7, High Case Temp
Rosemount Analytical Inc.
A Division of Emerson Process Management
1. If the case temperature exceeds 185°F
(85°C), the temperature control will
shut off and a fieldbus alarm will be
sent.
2. This signifies that the environment
where the Oxymitter 5000 is installed
exceeds the ambient temperature requirements or that heat due to convection is causing case temperature to rise
above the limit.
3. Placing a spool piece between the
stack flange and the Oxymitter 5000
flange may eliminate this problem.
4. If a spool piece does not solve the
problem, relocation is the only solution.
Troubleshooting
5-9
5
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
h. Fault 8, Low Heater Temp
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The HEATER LED flashes four times,
pauses for three seconds, and repeats (Figure 5-8).
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
J1
TP1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
CAL
TEST GAS +
PROCESS % O2
TP6
Figure 5-8. Fault 8, Low Heater Temp
Troubleshooting
2. If the thermocouple reading continues
to ramp downward for one minute and
does not return to the temperature set
point of approximately 29.3 mV, then
an Open Heater fault will be displayed.
TP5
28550020
5-10
1. The low heater temperature alarm is
active when the thermocouple reading
has dropped below 28.6 mV.
3. Power down the electronics. Remove
the electronic assembly per paragraph
4-5b, Electronic Assembly Replacement. Using a multimeter, measure
across the heater connector, J8.
4. If the heater is good, the reading will be
approximately 70 ohms. If the heater is
open, see paragraph 4-7, Heater Strut
Replacement.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
i.
HEATER T/C
HEATER
O2 CELL
CALIBRATION
The HEATER LED flashes five times,
pauses for three seconds, and repeats (Figure 5-9).
SW2
ON
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
J1
TP1
2. An alarm is sent via fieldbus.
TP3
TP4
CAL
TEST GAS +
PROCESS % O2
1. If the thermocouple produces a voltage
in excess of approximately 30.7 mV,
the high heater temp alarm activates.
TP2
RED
YEL
GRN
ORG
TEST
POINTS
Fault 9, High Heater Temp
TP5
3. This alarm is self-clearing. When temperature control is restored and the
thermocouple voltage returns to the
normal range, the alarm clears.
TP6
4. If the temperature continues to rise, the
next alarm will be the high high heater
temp alarm.
28550021
Figure 5-9. Fault 9, High Heater Temp
Rosemount Analytical Inc.
A Division of Emerson Process Management
5
Troubleshooting
5-11
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
j.
Fault 10, High Cell mV
The O2 CELL flashes once, pauses for three
seconds, and repeats (Figure 5-10).
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
1. Using a multimeter, measure across
TP1+ to TP2-.
ON
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
TP1
J1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
CAL
TEST GAS +
PROCESS % O2
TP6
Figure 5-10. Fault 10, High Cell mV
Troubleshooting
3. One possible cause is connector J1.
The orange or green wire has come
loose from the crimped connection.
TP5
4. The platinum pad could also be at fault.
The pad could have broken free from
the back of the cell.
28550022
5-12
2. If you measure 1.2 VDC, the cell wires,
either orange or green, have become
detached from the input.
5. Replace heater strut per paragraph
4-7, Heater Strut Replacement. If necessary, replace the cell flange assembly per paragraph 4-8, Cell
Replacement.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
k. Fault 11, Bad Cell
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The O2 CELL flashes three times, pauses
for three seconds, and repeats (Figure 511).
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
TP1
J1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
1. The bad cell alarm activates when the
cell exceeds the maximum resistance
value.
2. The cell should be replaced. See paragraph 4-8, Cell Replacement, for cell
replacement instructions.
CAL
TEST GAS +
PROCESS % O2
TP5
TP6
28550023
Figure 5-11. Fault 11, Bad Cell
Rosemount Analytical Inc.
A Division of Emerson Process Management
5
Troubleshooting
5-13
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
l.
HEATER T/C
HEATER
O2 CELL
CALIBRATION
The O2 CELL LED flashes four times,
pauses for three seconds, and repeats (Figure 5-12).
SW2
ON
DIAGNOSTIC
ALARMS
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
J1
TP1
1. This alarm can occur if the EEPROM is
changed for a later version. At power
up, the EEPROM is not updated.
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
Fault 12, EEPROM Corrupt
2. To correct this problem, power down
and then restore power. The alarm
should clear.
CAL
TEST GAS +
PROCESS % O2
3. If the alarm occurs while the unit is
running, there is a hardware problem
on the microprocessor board.
TP5
TP6
28550024
4. If cycling the power does not clear the
alarm, see paragraph 4-5b, Electronic
Assembly Replacement.
Figure 5-12. Fault 12, EEPROM Corrupt
5-14
Troubleshooting
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
m. Fault 13, Invalid Slope
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The CALIBRATION LED flashes once,
pauses for three seconds, and repeats (Figure 5-13).
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
TP1
J1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
CAL
TEST GAS +
PROCESS % O2
1. During a calibration, the electronics
calculates a slope value. If the value of
the slope is less than 35 mV/deg or
more than 52 mV/deg, the slope alarm
will be active until the end of the purge
cycle.
2. See paragraph 4-2, Calibration. Verify
the calibration by carefully repeating it.
Ensure the calibration gases match the
calibration gas parameters. If you attach a multimeter to TP1+ and TP2-,
sample gas measurements are:
TP5
TP6
28550025
Figure 5-13. Fault 13, Invalid Slope
8% O2 ≈ 23 mV
0.4% O2 ≈ 85 mV
5
3. Power down the Oxymitter 5000 and
remove it from the stack.
4. Replace the cell per paragraph 4-8,
Cell Replacement.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Troubleshooting
5-15
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
n. Fault 14, Invalid Constant
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The CALIBRATION LED flashes twice,
pauses for three seconds, and repeats (Figure 5-14).
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
J1
TP1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
CAL
TEST GAS +
PROCESS % O2
1. After a calibration has been performed,
the electronics calculates a cell constant value.
2. If the cell constant value is outside of
the range, -4 mV to 10 mV, the alarm
will activate. See paragraph 4-2, Calibration, and verify the last calibration
was performed correctly.
TP5
3. Power down the Oxymitter 5000 and
remove it from the stack.
TP6
28550026
4. Replace the cell per paragraph 4-8,
Cell Replacement.
Figure 5-14. Fault 14, Invalid Constant
5-16
Troubleshooting
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
o. Fault 15, Last Calibration Failed
HEATER T/C
HEATER
O2 CELL
CALIBRATION
SW2
ON
DIAGNOSTIC
ALARMS
The CALIBRATION LED flashes three
times, pauses for three seconds, and repeats (Figure 5-15).
CALIBRATION RECOMMENDED
INC
INC
HIGH
GAS
LOW
GAS
DEC
DEC
O2 CELL mV +
O2 CELL mv HEATER T/C +
HEATER T/C -
TP1
J1
TP2
TP3
TP4
RED
YEL
GRN
ORG
TEST
POINTS
2. The cell should be replaced. See paragraph 4-8, Cell Replacement, for cell
replacement instructions.
CAL
TEST GAS +
PROCESS % O2
1. The last calibration failed alarm activates when the slope and constant
values calculated are out of range and
the unit reverts to using the previous
calibration values.
TP5
TP6
28550027
Figure 5-15. Fault 15, Last Calibration Failed
Rosemount Analytical Inc.
A Division of Emerson Process Management
5
Troubleshooting
5-17
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Install all protective equipment covers
and safety ground leads after troubleshooting. Failure to replace covers
and ground leads could result in serious injury or death.
5-5
SPS 4000 TROUBLESHOOTING
Use the CAL FAIL and IN CAL relay outputs to
identify possible SPS 4000 faults.
Oxymitter 5000
MAINTENANCE AND SERVICE,
Also, verify your calibration gas
setup.
(b) Perform another calibration and
monitor the process. If the calibration fails before both calibration
gases finish sequencing, a gas
flow problem exists. Refer to Table
5-2 or Figure 5-16 to troubleshoot
the SPS 4000.
If the calibration setup is correct
and the Oxymitter 5000 indicates
an invalid slope fault (fault 12) before the gases are purged and a
last calibration failed fault (fault 14)
after the gases are purged, replace
the Oxymitter 5000 cell per paragraph 4-8 in Section 4, MAINTENANCE AND SERVICE.
a. If a calibration was not successfully completed, the SPS 4000 sends a CAL FAIL
contact indication to the control room. To
determine if the SPS 4000 caused the failed
calibration, go to the Oxymitter 5000 site to
view the keypad. Or, access the Oxymitter
via fieldbus.
1. If no alarms are indicated on the keypad or via fieldbus, the calibration did
not fail because of an Oxymitter 5000
fault. Therefore, a calibration gas flow
problem occurred. Refer to Table 5-2
or Figure 5-16 to troubleshoot the SPS
4000.
2. If the LAST CAL FAILED alarm is indicated on the keypad or via fieldbus, the
failure is due to either a bad Oxymitter
5000 cell or a calibration gas flow
problem.
(a) Verify your calibration setup per
paragraph 4-2 in Section 4,
5-18
Troubleshooting
b. If a semi-automatic or manual calibration is
being performed but no 5-30 VDC relay
output contact (IN CAL or CAL FAIL) is being received by the control room, the interface board relays are malfunctioning.
Replace the interface board per paragraph
1-1a.
NOTE
If the unit is performing frequent autocalibrations, investigate at the Oxymitter 5000 site or via fieldbus. This
condition may indicate an aging cell in
the Oxymitter 5000.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 5-2. SPS 4000 Fault Finding
SYMPTOM
No calibration gas flow
CHECK
FAULT
REMEDY
Wiring
Improper wire connections, loose connections,
or damaged wiring
Properly connect wiring or secure
loose wiring connections; replace
damaged wiring if necessary.
Logic I/O
Oxymitter 5000 logic I/O
not set for calibration
handshaking with SPS
4000
Set logic I/O to mode 8 via fieldbus
using the IO_PIN_MODE
parameter.
Calibration gas lines between cylinders and
manifold
Clogged calibration gas
line
Replace clogged calibration gas
line.
Calibration gas flowmeter
knob
Flowmeter knob not
turned counterclockwise
to allow flow
Turn calibration gas flowmeter
knob counterclockwise to allow
calibration gas to flow.
Calibration gas line between manifold and calibration gas flowmeter
Clogged calibration gas
line
Replace clogged calibration gas
line.
Fuse on power supply
board
Blown fuse
Replace fuse per paragraph 4-10a.
Interface board operation
Interface board not
sending signals
Replace interface board per paragraph 1-1a.
Check valve
Clogged check valve
Replace check valve per paragraph 4-10e.
Calibration gas line between calibration gas
flowmeter and check
valve
Clogged calibration gas
line
Replace calibration gas line.
Calibration gas flowmeter
Clogged flowmeter
Replace flowmeter per paragraph
4-10h.
Power supply output
Power supply failure
Replace power supply board per
paragraph 1-1a.
Solenoid
Solenoid failure
Replace solenoid per paragraph
4-10c.
Pressure switch
Pressure switch failure
Replace pressure switch per paragraph 4-10d.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Troubleshooting
5-19
5
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SYMPTOM — NO TEST GAS FLOW
CHECK ALL WIRING BETWEEN
OXYMITTER 5000 AND SPS 4000.
IS
WIRING
PROPERLY
CONNECTED
AND
SECURE?
NO
PROPERLY CONNECT WIRING OR
SECURE LOOSE WIRING CONNECTIONS; REPLACE DAMAGED
WIRING.
YES
CHECK LOGIC I/O SETTING VIA
FIELDBUS.
IS
LOGIC I/O
SET FOR
MODE 8?
NO
SET LOGIC I/O TO MODE 8 VIA
FIELDBUS.
YES
DISCONNECT CAL GAS INPUT
LINES AT MANIFOLD.
NO
IS THERE
FLOW?
REPLACED CLOGGED CAL GAS
LINE BETWEEN CAL GAS
CYLINDER AND MANIFOLD.
YES
F1
ENSURE CAL GAS FLOWMETER
KNOB IS TURNED COUNTERCLOCKWISE TO ALLOW FLOW.
J2
DOES
CAL GAS
FLOWMETER
REGISTER
FLOW?
REPLACED CLOGGED CAL GAS
LINE BETWEEN MANIFOLD AND
CAL GAS FLOWMETER.
HI GAS
LO GAS
NO GAS
CAL RET
NO
YES
J3
J4
J5
CHECK FUSE F1 ON POWER
SUPPLY BOARD.
IS
FUSE
BLOWN?
YES
REPLACE FUSE PER
PARAGRAPH 4-10.a.
POWER SUPPLY BOARD
NO
CONTINUED
ON SHEET
2 OF 2
35950004
Figure 5-16. SPS 4000 Troubleshooting Flowchart (Sheet 1 of 2)
5-20
Troubleshooting
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SYMPTOM — NO TEST GAS FLOW (CONTINUED)
NOTE 1: SECURELY TIGHTEN ALL J3 SCREW TERMINALS ON
POWER SUPPLY BOARD TO MAKE CONNECTIONS.
CONTINUED
FROM SHEET
1 OF 2
NOTE 2: USE A SIMPSON MODEL 260 OR EQUIVALENT
MULTIMETER.
NOTE 3: IF REPLACING THE CHECK VALVE DOES NOT
CORRECT THE PROBLEM, A CLOG COULD EXIST IN
THE RED SILICON GAS TUBE WITHIN THE PROBE.
PLACE JUMPER BETWEEN CAL
RET TERMINAL AND EITHER HI
GAS OR LO GAS TERMINAL OF J3.
SEE NOTE 1.
YES
IS THERE
FLOW?
INTERFACE BOARD IS
NOT SENDING SIGNAL.
REPLACE INTERFACE
BOARD PER PARAGRAPH
4-10b.
NOTE 4: IF CHECKING CAL GAS 1 SOLENOID CONNECTOR J5,
ENSURE CAL RET TERMINAL IS JUMPERED TO HI GAS
TERMINAL OF J3. IF CHECKING CAL GAS 2 SOLENOID
CONNECTOR J4, ENSURE CAL RET TERMINAL IS
JUMPERED TO LO GAS TERMINAL OF J3.
NO
USE METER (SEE NOTE 2)
TO CHECK FOR SHORT
BETWEEN CAL RET AND NO GAS
TERMINALS OF J3.
5
YES
IS THERE
A SHORT?
IS THERE
FLOW?
DISCONNECT CAL GAS
LINE AT CHECK VALVE.
YES
REPLACE CHECK VALVE
PER PARAGRAPH 4-10e.
SEE NOTE 3.
NO
NO
DISCONNECT CAL GAS LINE
AT TOP FITTING OF CAL GAS
FLOWMETER.
DISCONNECT SOLENOID FROM
POWER SUPPLY BOARD AND USE
METER TO MEASURE ACROSS
TWO OUTER PINS OF BOARD
CONNECTOR. SEE NOTE 4.
CHECK BOTH SOLENOIDS.
IS THERE
FLOW?
NO
IS THERE
+30VDC?
REPLACE POWER
SUPPLY BOARD PER
PARAGRAPH 4-10b.
DISCONNECT CAL GAS LINE
AT MANIFOLD OUTPUT PORT.
NO
REPLACE CLOGGED
CAL GAS LINE BETWEEN
CAL GAS FLOWMETER
AND CHECK VALVE.
NO
REPLACE FAULTY CAL GAS
FLOWMETER PER PARAGRAPH
4-10h.
YES
IS THERE
FLOW?
YES
REPLACE SOLENOID
PER PARAGRAPH 4-10c.
YES
REPLACE PRESSURE SWITCH
PER PARAGRAPH 4-10d.
35950003
Figure 5-16. SPS 4000 Troubleshooting Flowchart (Sheet 2 of 2)
Rosemount Analytical Inc.
A Division of Emerson Process Management
Troubleshooting
5-21
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
5-22
Troubleshooting
Oxymitter 5000
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
T
WHE N
CI R
CU
VE ATM
OS I
O
PL WA RN I NG - SPH
EX -
IG
H
For more information, call Rosemount Analytical at
1-800-433-6076.
EE
P
T
CAL.
GAS
IN
The specially designed Rosemount Analytical By-Pass
Package for oxygen analyzers has proven to withstand
the high temperatures in process heaters while providing the same advantages offered by the in situ sensor. Inconel or Kanthal steel tubes provide effective
resistance to corrosion, and the package uses no
moving parts, air pumps, or other components common to other sampling systems.
I VE
-
E
ER
AL
BY-PASS PACKAGES
IT
SECTION 6
OPTIONAL ACCESSORIES
26170024
IMPS 4000 INTELLIGENT MULTIPROBE
TEST GAS SEQUENCER
The IMPS 4000 Intelligent Multiprobe Test Gas Sequencer is housed within an IP56 (NEMA 4X) enclosure and has the intelligence to provide calibration gas
sequencing of up to four Oxymitter 5000 units to accommodate automatic and semi-automatic calibration
routines.
6
This sequencer works in conjunction with the Oxymitter 5000 CALIBRATION RECOMMENDED feature,
eliminating out-of-calibration occurrences and the
need to send a technician to the installation site. In
addition, the SPS 4000 provides a remote contact input to initiate a calibration from a remote location and
relay outputs to alert when a calibration is in progress,
an Oxymitter 5000 is out of calibration, calibration
gases are on, and calibration gas pressure is low.
For more information, call Rosemount Analytical at
1-800-433-6076.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Optional Accessories
6-1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SPS 4000 SINGLE PROBE
AUTOCALIBRATION SEQUENCER
Rosemount Analytical specifically designed the SPS
4000 Single Probe Autocalibration Sequencer to provide the capability to perform automatic or on-demand
Oxymitter 5000 calibrations. The system can be installed either as an integral component to an Oxymitter
5000 or at a remote location if space is limited or corrosive conditions exist at the installation site.
The SPS 4000 works in conjunction with the Oxymitter
5000’s CALIBRATION RECOMMENDED feature,
eliminating out-of-calibration occurrences and the
need to send a technician to the installation site. In
addition, the SPS 4000 provides a remote contact input to initiate a calibration from a remote location and
relay outputs to indicate when a calibration is in progress or the Oxymitter 5000 is out of calibration.
For more information, call Rosemount Analytical at
1-800-433-6076.
O2 CALIBRATION GAS SEQUENCER
Rosemount Analytical’s O2 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
6-2
Optional Accessories
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 7
RETURN OF MATERIAL
7-1
Equipment return procedure. If factory repair of
defective equipment is required, proceed as
follows:
a. Secure a return authorization number from
a Rosemount Analytical Sales Office or representative before returning the equipment.
Equipment must be returned with complete
identification in accordance with Rosemount
instructions or it will not be accepted.
In no event will Rosemount be responsible
for equipment returned without proper
authorization and identification.
b. Carefully pack defective unit 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 determined that the equipment is faulty.
2. The environment in which the equipment has been operating (housing,
weather, vibration, dust, etc.).
3. Site from which equipment was removed.
5. Complete shipping instructions for return 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 Return Authorization, prepaid, to:
Rosemount Analytical Inc.
RMR Department
1201 N. Main Street
Orrville, Ohio 44667
If warranty service is requested, the defective 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 customer in accordance with shipping instructions 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.
4. Whether warranty or nonwarranty
service is requested.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Return of Material
7-1
7
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
7-2
Return of Material
Oxymitter 5000
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 8
REPLACEMENT PARTS
Table 8-1. Replacement Parts for Probe
FIGURE and
INDEX No.
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
PART NUMBER
No Dust Seal
Dust Seal
3D39648G01 3D39649G01
3D39648G02 3D39649G02
3D39648G03 3D39649G03
3D39648G04 3D39649G04
3D39648G05 3D39649G05
3D39648G06 3D39649G06
3D39648G07 3D39649G07
3D39648G08 3D39649G08
3D39648G09 3D39649G09
3D39648G10 3D39649G10
3D39648G11 3D39649G11
3D39648G12 3D39649G12
3D39648G13 3D39649G13
3D39648G14 3D39649G14
3D39648G15 3D39649G15
DESCRIPTION
18 in. ANSI Probe with Ceramic Diffuser
3 ft ANSI Probe with Ceramic Diffuser
6 ft ANSI Probe with Ceramic Diffuser
9 ft ANSI Probe with Ceramic Diffuser
12 ft ANSI Probe with Ceramic Diffuser
18 in. JIS Probe with Ceramic Diffuser
3 ft JIS Probe with Ceramic Diffuser
6 ft JIS Probe with Ceramic Diffuser
9 ft JIS Probe with Ceramic Diffuser
12 ft JIS Probe with Ceramic Diffuser
18 in. DIN Probe with Ceramic Diffuser
3 ft DIN Probe with Ceramic Diffuser
6 ft DIN Probe with Ceramic Diffuser
9 ft DIN Probe with Ceramic Diffuser
12 ft DIN Probe with Ceramic Diffuser
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
3D39648G17
3D39648G18
3D39648G19
3D39648G20
3D39648G21
3D39648G22
3D39648G23
3D39648G24
3D39648G25
3D39648G26
3D39648G27
3D39648G28
3D39648G29
3D39648G30
3D39648G31
18 in. ANSI Flame Arrestor with Ceramic Diffuser Probe
3 ft ANSI Flame Arrestor with Ceramic Diffuser Probe
6 ft ANSI Flame Arrestor with Ceramic Diffuser Probe
9 ft ANSI Flame Arrestor with Ceramic Diffuser Probe
12 ft ANSI Flame Arrestor with Ceramic Diffuser Probe
18 in. JIS Flame Arrestor with Ceramic Diffuser Probe
3 ft JIS Flame Arrestor with Ceramic Diffuser Probe
6 ft JIS Flame Arrestor with Ceramic Diffuser Probe
9 ft JIS Flame Arrestor with Ceramic Diffuser Probe
12 ft JIS Flame Arrestor with Ceramic Diffuser Probe
18 in. DIN Flame Arrestor with Snubber Diffuser Probe
3 ft DIN Flame Arrestor with Snubber Diffuser Probe
6 ft DIN Flame Arrestor with Snubber Diffuser Probe
9 ft DIN Flame Arrestor with Snubber Diffuser Probe
12 ft DIN Flame Arrestor with Snubber Diffuser Probe
3D39649G17
3D39649G18
3D39649G19
3D39649G20
3D39649G21
3D39649G22
3D39649G23
3D39649G24
3D39649G25
3D39649G26
3D39649G27
3D39649G28
3D39649G29
3D39649G30
3D39649G31
8
Rosemount Analytical Inc.
A Division of Emerson Process Management
Replacement Parts
8-1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 8-1. Replacement Parts for Probe (Continued)
FIGURE and
INDEX No.
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 thru 6, 8, 9
4-1, 2 through 6, 8, 9
FIGURE and
INDEX No.
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 6
4-1, 1
4-1, 1
4-1, 1
4-1, 1
4-1, 1
8-2
Replacement Parts
PART NUMBER
No Dust Seal
Dust Seal
3D39648G33 3D39649G33
3D39648G34 3D39649G34
3D39648G35 3D39649G35
3D39648G36 3D39649G36
3D39648G37 3D39649G37
3D39648G38 3D39649G38
3D39648G39 3D39649G39
3D39648G40 3D39649G40
3D39648G41 3D39649G41
3D39648G42 3D39649G42
3D39648G43 3D39649G43
3D39648G44 3D39649G44
3D39648G45 3D39649G45
3D39648G46 3D39649G46
3D39648G47 3D39649G47
PART NUMBER
3D39644G01
3D39644G02
3D39644G03
3D39644G04
3D39644G05
3D39644G06
3D39644G07
3D39644G08
3D39644G09
3D39644G10
3D39644G11
3D39644G12
3D39644G13
3D39644G14
3D39644G15
3D39645G01
3D39645G02
3D39645G03
3D39645G04
3D39645G05
DESCRIPTION
18 in. ANSI Probe with Snubber Diffuser
3 ft ANSI Probe with Snubber Diffuser
6 ft ANSI Probe with Snubber Diffuser
9 ft ANSI Probe with Snubber Diffuser
12 ft ANSI Probe with Snubber Diffuser
18 in. JIS Probe with Snubber Diffuser
3 ft JIS Probe with Snubber Diffuser
6 ft JIS Probe with Snubber Diffuser
9 ft JIS Probe with Snubber Diffuser
12 ft JIS Probe with Snubber Diffuser
18 in. DIN Probe with Snubber Diffuser
3 ft DIN Probe with Snubber Diffuser
6 ft DIN Probe with Snubber Diffuser
9 ft DIN Probe with Snubber Diffuser
12 ft DIN Probe with Snubber Diffuser
DESCRIPTION
18 in. ANSI Probe Tube Assy.
3 ft ANSI Probe Tube Assy.
6 ft ANSI Probe Tube Assy.
9 ft ANSI Probe Tube Assy.
12 ft ANSI Probe Tube Assy.
18 in. JIS Probe Tube Assy.
3 ft JIS Probe Tube Assy.
6 ft JIS Probe Tube Assy.
9 ft JIS Probe Tube Assy.
12 ft JIS Probe Tube Assy.
18 in. DIN Probe Tube Assy.
3 ft DIN Probe Tube Assy.
6 ft DIN Probe Tube Assy.
9 ft DIN Probe Tube Assy.
12 ft DIN Probe Tube Assy.
18 in. Heater Strut Assy.
3 ft Heater Strut Assy.
6 ft Heater Strut Assy.
9 ft Heater Strut Assy.
12 ft Heater Strut Assy.
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 8-1. Replacement Parts for Probe (Continued)
FIGURE and
INDEX No.
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-3
*Includes pad and wire.
PART NUMBER
4847B61G02
4847B61G03
4847B61G04
4847B61G05
4847B61G06
4847B61G07
4847B61G08
4847B61G09
4847B61G10
4847B61G11
4847B61G12
4847B61G14
4847B61G15
4847B61G16
4847B61G17
3D39003G01
3D39003G02
3D39003G03
3D39003G04
3D39003G05
3D39003G06
3D39003G07
3D39003G08
DESCRIPTION
ANSI 18 in. Cell Replacement Kit*
ANSI 3 ft Cell Replacement Kit*
ANSI 6 ft Cell Replacement Kit*
ANSI 9 ft Cell Replacement Kit*
ANSI 12 ft Cell Replacement Kit*
JIS 18 in. Cell Replacement Kit*
JIS 3 ft Cell Replacement Kit*
JIS 6 ft Cell Replacement Kit*
JIS 9 ft Cell Replacement Kit*
JIS 12 ft Cell Replacement Kit*
DIN 18 in. Cell Replacement Kit*
DIN 3 ft Cell Replacement Kit*
DIN 6 ft Cell Replacement Kit*
DIN 9 ft Cell Replacement Kit*
DIN 12 ft Cell Replacement Kit*
ANSI 3 ft Abrasive Shield Assy.
ANSI 6 ft Abrasive Shield Assy.
JIS 3 ft Abrasive Shield Assy.
JIS 6 ft Abrasive Shield Assy.
DIN 3 ft Abrasive Shield Assy.
DIN 6 ft Abrasive Shield Assy.
ANSI 9 ft Abrasive Shield Assy.
ANSI 12 ft Abrasive Shield Assy.
8
Rosemount Analytical Inc.
A Division of Emerson Process Management
Replacement Parts
8-3
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
ANSI
GASKET
WIRE AND
PAD ASSEMBLY
ANTI-SEIZE
COMPOUND
PROBE TUBE
(NOT INCLUDED
IN KIT)
22 GA.
WIRE
CORRUGATED
SEAL
CLOSED END
CONNECTOR
CELL AND
FLANGE
ASSEMBLY
SOCKET HEAD
CAP SCREWS
SET SCREWS
TEFLON
TUBING
CALIBRATION GAS
PASSAGE
22220068
Figure 8-1. Cell Replacement Kit
8-4
Replacement Parts
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 8-1. Replacement Parts for Probe (Continued)
FIGURE and
INDEX No.
PART NUMBER
DESCRIPTION
2-3
2-3
2-3
2-3
2-3
2-3
2-3
3D39003G09
3D39003G10
3D39003G11
3D39003G12
3D39003G13
3D39003G14
3D39003G15
JIS 9 ft Abrasive Shield Assy.
JIS 12 ft Abrasive Shield Assy.
DIN 9 ft Abrasive Shield Assy.
DIN 12 ft Abrasive Shield Assy.
ANSI 18 in. Abrasive Shield Assy.
JIS 18 in. Abrasive Shield Assy.
DIN 18 in. Abrasive Shield Assy.
2-1
2-1
2-1
2-1
2-1
4-1, 2
8-2
3535B60G01
3535B63G01
4843B38G01
3534B18G01
3534B48G01
4843B37G01
3535B42G02
Ceramic Diffuser with Dust Seal
Flame Arrest Ceramic Diffuser with Dust Seal
Snubber Diffuser with Dust Seal
Ceramic Diffuser Hub Assy.
Vee Deflector Assy.
Snubber Diffusion Assy.
Probe Disassembly Kit
HEX KEYS
SPANNER
WRENCH
ANTI-SEIZE
COMPOUND
PHILIPS
SCREWDRIVER
8
WRENCH
TUBE INSERTION
TUBE
22220070
Figure 8-2. Probe Disassembly Kit
Rosemount Analytical Inc.
A Division of Emerson Process Management
Replacement Parts
8-5
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 8-2. Replacement Parts for Electronics
FIGURE and
INDEX No.
PART NUMBER
DESCRIPTION
4-1, 21, 27
4-1, 12
4-1, 25
4-1, 11
4850B10G11
4849B95G04
3D39768G02
3D39767G01
5R10145G01
Electronics English-Standard
Housing and Cover
Electronic Assembly and keypad English
Termination Block-Standard
Cover
4-1, 21, 27
4-1, 12
4-1, 25
4-1, 11
4850B10G12
4849B95G04
3D39768G03
3D39767G01
5R10145G01
Electronics German-Standard
Housing and Cover
Electronic Assembly and keypad German
Termination Block-Standard
Cover
4-1, 21, 27
4-1, 12
4-1, 25
4-1, 11
4850B10G13
4849B95G04
3D39768G04
3D39767G01
5R10145G01
Electronics French-Standard
Housing and Cover
Electronic Assembly and keypad French
Termination Block-Standard
Cover
4-1, 21, 27
4-1, 12
4-1, 25
4-1, 11
4850B10G14
4849B95G04
3D39768G05
3D39767G01
5R10145G01
Electronics Spanish-Standard
Housing and Cover
Electronic Assembly and keypad Spanish
Termination Block-Standard
Cover
4-1, 21, 27
4-1, 12
4-1, 25
4-1, 11
4850B10G15
4849B95G04
3D39768G06
3D39767G01
5R10145G01
Electronics Italian-Standard
Housing and Cover
Electronic Assembly and keypad Italian
Termination Block-Standard
Cover
4-1, 21
4-1, 12
4-1, 25
4-1, 11
4850B10G16
4849B95G04
3D39768G02
3D39767G02
5R10145G01
Electronics English-Transient Protected
Housing and Cover
Electronic Assembly and keypad English
Termination Block-Transient Protected
Cover
4-1, 21
4-1, 12
4-1, 25
4-1, 11
4850B10G17
4849B95G04
3D39768G03
3D39767G02
5R10145G01
Electronics German-Transient Protected
Housing and Cover
Electronic Assembly and keypad German
Termination Block-Transient Protected
Cover
4-1, 21
4-1, 12
4-1, 25
4-1, 11
4850B10G18
4849B95G04
3D39768G04
3D39767G02
5R10145G01
Electronics French-Transient Protected
Housing and Cover
Electronic Assembly and keypad French
Termination Block-Transient Protected
Cover
8-6
Replacement Parts
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 8-2. Replacement Parts for Electronics (Continued)
FIGURE and
INDEX No.
PART NUMBER
DESCRIPTION
4-1, 21
4-1, 12
4-1, 25
4-1, 11
4850B10G19
4849B95G04
3D39768G05
3D39767G02
5R10145G01
Electronics Spanish-Transient Protected
Housing and Cover
Electronic Assembly and keypad Spanish
Termination Block-Transient Protected
Cover
4-1, 21
4-1, 12
4-1, 25
4-1, 11
4850B10G20
4849B95G04
3D39768G06
3D39767G02
5R10145G01
Electronics Italian-Transient Protected
Housing and Cover
Electronic Assembly and keypad Italian
Termination Block-Transient Protected
Cover
4-1, 12
4-1, 14
4-1, 14
4-1, 14
4-1, 14
4-1, 14
3D39762G01
4849B72H01
4849B72H02
4849B72H03
4849B72H04
4849B72H05
Electronic Assembly
Membrane Keypad English
Membrane Keypad German
Membrane Keypad French
Membrane Keypad Spanish
Membrane Keypad Italian
4-1, 25
4-1, 25
3D39767G01
3D39767G02
Termination Block Standard
Termination Block Transient Protected
8
Rosemount Analytical Inc.
A Division of Emerson Process Management
Replacement Parts
8-7
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Table 8-3. Replacement Parts for SPS 4000
FIGURE and
INDEX No.
PART NUMBER
4-11, 4
4-13, 19
4-11, 15
4-13, 17
4-13, 16
4-13, 8
4-11, 17
4-11, 19
4-11, 18
5-12, 12
4-11, 13 and 20
4-11, 8
4-11, 28
4-11, 25
1A99093H01
6292A97H03
1A99089H01
771B635H01
771B635H02
1A99094H01
1A97913H03
4850B56G01
4850B54G01
7305A67H01
3D39435G01
120039-0077
4850B75H01
1A99147H01
DESCRIPTION
Bushing Gasket
Check Valve
Cover O-ring
Flowmeter Assembly, Calibration Gas
Flowmeter Assembly, Reference Air (Optional)
Pressure Regulator, Reference Air (Optional)
Fuse, 5A, 250V, 5 × 20 mm, Slow Blow
Interface Board
Power Supply Board
Pressure Switch
Solenoid
O-ring
Terminal Cover Gasket
Terminal Strip
Table 8-4. Replacement Parts for Calibration Gas Bottles
FIGURE and
INDEX No.
PART NUMBER
DESCRIPTION
1A9911G01
Calibration Gas Bottles — 0.4% and 8.0% O2, balance nitrogen — 550 litres each, includes bottle
rack*
Two flow gas regulators for calibration gas bottles
1A99119G02
* Calibration gas bottles cannot be shipped via airfreight.
8-8
Replacement Parts
Rosemount Analytical Inc.
A Division of Emerson Process Management
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 9
APPENDICES
APPENDIX A. FIELDBUS PARAMETER DESCRIPTION
APPENDIX B. ANALOG INPUT (AI) FUNCTION BLOCK
APPENDIX C. PID FUNCTION BLOCK
9
Rosemount Analytical Inc.
A Division of Emerson Process Management
Appendices
9-1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
9-2
Appendices
Oxymitter 5000
Rosemount Analytical Inc.
A Division of Emerson Process Management
APPENDIX A. FIELDBUS PARAMETER DESCRIPTION
A
Parameter Mnemonic
ALARM_POINT_LOW
Valid Range
Initial
Value
0.0-40.0
Units
Description
%O2
ALERT_KEY
AUTOCAL_ENABLED
AUTOCAL_INTERVAL
0: Not enabled
1: Enabled
0-9999
Enumerated
Hours
This is the time between automatic calibrations, in
hours.
See Function Block Specification, part 2. FF-891,
page 41.
See Function Block Specification, part 2. FF-891,
page 41.
This is the date that the Oxymitter software was built.
This is the build number of the Oxymitter software.
This parameter represents the constant (offset) value
used in the calculation of converting the sensor
voltage to an O2 value. The value of this parameter
may be manually entered or calculated during a
sensor calibration.
This is the length of time test gases are applied to
the O2 probe before each measurement of the
calibration cycle.
The constant from the last successful calibration.
BLOCK_ALM
BLOCK_ERR
BUILD_DATE
BUILD_NUMBER
CAL_CONSTANT
0-65535
± 20.0
CAL_GAS_TIME
60-1200
Sec
CAL_LAST_
CONSTANT
CAL_LAST_SLOPE
CAL_POINT_HI
± 20.0
mV
34.5-57.5
0.0-40.0
mV/Decade
%O2
CAL_POINT_LO
0.0-40.0
%O2
CAL_PURGE_TIME
60-1200
Sec
CAL_SENSOR_
IMPEDANCE
CAL_SLOPE
0-10000
Ohms
34.5-57.5
mV/Decade
CAL_STATE
See Table 1
Enumerated
CAL_STATE_STEP
0: No effect
1: Go to next
step
2: Abort
Calibration
CAL_STATE_TIME
0-1200
Sec
CAL_TRACKS
CELL_MV_VALUE
CELL_TC_MV_VALUE
± INF
-1000.0 - 500.0
mV
mV
CELL_TEMPERATURE
CHECKSUM
0
0
0
0000
N/A
N/A
mV
Enumerated
N/A
This is the point at which the Low O2 alarm will
become active.
See Function Block Specification, part 1. FF-890,
page 50.
This parameter enables automatic calibrations.
The slope from the last successful calibration.
This is the actual value of the gas being applied
during the high test gas phase of a calibration.
This is the actual value of the gas being applied
during the low test gas phase of a calibration.
This is the length of time after a calibration is
complete before the O2 value status returns to
normal.
This is the sensor impedance value measured at the
time of the last calibration.
This parameter represents the slope value used in
the calculation of converting the sensor voltage to an
O2 value. The value of this parameter may be
manually entered or calculated during a sensor
calibration.
This parameter represents the present state the
calibration cycle is in. Refer to Table 1 for the
definition of states.
This parameter is used to step the transmitter
through a sensor calibration. Setting this parameter
to 1 requests the transmitter to move to the next
cycle state of the calibration procedure. The request
is only valid when the CAL_STATE value represents
a state that is waiting for an external event such as
the changing of a test gas value. The transmitter will
set this parameter value back to 0 when it has
completed processing the step request. Setting this
parameter to a value of 2 will cause the present
calibration to be aborted.
This is the time in seconds remaining in the present
calibration state.
This parameter is no longer used.
This is the raw signal from the O2 sensor.
This is the raw signal from the O2 sensor
thermocouple.
This is the current temperature of the O2 sensor.
This is the checksum of the Oxymitter software.
IB-106-350
A-1
Parameter
Number
37
4
46
47
8
6
62
60
27
22
29
28
17
18
23
25
26
19
20
21
24
43
44
54
61
Parameter Mnemonic
COLD_JUNC_MV_
VALUE
COLLECTION_
DIRECTORY
CONFIG_CHANGED
Valid Range
Initial
Value
± INF
Units
Description
mV
0-255
0
N/A
TB_DETAILED_
STATUS
0-16777215
0
Enumerated
HIGH_CASE_TEMP
0-10000.0
HIGH_CASE_TEMP_
RESET
0: No effect
1: Reset high
case
temperature
IO_PIN_MODE
See table 2
Enumerated
IO_PIN_STATE
0: Off
1: On
Enumerated
O
0
C
Enumerated
MODE_BLK
O2_PERCENT_OF_
RANGE
O2_RANGE
OXY_BLOCK_ALARM
OXY_BLOCK_ERR
0.0-100.0
%
0-40
%O2
See section 4.7
in FF-903
See table 3
PRIMARY_VALUE
(O2_VALUE)
0.0-25.0
PRIMARY_VALUE_
TYPE
SECONDARY_VALUE
See section 4.1
in FF-903
-10000 - 10000
0
Enumerated
0
Enumerated
%O2
0
Enumerated
O
C
SECONDARY_VALUE_
UNITS
SENSOR_CAL_DATE
SENSOR_CAL_LOC
SENSOR_CAL_
METHOD
SENSOR_CAL_WHO
SENSOR_IMPEDANCE
0-10000
Ohms
SENSOR_RANGE
0-100
%O2
SENSOR_SN
This is the raw signal from the case/thermocouple
cold junction sensor.
See Transducer Block Specification, part 1. FF-902,
page 11.
This indicates that a static parameter in the Oxymitter
has changed by some means other than Fieldbus.
This is a bit-enumerated value used to communicate
the status of the Oxymitter. (This is similar in nature
to the command 48 status bits in HART.)
This is the highest temperature that has been
measured inside the electronics enclosure.
This parameter is used to request the parameter
CASE_TEMP_MAX be reset to the current internal
case temperature. Setting this parameter at a value
of 1 will cause the transmitter to reset the
CASE_TEMP_MAX value. The transmitter will set
this parameter to 0 once it has completed this
process.
This parameter represents the operating mode of the
discrete IO pin of the transmitter. 0 = Alarm Contact
Mode, 1=Calibration Sequence Mode.
This parameter represents the current state of the
transmitters discrete IO pin. 0 = FALSE, 1 = TRUE.
See Function Block Specification, part 1. FF-890,
page 50.
This is the percent of total range value.
This contains the upper and lower %O2 range values,
the units, and the precision.
This is the FF block alarm code. See Transducer
Blocks, part 2. FF-903, page 41.
This is the Oxymitter's device alarm code. See Table
3.
This is the value that should appear on the output
channel of the transducer block. In the Oxymitter,
this is the present %O2 reading and should reflect
any test gas being applied.
Selected from list in Transducer Block Specification,
part 2. FF-903, page 39, section 4.1.
See Transducer Block Specification, part 2. FF-903,
page 37. In the Oxymitter, this is the temperature of
the electronics.
See Transducer Block Specification, part 2. FF-903,
page 37.
See Transducer Block Specification, part 2. FF-903,
page 37.
See Transducer Block Specification, part 2. FF-903,
page 37.
Last calibration method. Selected from list in
Transducer Block Specification, part 2. FF-903,
page 40, section 4.5.
This is used to store the name of the individual who
last performed a calibration.
This is the sensor impedance value that was last
measured.
See Transducer Block Specification, part 2. FF-903,
page 37.
See Transducer Block Specification, part 2. FF-903,
page 37.
IB-106-350
A-2
Parameter
Number
45
12
51
55
38
39
40
41
5
15
16
53
52
13
14
49
50
36
35
34
42
30
32
33
Parameter Mnemonic
Valid Range
Initial
Value
Units
SENSOR_TYPE
ST_REV
STATS_ATTEMPTS
STATS_FAILURES
STATS_TIMEOUTS
STRATEGY
TAG_DESC
TIME_TO_NEXT_CAL
0.0-9999.0
Hours
TRANSDUCER_
DIRECTORY
TRANSDUCER_TYPE
UPDATE_EVT
VERSION
XD_ERROR
N/A
Description
Selected from list in Transducer Block Specification,
part 2. FF-903, page 40, section 4.3.
See Function Block Specification, part 1. FF-890,
page 49.
This shows the number of communication attempts
between the Oxymitter and the internal fieldbus
interface card.
This shows the number of communication failures
between the Oxymitter and the internal fieldbus
interface card.
This shows the number of communication failures
due to reply timeout between the Oxymitter and the
internal fieldbus interface card.
See Function Block Specification, part 1. FF-890,
page 49.
See Function Block Specification, part 1. FF-890,
page 49.
This is the time remaining until the next automatic
calibration.
See Transducer Block Specification, part 1. FF-902,
page 11.
Selected from list in Transducer Block Specification,
part 2. FF-903, page 39, section 4.2.
See Function Block Specification, part 2. FF-891,
page 45.
This is the version of the Oxymitter software.
See Transducer Block Specification, part 2. FF-903,
page 38.
IB-106-350
A-3
Parameter
Number
31
1
56
57
58
3
2
48
9
10
7
59
11
A
Table A-1. Calibration State Values
Code Value
External Event Required to
Go to Next Step?
Description
0
Normal System Operation
Yes
1
Calibration Required
Yes
2
Apply Test Gas 1
Yes
3
Test Gas 1 Flow
No
4
Test Gas 1 Read
No
5
Test Gas 1 Done
No
6
Apply Test Gas 2
Yes
7
Test Gas 2 Flow
No
8
Test Gas 2 Read
No
9
Test Gas 2 Done
No
10
Abort/Fail
Yes
11
Stop Gas
Yes
12
Purge
No
Table A-2. IO Pin Mode Values
Code Value
Description
0
No Alarm
1
Unit Alarm
2
Low 02 Alarm
3
Low 02/Unit Alarm
4
Cal Recommended
5
Cal Recommended/Unit Alarm
6
Low 02/Cal Recommended
7
Low 02/Unit/Cal
8
Cal Recommended->Handshake
9
Handshake
IB-106-350
A-4
Table A-3. Unit Alarm Values
A
Alarm
Number
Value Of
DETAILED_STATUS
Value of BLOCK_ALARM
(see FF-903)
0
0
NONE
No Alarm Active
1
1
MECHANICAL_FAILURE
Open Thermocouple
2
2
MECHANICAL_FAILURE
Shorted Thermocouple
3
4
MECHANICAL_FAILURE
Reversed Thermocouple
4
8
N/A
Not a valid alarm
5
16
N/A
Not a valid alarm
6
32
MECHANICAL_FAILURE
Heater Open Circuit
7
64
MECHANICAL_FAILURE
High High Heater Temperature
8
128
MECHANICAL_FAILURE
High Case Temp
9
256
MECHANICAL_FAILURE
Low Heater Temperature
10
512
MECHANICAL_FAILURE
High Heater Temperature
11
1024
MECHANICAL_FAILURE
Open Cell Circuit
12
2048
N/A
Not a valid alarm
13
4096
MECHANICAL_FAILURE
High AC Impedance / Cell Bad
14
8192
DATA_INTEGRITY_ERROR
Eeprom Parameters Corrupt
15
16384
N/A
Calibration Recommended
16
32768
CONFIGURATION_ERROR
Invalid Slope value
17
65536
CONFIGURATION_ERROR
Invalid Cell Constant Value
18
131072
CONFIGURATION_ERROR
Bad Calibration
Description
Table A-4. I/O Channel Configuration
Transducer Block
Channel Value
Process Variable
XD_SCALE Units
1
Oxygen
%
2
Case Temperature
ºC
3
Sensor Temperature
ºC
Refer to Appendix B for instructions on how to implement these variables.
IB-106-350
A-5
Table A-5. Channel 1 Status
Alarm Condition
Channel 1 Status
Self-clearing?
Open Thermocouple
Bad
No
Shorted Thermocouple
Bad
No
Reversed Thermocouple
Bad
No
Heater Open Circuit
Bad
No
High High Heater Temperature
Bad
No
High Case Temperature
Bad
Yes
Low Heater Temperature
Bad
Yes
High Heater Temperature
Bad
Yes
Open Cell Circuit
Bad
Yes
High AC Impedance / Cell Bad
Uncertain
Yes
EEPROM Parameters Corrupt
Bad
No
Calibration Recommended
Good
No
Invalid Slope Value
Uncertain
No
Invalid Cell Constant Value
Uncertain
No
Bad Calibration
Uncertain
No
In Calibration
Uncertain
Yes
During Warm Up
Bad
Yes
The status of channel 1 is affected by the state of the unit alarm, as shown in Table A-5. In
all cases, the channel will read what it believes is the correct oxygen value. Self-clearing
alarms are reset when the alarm condition goes away. All others require the Oxymitter 5000
to be restarted.
IB-106-350
A-6
Appendix
B
Analog Input (AI)
Function Block
B
AI
OUT
OUT_D
fieldbus-fbus_31a
OUT_D
OUT
= The block output value and status
= Discrete output that signals a selected
alarm condition
The Analog Input (AI) function block processes field device
measurements and makes them available to other function blocks. The
output value from the AI block is in engineering units and contains a
status indicating the quality of the measurement. The measuring
device may have several measurements or derived values available in
different channels. Use the channel number to define the variable that
the AI block processes.
The AI block supports alarming, signal scaling, signal filtering, signal
status calculation, mode control, and simulation. In Automatic mode,
the block’s output parameter (OUT) reflects the process variable (PV)
value and status. In Manual mode, OUT may be set manually. The
Manual mode is reflected on the output status. A discrete output
(OUT_D) is provided to indicate whether a selected alarm condition is
active. Alarm detection is based on the OUT value and user specified
alarm limits. Figure B-1 on page B-4 illustrates the internal
components of the AI function block, and Table B-1 lists the AI block
parameters and their units of measure, descriptions, and
index numbers.
TABLE B-1. Definitions of Analog Input
Function Block System Parameters.
Parameter
Index
Number
Units
Description
ACK_OPTION
23
None
ALARM_HYS
24
Percent
The amount the alarm value must return within the alarm limit before the associated active
alarm condition clears.
ALARM_SEL
38
None
Used to select the process alarm conditions that will cause the OUT_D parameter to be set.
ALARM_SUM
22
None
The summary alarm is used for all process alarms in the block. The cause of the alert is
entered in the subcode field. The first alert to become active will set the Active status in the
Status parameter. As soon as the Unreported status is cleared by the alert reporting task,
another block alert may be reported without clearing the Active status, if the subcode
has changed.
ALERT_KEY
04
None
The identification number of the plant unit. This information may be used in the host for
sorting alarms, etc.
Used to set auto acknowledgment of alarms.
B-1
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Parameter
Index
Number
Units
Description
BLOCK_ALM
21
None
The block alarm is used for all configuration, hardware, connection failure or system
problems in the block. The cause of the alert is entered in the subcode field. The first alert
to become active will set the Active status in the Status parameter. As soon as the
Unreported status is cleared by the alert reporting task, another block alert may be reported
without clearing the Active status, if the subcode has changed.
BLOCK_ERR
06
None
This parameter reflects the error status associated with the hardware or software
components associated with a block. It is a bit string, so that multiple errors may be shown.
CHANNEL
15
None
The CHANNEL value is used to select the measurement value. Refer to the appropriate
device manual for information about the specific channels available in each device.
You must configure the CHANNEL parameter before you can configure the XD_SCALE
parameter.
FIELD_VAL
19
Percent
The value and status from the transducer block or from the simulated input when simulation
is enabled.
GRANT_DENY
12
None
Options for controlling access of host computers and local control panels to operating,
tuning, and alarm parameters of the block. Not used by device.
HI_ALM
34
None
The HI alarm data, which includes a value of the alarm, a timestamp of occurrence and the
state of the alarm.
HI_HI_ALM
33
None
The HI HI alarm data, which includes a value of the alarm, a timestamp of occurrence and
the state of the alarm.
HI_HI_LIM
26
EU of PV_SCALE
HI_HI_PRI
25
None
HI_LIM
28
EU of PV_SCALE
HI_PRI
27
None
The priority of the HI alarm.
IO_OPTS
13
None
Allows the selection of input/output options used to alter the PV. Low cutoff enabled is the
only selectable option.
L_TYPE
16
None
Linearization type. Determines whether the field value is used directly (Direct), is converted
linearly (Indirect), or is converted with the square root (Indirect Square Root).
LO_ALM
35
None
The LO alarm data, which includes a value of the alarm, a timestamp of occurrence and
the state of the alarm.
LO_LIM
30
EU of PV_SCALE
LO_LO_ALM
36
None
LO_LO_LIM
32
EU of PV_SCALE
LO_LO_PRI
31
None
The priority of the LO LO alarm.
LO_PRI
29
None
The priority of the LO alarm.
LOW_CUT
17
%
MODE_BLK
05
None
The setting for the alarm limit used to detect the HI HI alarm condition.
The priority of the HI HI alarm.
The setting for the alarm limit used to detect the HI alarm condition.
The setting for the alarm limit used to detect the LO alarm condition.
The LO LO alarm data, which includes a value of the alarm, a timestamp of occurrence and
the state of the alarm.
The setting for the alarm limit used to detect the LO LO alarm condition.
If percentage value of transducer input fails below this, PV = 0.
The actual, target, permitted, and normal modes of the block.
Target: The mode to “go to”
Actual: The mode the “block is currently in”
Permitted: Allowed modes that target may take on
Normal: Most common mode for target
OUT
08
EU of OUT_SCALE
OUT_D
37
None
Discrete output to indicate a selected alarm condition.
OUT_SCALE
11
None
The high and low scale values, engineering units code, and number of digits to the right of
the decimal point associated with OUT.
PV
07
EU of XD_SCALE
B-2
The block output value and status.
The process variable used in block execution.
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Parameter
Index
Number
Units
Description
PV_FTIME
18
Seconds
The time constant of the first-order PV filter. It is the time required for a 63% change in the
IN value.
SIMULATE
09
None
A group of data that contains the current transducer value and status, the simulated
transducer value and status, and the enable/disable bit.
STRATEGY
03
None
The strategy field can be used to identify grouping of blocks. This data is not checked or
processed by the block.
ST_REV
01
None
The revision level of the static data associated with the function block. The revision value
will be incremented each time a static parameter value in the block is changed.
TAG_DESC
02
None
The user description of the intended application of the block.
UPDATE_EVT
20
None
This alert is generated by any change to the static data.
VAR_INDEX
39
% of OUT Range
VAR_SCAN
40
Seconds
XD_SCALE
10
None
The average absolute error between the PV and its previous mean value over that
evaluation time defined by VAR_SCAN.
The time over which the VAR_INDEX is evaluated.
The high and low scale values, engineering units code, and number of digits to the right of
the decimal point associated with the channel input value.
The XD_SCALE units code must match the units code of the measurement channel in the
transducer block. If the units do not match, the block will not transition to MAN or AUTO
Simulation
To support testing, you can either change the mode of the block to
manual and adjust the output value, or you can enable simulation
through the configuration tool and manually enter a value for the
measurement value and its status. In both cases, you must first set the
ENABLE jumper on the field device.
NOTE
All fieldbus instruments have a simulation jumper. As a safety measure,
the jumper has to be reset every time there is a power interruption. This
measure is to prevent devices that went through simulation in the
staging process from being installed with simulation enabled.
With simulation enabled, the actual measurement value has no impact
on the OUT value or the status.
B-3
B
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
FIGURE B-1. Analog Input
Function Block Schematic.
Analog
Measurement
ALARM_TYPE
Access
Analog
Meas.
HI_HI_LIM
HI_LIM
LO_LO_LIM
LO_LIM
CHANNEL
Alarm
Detection
OUT_D
ALARM_HYS
LOW_CUT
SIMULATE
L_TYPE
FIELD_VAL
Filter
PV
PV_FTIME
MODE
IO_OPTS
Status
Calc.
OUT
FIELDBUS-FBUS_02A
Cutoff
Convert
STATUS_OPTS
OUT_SCALE
XD_SCALE
NOTES:
OUT = block output value and status.
OUT_D = discrete output that signals a selected alarm condition.
FIGURE B-2. Analog Input
Function Block Timing Diagram.
OUT (mode in man)
OUT (mode in auto)
PV
FIELD_VAL
Time (seconds)
PV_FTIME
Filtering
B-4
FIELDBUS-FBUS_03A
63% of Change
The filtering feature changes the response time of the device to smooth
variations in output readings caused by rapid changes in input. You can
adjust the filter time constant (in seconds) using the PV_FTIME
parameter. Set the filter time constant to zero to disable the
filter feature.
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Signal Conversion
You can set the signal conversion type with the Linearization Type
(L_TYPE) parameter. You can view the converted signal (in percent of
XD_SCALE) through the FIELD_VAL parameter.
100 × ( Channel Value – EU*@0% )
FIELD_VAL = -------------------------------------------------------------------------------------( EU*@100% – EU*@0% )
* XD_SCALE values
B
You can choose from direct, indirect, or indirect square root signal
conversion with the L_TYPE parameter.
Direct
Direct signal conversion allows the signal to pass through the accessed
channel input value (or the simulated value when simulation is enabled).
PV = Channel Value
Indirect
Indirect signal conversion converts the signal linearly to the accessed
channel input value (or the simulated value when simulation is
enabled) from its specified range (XD_SCALE) to the range and units of
the PV and OUT parameters (OUT_SCALE).
FIELD_VAL
PV =  -------------------------------- × ( EU**@100% – EU**@0% ) + EU**@0%


100
** OUT_SCALE values
Indirect Square Root
Indirect Square Root signal conversion takes the square root of the
value computed with the indirect signal conversion and scales it to the
range and units of the PV and OUT parameters.
PV =
 FIELD_VAL
-------------------------------- × ( EU**@100% – EU**@0% ) + EU**@0%


100
** OUT_SCALE values
When the converted input value is below the limit specified by the
LOW_CUT parameter, and the Low Cutoff I/O option (IO_OPTS) is
enabled (True), a value of zero is used for the converted value (PV). This
option is useful to eliminate false readings when the differential
pressure measurement is close to zero, and it may also be useful with
zero-based measurement devices such as flowmeters.
NOTE
Low Cutoff is the only I/O option supported by the AI block. You can set
the I/O option in Manual or Out of Service mode only.
Block Errors
Table B-2 lists conditions reported in the BLOCK_ERR parameter.
Conditions in italics are inactive for the AI block and are given here
only for your reference.
B-5
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
TABLE B-2. BLOCK_ERR Conditions.
Condition
Number
Modes
Condition Name and Description
0
Other
1
Block Configuration Error: the selected channel carries a measurement that
is incompatible with the engineering units selected in XD_SCALE, the L_TYPE
parameter is not configured, or CHANNEL = zero.
2
Link Configuration Error
3
Simulate Active: Simulation is enabled and the block is using a simulated value
in its execution.
4
Local Override
5
Device Fault State Set
6
Device Needs Maintenance Soon
7
Input Failure/Process Variable has Bad Status: The hardware is bad, or a bad
status is being simulated.
8
Output Failure: The output is bad based primarily upon a bad input.
9
Memory Failure
10
Lost Static Data
11
Lost NV Data
12
Readback Check Failed
13
Device Needs Maintenance Now
14
Power Up
15
Out of Service: The actual mode is out of service.
The AI Function Block supports three modes of operation as defined by
the MODE_BLK parameter:
• Manual (Man) The block output (OUT) may be set manually
• Automatic (Auto) OUT reflects the analog input measurement
or the simulated value when simulation is enabled.
• Out of Service (O/S) The block is not processed. FIELD_VAL
and PV are not updated and the OUT status is set to Bad: Out of
Service. The BLOCK_ERR parameter shows Out of Service. In
this mode, you can make changes to all configurable parameters.
The target mode of a block may be restricted to one or more of the
supported modes.
Alarm Detection
A block alarm will be generated whenever the BLOCK_ERR has an
error bit set. The types of block error for the AI block are defined above.
Process Alarm detection is based on the OUT value. You can configure
the alarm limits of the following standard alarms:
• High (HI_LIM)
• High high (HI_HI_LIM)
• Low (LO_LIM)
• Low low (LO_LO_LIM)
B-6
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
In order to avoid alarm chattering when the variable is oscillating
around the alarm limit, an alarm hysteresis in percent of the PV span
can be set using the ALARM_HYS parameter. The priority of each
alarm is set in the following parameters:
• HI_PRI
• HI_HI_PRI
• LO_PRI
B
• LO_LO_PRI
Alarms are grouped into five levels of priority:
Priority
Number
Status Handling
Priority Description
0
The priority of an alarm condition changes to ) after the condition that caused
the alarm is corrected.
1
An alarm condition with a priority of 1 is recognized by the system, but is not
reported to the operator.
2
An alarm condition with a priority of 2 is reported to the operator, but does not
require operator attention (such as diagnostics and system alerts).
3-7
Alarm conditions of priority 3 to 7 are advisory alarms of increasing priority.
8-15
Alarm conditions of priority 8 to 15 are critical alarms of increasing priority.
Normally, the status of the PV reflects the status of the measurement
value, the operating condition of the I/O card, and any active alarm
condition. In Auto mode, OUT reflects the value and status quality of
the PV. In Man mode, the OUT status constant limit is set to indicate
that the value is a constant and the OUT status is Good.
The Uncertain - EU range violation status is always set, and the PV
status is set high- or low-limited if the sensor limits for conversion are
exceeded.
In the STATUS_OPTS parameter, you can select from the following
options to control the status handling:
BAD if Limited – sets the OUT status quality to Bad when the value
is higher or lower than the sensor limits.
Uncertain if Limited – sets the OUT status quality to Uncertain
when the value is higher or lower than the sensor limits.
Uncertain if in Manual mode – The status of the Output is set to
Uncertain when the mode is set to Manual
NOTES
1. The instrument must be in Manual or Out of Service mode to set the
status option.
2. The AI block only supports the BAD if Limited option. Unsupported
options are not grayed out; they appear on the screen in the same
manner as supported options.
B-7
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Advanced Features
The AI function block provided with Fisher-Rosemount fieldbus devices
provides added capability through the addition of the following parameters:
ALARM_TYPE – Allows one or more of the process alarm conditions
detected by the AI function block to be used in setting its OUT_D parameter.
OUT_D – Discrete output of the AI function block based on the
detection of process alarm condition(s). This parameter may be linked
to other function blocks that require a discrete input based on the
detected alarm condition.
VAR_SCAN – Time period in seconds over which the variability index
(VAR_INDEX) is computed.
VAR_INDEX – Process variability index measured as the integral of
average absolute error between PV and its mean value over the
previous evaluation period. This index is calculated as a percent of OUT
span and is updated at the end of the time period defined by
VAR_SCAN.
Application Information
The configuration of the AI function block and its associated output
channels depends on the specific application. A typical configuration for
the AI block involves the following parameters:
CHANNEL
If the device supports more than one measurement,
verify that the selected channel contains the
appropriate measurement or derived value.
L_TYPE
Select Direct when the measurement is already in the
engineering units that you want for the block output.
Select Indirect when you want to convert the
measured variable into another, for example, pressure
into level or flow into energy.
Select Indirect Square Root when the block I/O
parameter value represents a flow measurement made
using differential pressure, and when square root
extraction is not performed by the transducer.
SCALING
B-8
XD_SCALE provides the range and units of the
measurement and OUT_SCALE provides the range
and engineering units of the output.
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Application Example:
Temperature Transmitter
Situation
A temperature transmitter with a range of –200 to 450 ˚C.
Solution
Table B-3 lists the appropriate configuration settings, and Figure B-3
illustrates the correct function block configuration.
FIGURE B-3. Analog Input Function
Block Diagram for a Typical
Temperature Transmitter.
.
Parameter
Configured Values
L_TYPE
Direct
XD_SCALE
Not Used
OUT_SCALE
Not Used
B
Temperature
Measurement
FIELDBUS-FBUS_04A
TABLE B-3. Analog Input Function
Block Configuration for a Typical
Temperature Transmitter.
OUT_D
AI Function Block
OUT
To Another
Function Block
B-9
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Application Example: Pressure
Transmitter used to Measure
Level in an Open Tank
Situation #1
The level of an open tank is to be measured using a pressure tap at the
bottom of the tank. The level measurement will be used to control the
level of liquid in the tank. The maximum level at the tank is 16 ft. The
liquid in the tank has a density that makes the level correspond to a
pressure of 7.0 psi at the pressure tap (see Figure B-4).
FIGURE B-4. Situation #1 Diagram.
Full Tank
16 ft
7.0 psi measured at
the transmitter
Solution to Situation #1
Table B-4 lists the appropriate configuration settings, and Figure B-5
illustrates the correct function block configuration.
TABLE B-4. Analog Input Function
Block Configuration for a Pressure
Transmitter used in Level Measurement
(situation #1).
FIGURE B-5. Function Block Diagram
for a Pressure Transmitter used in Level
Measurement.
Parameter
Configured Values
L_TYPE
Indirect
XD_SCALE
0 to 7 psi
OUT_SCALE
0 to 16 ft
Analog
Measurement
AI
Function
Block
OUT_D
OUT
BKCAL_OUT
BKCAL_IN
PID
Function
Block
CAS_IN
B-10
OUT
CAS_IN
AO
Function
Block
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Situation #2
The transmitter in situation #1 is installed below the tank in a position
where the liquid column in the impulse line, when the tank is empty, is
equivalent to 2.0 psi (see Figure B-6).
FIGURE B-6. Situation #2 Diagram.
B
16 ft
Empty Tank
0 ft
2.0 psi measured at
the transmitter
Solution
Table B-5 lists the appropriate configuration settings.
TABLE B-5. Analog Input Function
Block Configuration for a Pressure
Transmitter used in Level Measurement
(Situation #2).
Parameter
Configured Values
L_TYPE
Indirect
XD_SCALE
2 to 9 psi
OUT_SCALE
0 to 16 ft
B-11
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Application Example:
Differential Pressure Transmitter
to Measure Flow
Situation
The liquid flow in a line is to be measured using the differential
pressure across an orifice plate in the line, and the flow measurement
will be used in a flow control loop. Based on the orifice specification
sheet, the differential pressure transmitter was calibrated for 0 to 20
inH20 for a flow of 0 to 800 gal/min, and the transducer was not
configured to take the square root of the differential pressure.
Solution
Table B-6 lists the appropriate configuration settings, and Figure B-7
illustrates the correct function block configuration.
TABLE B-6. Analog Input Function
Block Configuration for a Differential
Pressure Transmitter.
Parameter
Configured Values
L_TYPE
Indirect Square Root
XD_SCALE
0 to 20 in.
OUT_SCALE
0 to 800 gal/min.
FIGURE B-7. Function Block Diagram
for a Differential Pressure Transmitter
Used in a Flow Measurement.
Analog
Measurement
AI
Function
Block
BKCAL_IN
OUT_D
OUT
B-12
BKCAL_OUT
PID
Function
Block
IN
AO
Function
Block
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Troubleshooting
Refer to Table B-7 to troubleshoot any problems that you encounter.
TABLE B-7. Troubleshooting.
Symptom
Mode will not leave
OOS
Process and/or
block alarms will not
work.
Value of output
does not make
sense
Cannot set
HI_LIMIT,
HI_HI_LIMIT,
LO_LIMIT, or
LO_LO_LIMIT
Values
Possible Causes
Corrective Action
1. Target mode not set.
1. Set target mode to something other
than OOS.
2. Configuration error
2. BLOCK_ERR will show the
configuration error bit set. The following
are parameters that must be set before
the block is allowed out of OOS:
a. CHANNEL must be set to a valid
value and cannot be left at initial
value of 0.
b. XD_SCALE.UNITS_INDX must
match the units in the transducer
block channel value.
c. L_TYPE must be set to Direct,
Indirect, or Indirect Square Root and
cannot be left at initial value of 0.
3. Resource block
3. The actual mode of the Resource block
is OOS. See Resource Block Diagnostics
for corrective action.
4. Schedule
4. Block is not scheduled and therefore
cannot execute to go to Target Mode.
Schedule the block to execute.
1. Features
1. FEATURES_SEL does not have Alerts
enabled. Enable the Alerts bit.
2. Notification
2. LIM_NOTIFY is not high enough. Set
equal to MAX_NOTIFY.
3. Status Options
3. STATUS_OPTS has Propagate Fault
Forward bit set. This should be cleared to
cause an alarm to occur.
1. Linearization Type
1. L_TYPE must be set to Direct, Indirect,
or Indirect Square Root and cannot be left
at initial value of 0.
2. Scaling
2. Scaling parameters are set incorrectly:
a. XD_SCALE.EU0 and EU100 should
match that of the transducer block
channel value.
b. OUT_SCALE.EU0 and EU100 are
not set properly.
1. Scaling
1. Limit values are outside the
OUT_SCALE.EU0 and
OUT_SCALE.EU100 values. Change
OUT_SCALE or set values within range.
B-13
B
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
B-14
Appendix
C
PID Function Block
BKCAL_IN
BKCAL_OUT
CAS_IN
IN
PID
OUT
fieldbus-fbus_34a
FF_VAL
TRK_IN_D
TRK_VAL
BKCAL_IN
CAS_IN
FF_VAL
IN
= The analog input value and status from another
block’s BKCAL_OUT output that is used for
backward output tracking for bumpless transfer
and to pass limit status.
= The remote setpoint value from another function
block.
= The feedforward control input value and status.
= The connection for the process variable from
another function block.
TRK_IN_D
TRK_VAL
= Initiates the external tracking function.
= The value after scaling applied to OUT in
Local Override mode.
BKCAL_OUT = The value and status required by the
BKCAL_IN input of another function block
to prevent reset windup and to provide
bumpless transfer to closed loop control.
OUT
= The block output and status.
The PID function block combines all of the necessary logic to perform
proportional/integral/derivative (PID) control. The block supports mode
control, signal scaling and limiting, feedforward control, override
tracking, alarm limit detection, and signal status propagation.
The block supports two forms of the PID equation: Standard and Series.
You can choose the appropriate equation using the FORM parameter.
The Standard ISA PID equation is the default selection.
τd s
1
Standard Out = GAIN × e ×  1 + ---------------- + -------------------------- + F

τ r s + 1 α × τ d s + 1
τd s + 1
1
Series Out = GAIN × e ×  1 + -------  +  --------------------------- + F



α × τ d s + 1
τr s
Where
τ
τ
GAIN:
r:
s:
d:
α:
F:
e:
proportional gain value
integral action time constant (RESET parameter) in seconds
laplace operator
derivative action time constant (RATE parameter)
fixed smoothing factor of 0.1 applied to RATE
feedforward control contribution from the feedforward input (FF_VAL parameter)
error between setpoint and process variable
C-1
C
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
To further customize the block for use in your application, you can
configure filtering, feedforward inputs, tracking inputs, setpoint and
output limiting, PID equation structures, and block output action.
Table C-1 lists the PID block parameters and their descriptions, units of
measure, and index numbers, and Figure C-1 on page C-5 illustrates
the internal components of the PID function block.
TABLE C-1. PID Function Block System Parameters.
Parameter
Index
Number
Units
ACK_OPTION
46
None
ALARM_HYS
47
Percent
The amount the alarm value must return to within the alarm limit before the associated active
alarm condition clears.
ALARM_SUM
45
None
The summary alarm is used for all process alarms in the block. The cause of the alert is
entered in the subcode field. The first alert to become active will set the Active status in the
Status parameter. As soon as the Unreported status is cleared by the alert reporting task,
another block alert may be reported without clearing the Active status, if the subcode has
changed.
ALERT_KEY
04
None
The identification number of the plant unit. This information may be used in the host for
sorting alarms, etc.
ALG_TYPE
74
None
Selects filtering algorithm as Backward or Bilinear.
BAL_TIME
25
Seconds
BIAS
66
EU of OUT_SCALE
BKCAL_HYS
30
Percent
The amount the output value must change away from the its output limit before limit status
is turned off.
BKCAL_IN
27
EU of OUT_SCALE
The analog input value and status from another block’s BKCAL_OUT output that is used for
backward output tracking for bumpless transfer and to pass limit status.
BKCAL_OUT
31
EU of PV_SCALE
BLOCK_ALM
44
None
The block alarm is used for all configuration, hardware, connection failure, or system
problems in the block. The cause of the alert is entered in the subcode field. The first alert
to become active will set the active status in the status parameter. As soon as the
Unreported status is cleared by the alert reporting task, and other block alert may be
reported without clearing the Active status, if the subcode has changed.
BLOCK_ERR
06
None
This parameter reflects the error status associated with the hardware or software
components associated with a block. It is a bit string so that multiple errors may be shown.
BYPASS
17
None
Used to override the calculation of the block. When enabled, the SP is sent directly
to the output.
CAS_IN
18
EU of PV_SCALE
CONTROL_OPTS
13
None
Allows you to specify control strategy options. The supported control options for the PID
block are Track enable, Track in Manual, SP-PV Track in Man, SP-PV Track in LO or IMAN,
Use PV for BKCAL OUT, and Direct Acting
DV_HI_ALM
64
None
The DV HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and
the state of the alarm.
DV_HI_LIM
57
EU of PV_SCALE
DV_HI_PRI
56
None
C-2
Description
Used to set auto acknowledgment of alarms.
The specified time for the internal working value of bias to return to the operator set bias.
Also used to specify the time constant at which the integral term will move to obtain balance
when the output is limited and the mode is AUTO, CAS, or RCAS.
The bias value used to calculate output for a PD type controller.
The value and status required by the BKCAL_IN input of another block to prevent reset
windup and to provide bumpless transfer of closed loop control.
The remote setpoint value from another block.
The setting for the alarm limit used to detect the deviation high alarm condition.
The priority of the deviation high alarm.
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Parameter
Index
Number
Units
Description
DV_LO_ALM
65
None
The DV LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and
the state of the alarm.
DV_LO_LIM
59
EU of PV_SCALE
DV_LO_PRI
58
None
ERROR
67
EU of PV_SCALE
FF_ENABLE
70
None
Enables the use of feedforward calculations
FF_GAIN
42
None
The feedforward gain value. FF_VAL is multiplied by FF_GAIN before it is added to the
calculated control output.
FF_SCALE
41
None
The high and low scale values, engineering units code, and number of digits to the right of
the decimal point associated with the feedforward value (FF_VAL).
FF_VAL
40
EU of FF_SCALE
GAIN
23
None
The proportional gain value. This value cannot = 0.
GRANT_DENY
12
None
Options for controlling access of host computers and local control panels to operating,
tuning, and alarm parameters of the block. Not used by the device.
HI_ALM
61
None
The HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and the
state of the alarm.
HI_HI_ALM
60
None
The HI HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and
the state of the alarm.
HI_HI-LIM
49
EU of PV_SCALE
HI_HI_PRI
48
None
HI_LIM
51
EU of PV_SCALE
HI_PRI
50
None
IN
15
EU of PV_SCALE
LO_ALM
62
None
LO_LIM
53
EU of PV_SCALE
LO_LO_ALM
63
None
LO_LO_LIM
55
EU of PV_SCALE
LO_LO_PRI
54
None
The priority of the LO LO alarm.
LO_PRI
52
None
The priority of the LO alarm.
MATH_FORM
73
None
Selects equation form (series or standard).
MODE_BLK
05
None
OUT
09
EU of OUT SCALE
The block input value and status.
OUT_HI_LIM
28
EU of OUT_SCALE
The maximum output value allowed.
The setting for the alarm limit use to detect the deviation low alarm condition.
The priority of the deviation low alarm.
The error (SP-PV) used to determine the control action.
C
The feedforward control input value and status.
The setting for the alarm limit used to detect the HI HI alarm condition.
The priority of the HI HI Alarm.
The setting for the alarm limit used to detect the HI alarm condition.
The priority of the HI alarm.
The connection for the PV input from another block.
The LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the
state of the alarm.
The setting for the alarm limit used to detect the LO alarm condition.
The LO LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and
the state of the alarm.
The setting for the alarm limit used to detect the LO LO alarm condition.
The actual, target, permitted, and normal modes of the block.
Target: The mode to “go to”
Actual: The mode the “block is currently in”
Permitted: Allowed modes that target may take on
Normal: Most common mode for target
C-3
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Parameter
Index
Number
Units
OUT-LO_LIM
29
EU of OUT_SCALE
OUT_SCALE
11
None
PV
07
EU of PV_SCALE
PV_FTIME
16
Seconds
The time constant of the first-order PV filter. It is the time required for a 63 percent change
in the IN value.
PV_SCALE
10
None
The high and low scale values, engineering units code, and number of digits to the right of
the decimal point associated with PV.
RATE
26
Seconds
RCAS_IN
32
EU of PV_SCALE
Target setpoint and status that is provided by a supervisory host. Used when mode is RCAS.
RCAS_OUT
35
EU of PV_SCALE
Block setpoint and status after ramping, filtering, and limiting that is provided to a supervisory
host for back calculation to allow action to be taken under limiting conditions or mode
change. Used when mode is RCAS.
RESET
24
Seconds per repeat
The integral action time constant.
ROUT_IN
33
EU of OUT_SCALE
Target output and status that is provided by a supervisory host. Used when mode is ROUT.
ROUT_OUT
36
EU of OUT_SCALE
Block output that is provided to a supervisory host for a back calculation to allow action to
be taken under limiting conditions or mode change. Used when mode is RCAS.
SHED_OPT
34
None
SP
08
EU of PV_SCALE
SP_FTIME
69
Seconds
SP_HI_LIM
21
EU of PV_SCALE
The highest SP value allowed.
SP_LO_LIM
22
EU of PV_SCALE
The lowest SP value allowed.
SP_RATE_DN
19
EU of PV_SCALE per
second
Ramp rate for downward SP changes. When the ramp rate is set to zero, the SP
is used immediately.
SP-RATE_UP
20
EU of PV_SCALE per
second
Ramp rate for upward SP changes. When the ramp rate is set to zero,
the SP is used immediately.
SP_WORK
68
EU of PV_SCALE
The working setpoint of the block after limiting and filtering is applied.
STATUS_OPTS
14
None
Allows you to select options for status handling and processing. The supported status option
for the PID block is Target to Manual if Bad IN.
STRATEGY
03
None
The strategy field can be used to identify grouping of blocks. This data is not checked or
processed by the block.
ST_REV
01
None
The revision level of the static data associated with the function block. The revision value will
be incremented each time a static parameter value in the block is changed.
STRUCTURE.
CONFIG
75
None
Defines PID equation structure to apply controller action.
TAG_DESC
02
None
The user description of the intended application of the block.
TRK_IN_D
38
None
Discrete input that initiates external tracking.
C-4
Description
The minimum output value allowed
The high and low scale values, engineering units code, and number of digits to the right of
the decimal point associated with OUT.
The process variable used in block execution.
The derivative action time constant.
Defines action to be taken on remote control device timeout.
The target block setpoint value. It is the result of setpoint limiting and setpoint
rate of change limiting.
The time constant of the first-order SP filter. It is the time required for a 63 percent change
in the IN value.
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Parameter
Index
Number
Units
Description
TRK_SCALE
37
None
The high and low scale values, engineering units code, and number of digits to the right of
the decimal point associated with the external tracking value (TRK_VAL).
TRK_VAL
39
EU of TRK SCALE
The value (after scaling from TRK_SCALE to OUT_SCALE) applied to OUT in LO mode.
UBETA
72
Percent
Used to set disturbance rejection vs. tracking response action for a 2.0 degree of
freedom PID.
UGAMMA
71
Percent
Used to set disturbance rejection vs. tracking response action for a 2.0 degree of
freedom PID.
UPDATE_EVT
43
None
This alert is generated by any changes to the static data.
C
FIGURE C-1. PID Function Block
Schematic.
FF_GAIN
FF_SCALE
Feedforward
Calculation
FF_VAL
BKCAL_IN
MODE
TRK_IN_D
BKCAL_OUT
RCAS_OUT
ROUT_OUT
ROUT_IN
RCAS_IN
CAS_IN
Operator
Setpoint
IN
SP_HI_LIM
SP_LO_LIM
SP_RATE_DN
SP_RATE_UP
SP_FTIME
Scaling
and
Filtering
PV_SCALE
PV_FTIME
TRK_VAL
PID
Equation
GAIN
RATE
RESET
Alarm
Detection
Output
Limiting
OUT
OUT_HI_LIM
OUT_LO_LIM
OUT_SCALE
Operator
Output
HI_HI_LIM
HI_LIM
DV_HI_LIM
DV_LO_LIM
LO_LIM
LO_LO_LIM
fieldbus-fbus_13a
Setpoint
Limiting
and
Filtering
Convert
TRK_SCALE
OUT_SCALE
C-5
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Setpoint Selection
and Limiting
The setpoint of the PID block is determined by the mode. You can
configure the SP_HI_LIM and SP_LO_LIM parameters to limit the
setpoint. In Cascade or RemoteCascade mode, the setpoint is adjusted
by another function block or by a host computer, and the output is
computed based on the setpoint.
In Automatic mode, the setpoint is entered manually by the operator,
and the output is computed based on the setpoint. In Auto mode, you
can also adjust the setpoint limit and the setpoint rate of change using
the SP_RATE_UP and SP_RATE_DN parameters.
In Manual mode the output is entered manually by the operator, and is
independent of the setpoint. In RemoteOutput mode, the output is
entered by a host computer, and is independent of the setpoint.
Figure C-2 illustrates the method for setpoint selection.
Operator
Setpoint
Auto
Man
Cas
SP_HI_LIM
SP_LO_LIM
SP_RATE_UP
SP_RATE_DN
Setpoint
Limiting
Rate
Limiting
Auto
Man
Cas
fieldbus-fbus_01a
FIGURE C-2. PID Function
Block Setpoint Selection.
Filtering
The filtering feature changes the response time of the device to smooth
variations in output readings caused by rapid changes in input. You can
configure the filtering feature with the FILTER_TYPE parameter, and
you can adjust the filter time constant (in seconds) using the
PV_FTIME or SP_FTIME parameters. Set the filter time constant to
zero to disable the filter feature.
Feedforward Calculation
The feedforward value (FF_VAL) is scaled (FF_SCALE) to a common
range for compatibility with the output scale (OUT_SCALE). A gain
value (FF_GAIN) is applied to achieve the total
feedforward contribution.
Tracking
You enable the use of output tracking through the control options. You
can set control options in Manual or Out of Service mode only.
The Track Enable control option must be set to True for the track
function to operate. When the Track in Manual control option is set to
True, tracking can be activated and maintained only when the block is
in Manual mode. When Track in Manual is False, the operator can
override the tracking function when the block is in Manual mode.
Activating the track function causes the block’s actual mode to revert to
Local Override.
The TRK_VAL parameter specifies the value to be converted and
tracked into the output when the track function is operating. The
TRK_SCALE parameter specifies the range of TRK_VAL.
When the TRK_IN_D parameter is True and the Track Enable control
option is True, the TRK_VAL input is converted to the appropriate
value and output in units of OUT_SCALE.
C-6
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Output Selection
and Limiting
Output selection is determined by the mode and the setpoint. In
Automatic, Cascade, or RemoteCascade mode, the output is computed
by the PID control equation. In Manual and RemoteOutput mode, the
output may be entered manually (see also Setpoint Selection
and Limiting on page C-6). You can limit the output by configuring the
OUT_HI_LIM and OUT_LO_LIM parameters.
Bumpless Transfer and
Setpoint Tracking
You can configure the method for tracking the setpoint by configuring
the following control options (CONTROL_OPTS):
SP-PV Track in Man — Permits the SP to track the PV when the
target mode of the block is Man.
SP-PV Track in LO or IMan — Permits the SP to track the PV when
the actual mode of the block is Local Override (LO) or Initialization
Manual (IMan).
When one of these options is set, the SP value is set to the PV value
while in the specified mode.
You can select the value that a master controller uses for tracking by
configuring the Use PV for BKCAL_OUT control option. The
BKCAL_OUT value tracks the PV value. BKCAL_IN on a master
controller connected to BKCAL_OUT on the PID block in an open
cascade strategy forces its OUT to match BKCAL_IN, thus tracking the
PV from the slave PID block into its cascade input connection
(CAS_IN). If the Use PV for BKCAL_OUT option is not selected, the
working setpoint (SP_WRK) is used for BKCAL_OUT.
You can set control options in Manual or Out of Service mode only.
When the mode is set to Auto, the SP will remain at the last value (it
will no longer follow the PV.
PID Equation Structures
Configure the STRUCTURE parameter to select the PID equation
structure. You can select one of the following choices:
• PI Action on Error, D Action on PV
• PID Action on Error
• I Action on Error, PD Action on PV
Set RESET to zero to configure the PID block to perform integral only
control regardless of the STRUCTURE parameter selection. When
RESET equals zero, the equation reduces to an integrator equation
with a gain value applied to the error:
GAIN × e ( s )
------------------------------s
Where
GAIN:
e:
s:
Reverse and Direct Action
proportional gain value
error
laplace operator
To configure the block output action, enable the Direct Acting control
option. This option defines the relationship between a change in PV and
the corresponding change in output. With Direct Acting enabled (True),
an increase in PV results in an increase in the output.
You can set control options in Manual or Out of Service mode only.
C-7
C
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
NOTE
Track Enable, Track in Manual, SP-PV Track in Man, SP-PV Track in LO
or IMan, Use PV for BKCAL_OUT, and Direct Acting are the only
control options supported by the PID function block. Unsupported
options are not grayed out; they appear on the screen in the same
manner as supported options.
Reset Limiting
The PID function block provides a modified version of feedback reset
limiting that prevents windup when output or input limits are
encountered, and provides the proper behavior in selector applications.
Block Errors
Table C-2 lists conditions reported in the BLOCK_ERR parameter.
Conditions in italics are inactive for the PID block and are given here
only for your reference.
TABLE C-2. BLOCK_ERR Conditions
.
Condition
Number
Modes
Condition Name and Description
0
Other
1
Block Configuration Error: The BY_PASS parameter is not configured and is
set to 0, the SP_HI_LIM is less than the SP_LO_LIM, or the OUT_HI_LIM is less
than the OUT_LO_LIM.
2
Link Configuration Error
3
Simulate Active
4
Local Override: The actual mode is LO.
5
Device Fault State Set
6
Device Needs Maintenance Soon
7
Input Failure/Process Variable has Bad Status: The parameter linked to IN is
indicating a Bad status.
8
Output Failure
9
Memory Failure
10
Lost Static Data
11
Lost NV Data
12
Readback Check Failed
13
Device Needs Maintenance Now
14
Power Up
15
Out of Service: The actual mode is out of service.
The PID function block supports the following modes:
Manual (Man)—The block output (OUT) may be set manually.
Automatic (Auto)—The SP may be set manually and the block
algorithm calculates OUT.
Cascade (Cas)—The SP is calculated in another block and is provided
to the PID block through the CAS_IN connection.
RemoteCascade (RCas)—The SP is provided by a host computer that
writes to the RCAS_IN parameter.
RemoteOutput (Rout)—The OUT is provided by a host computer that
writes to the ROUT_IN parameter.
Local Override (LO)—The track function is active. OUT is set by
TRK_VAL. The BLOCK_ERR parameter shows Local override.
C-8
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Initialization Manual (IMan)—The output path is not complete (for
example, the cascade-to-slave path might not be open). In IMan mode,
OUT tracks BKCAL_IN.
Out of Service (O/S)—The block is not processed. The OUT status is
set to Bad: Out of Service. The BLOCK_ERR parameter shows
Out of service.
You can configure the Man, Auto, Cas, and O/S modes as permitted
modes for operator entry.
Alarm Detection
A block alarm will be generated whenever the BLOCK_ERR has an
error bit set. The types of block error for the AI block are defined above.
Process alarm detection is based on the PV value. You can configure the
alarm limits of the following standard alarms:
• High (HI_LIM)
• High high (HI_HI_LIM)
• Low (LO_LIM)
• Low low (LO_LO_LIM)
Additional process alarm detection is based on the difference between
SP and PV values and can be configured via the following parameters:
• Deviation high (DV_HI_LIM)
• Deviation low (DV_LO_LIM)
In order to avoid alarm chattering when the variable is oscillating
around the alarm limit, an alarm hysteresis in percent of the PV span
can be set using the ALARM_HYS parameter. The priority of each
alarm is set in the following parameters:
• HI_PRI
• HI_HI_PRI
• LO_PRI
• LO_LO_PRI
• DV_HI_PRI
• DV_LO_PRI
Alarms are grouped into five levels of priority:
Priority
Number
Priority Description
0
The priority of an alarm condition changes to ) after the condition that caused
the alarm is corrected.
1
An alarm condition with a priority of 1 is recognized by the system, but is not
reported to the operator.
2
An alarm condition with a priority of 2 is reported to the operator, but does not
require operator attention (such as diagnostics and system alerts).
3-7
Alarm conditions of priority 3 to 7 are advisory alarms of increasing priority.
8-15
Alarm conditions of priority 8 to 15 are critical alarms of increasing priority.
C-9
C
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Status Handling
If the input status on the PID block is Bad, the mode of the block
reverts to Manual. In addition, you can select the Target to Manual if
Bad IN status option to direct the target mode to revert to manual. You
can set the status option in Manual or Out of Service mode only.
NOTE
Target to Manual if Bad IN is the only status option supported by the
PID function block. Unsupported options are not grayed out; they
appear on the screen in the same manner as supported options.
Application Information
The PID function block is a powerful, flexible control algorithm that is
designed to work in a variety of control strategies. The PID block is
configured differently for different applications. The following examples
describe the use of the PID block for closed-loop control (basic PID loop),
feedforward control, cascade control with master and slave, and
complex cascade control with override.
Closed Loop Control
To implement basic closed loop control, compute the error difference
between the process variable (PV) and setpoint (SP) values and
calculate a control output signal using a PID (Proportional Integral
Derivative) function block.
The proportional control function responds immediately and directly to
a change in the PV or SP. The proportional term GAIN applies a change
in the loop output based on the current magnitude of the error
multiplied by a gain value.
The integral control function reduces the process error by moving the
output in the appropriate direction. The integral term RESET applies a
correction based on the magnitude and duration of the error. Set the
RESET parameter to zero for integral-only control. To reduce reset
action, configure the RESET parameter to be a large value.
The derivative term RATE applies a correction based on the anticipated
change in error. Derivative control is typically used in temperature
control where large measurement lags exist.
The MODE parameter is a switch that indicates the target and actual
mode of operation. Mode selection has a large impact on the operation
of the PID block:
• Manual mode allows the operator to set the value of the loop
output signal directly.
• Automatic mode allows the operator to select a setpoint for
automatic correction of error using the GAIN, RESET, and RATE
tuning values.
• Cascade and Remote Cascade modes use a setpoint from
another block in a cascaded configuration.
• Remote Out mode is similar to Manual mode except that the block
output is supplied by an external program rather than by
the operator.
• Initialization Manual is a non-target mode used with cascade
configurations while transitioning from manual operation to
automatic operation.
• Local Override is a non-target mode that instructs the block to
revert to Local Override when the tracking or fail-safe control
options are activated.
• Out of Service mode disables the block for maintenance.
C-10
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Abrupt changes in the quality of the input signal can result in
unexpected loop behavior. To prevent the output from changing
abruptly and upsetting the process, select the SP-PV Track in Man I/O
option. This option automatically sets the loop to Manual if a Bad input
status is detected. While in manual mode, the operator can manage
control manually until a Good input status is reestablished.
Application Example: Basic PID
Block for Steam Heater Control
Situation
A PID block is used with an AI block and an AO block to control the flow
steam used to heat a process fluid in a heat exchanger. Figure C-3
illustrates the process instrumentation diagram.
FIGURE C-3. PID Function Block
Steam Heater Control Example.
TCV
101
TC
101
C
Steam Supply
TT
101
fieldbus-fbus_14a
TT
100
Steam Heater
Condensate
Solution
The PID loop uses TT101 as an input and provides a signal to the
analog output TCV101. The BKCAL_OUT of the AO block and the
BKCAL_IN of the PID block communicate the status and quality of
information being passed between the blocks. The status indication
shows that communications is functioning and the I/O is working
properly. Figure C-4 illustrates the correct function block configuration.
FIGURE C-4. PID Function
Block Diagram for Steam Heater
Control Example.
AI
Function
Block
PID
Function
Block
OUT
TT101
BKCAL_OUT
BKCAL_IN
OUT
CAS_IN
AO
Function
Block
OUT
IN
TC101
TCV101
C-11
fieldbus-fbus_15a
Outlet
Temperature
Input
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Application Example:
Feedforward Control
Situation
In the previous example, control problems can arise because of a time
delay caused by thermal inertia between the two flow streams (TT100
and TT101). Variations in the inlet temperature (TT100) take an
excessive amount of time to be sensed in the outlet (TT101). This delay
causes the product to be out of the desired temperature range.
Solution
Feedforward control is added to improve the response time of the basic
PID control. The temperature of the inlet process fluid (TT100) is input
to an AI function block and is connected to the FF_VAL connector on
the PID block. Feedforward control is then enabled (FF_ENABLE), the
feedforward value is scaled (FF_SCALE), and a gain (FF_GAIN) is
determined. Figure C-5 illustrates the process instrumentation
diagram, and Figure C-6 illustrates the correct function block
configuration.
FIGURE C-5. PID Function Block
Feedforward Control Example.
TCV
101
FF
TC
101
Steam Supply
TT
101
TT
100
fieldbus-fbus_16a
Steam Heater
Condensate
FIGURE C-6. Function Block Diagram
for Feedforward Control.
Outlet
Temperature
Input
AI
Function
Block
BKCAL_IN
IN
OUT
FF_VAL
BKCAL_OUT
PID
Function
Block
TC101
TT101
OUT
CAS_IN
AO
Function
Block
OUT
TCV101
AI
Function
Block
TT100
C-12
OUT
fieldbus-fbus_17a
Inlet
Temperature
Input
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Situation
A slave loop is added to a basic PID control configuration to measure
and control steam flow to the steam heater. Variations in the steam
pressure cause the temperature in the heat exchanger to change. The
temperature variation will later be sensed by TT101. The temperature
controller will modify the valve position to compensate for the steam
pressure change. The process is slow and causes variations in the
product temperature. Figure C-7 illustrates the process
instrumentation diagram.
FIGURE C-7. PID Function Block
Cascade Control Example.
FC
101
TC
101
C
FT
101
TCV
101
Steam
Supply
TT
100
TT
101
fieldbus-fbus_18a
Application Example: Cascade
Control with Master
and Slave Loops
Steam Heater
Condensate
Solution
If the flow is controlled, steam pressure variations will be compensated
before they significantly affect the heat exchanger temperature. The
output from the master temperature loop is used as the setpoint for the
slave steam flow loop. The BKCAL_IN and BKCAL_OUT connections
on the PID blocks are used to prevent controller windup on the master
loop when the slave loop is in Manual or Automatic mode, or it has
reached an output constraint. Figure C-8 illustrates the correct
function block configuration.
C-13
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
FIGURE C-8. PID Function Block
Diagram for Cascade Control Example.
Outlet
Temperature
Input
AI
Function
Block
BKCAL_OUT
BKCAL_IN
OUT
IN
TT 101
PID
Function
Block
OUT
TC 101
BKCAL_OUT
BKCAL_IN
Steam
Flow
Input
AI
Function
Block
FT 101
C-14
CAS_IN
OUT
PID
Function
Block
IN
FC 101
OUT
IN
AO
Module
Block
TCV 101
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
You can use the PID function block with other function blocks for
complex control strategies. Figure C-9 illustrates the function block
diagram for cascade control with override.
Application Example:
Cascade Control with Override
When configured for cascade control with override, if one of the PID
function blocks connected to the selector inputs is deselected, that PID
block filters the integral value to the selected value (the value at its
BKCAL_IN). The selected PID block behaves normally and the
deselected controller never winds up. At steady state, the deselected
PID block offsets its OUT value from the selected value by the
proportional term. When the selected block becomes output-limited, it
prevents the integral term from winding further into the limited region.
When the cascade between the slave PID block and the Control Selector
block is open, the open cascade status is passed to the Control Selector
block and through to the PID blocks supplying input to it. The Control
Selector block and the upstream (master) PID blocks have an actual
mode of IMan.
C
If the instrument connected to the AI block fails, you can place the AI
block in Manual mode and set the output to some nominal value for use
in the Integrator function block. In this case, IN at the slave PID
block is constant and prevents the integral term from increasing
or decreasing.
FIGURE C-9. Function Block Diagram
for Cascade Control
with Override.
BKCAL_OUT
BKCAL_IN
Slave Controller
PID
Function
Block
PID
Function
Block
CAS_IN
Master Controller
OUT
IN
OUT
CAS_IN
AO
Function
Block
BKCAL_SEL_1
Configured for High Selection
SEL_1
SEL_2
Control
Selector
Function
Block
IN_1
OUT
PID
Function
Block
BKCAL_SEL_2
PID
Function
Block
OUT
AI
Function
Block
OUT
C-15
fieldbus-fbus_20a
Master Controller
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Troubleshooting
Refer to Table C-3 to troubleshoot any problems that you encounter.
TABLE C-3. Troubleshooting.
Symptom
Mode will not leave
OOS
Corrective Action
1. Target mode not set.
1. Set target mode to something other
than OOS.
2. Configuration error
2. BLOCK_ERR will show the
configuration error bit set. The following
are parameters that must be set before
the block is allowed out of OOS:
a. BYPASS must be off or on and
cannot be left at initial value of 0.
b. OUT_HI_LIM must be less than or
equal to OUT_LO_LIM.
c. SP_HI_LIM must be less than or
equal to SP_LO_LIM.
3. Resource block
3. The actual mode of the Resource block
is OOS. See Resource Block Diagnostics
for corrective action.
4. Schedule
4. Block is not scheduled and therefore
cannot execute to go to Target Mode.
Schedule the block to execute.
Mode will not leave
IMAN
1. Back Calculation
1. BKCAL_IN
a. The link is not configured (the status
would show “Not Connected”).
Configure the BKCAL_IN link to the
downstream block.
b. The downstream block is sending
back a Quality of “Bad” or a Status of
“Not Invited”. See the appropriate
downstream block diagnostics for
corrective action.
Mode will not
change to AUTO
1. Target mode not set.
1. Set target mode to something other
than OOS.
2. Input
2. IN
a. The link is not configured (the status
would show “Not Connected”).
Configure the IN link to the block.
b. The upstream block is sending back
a Quality of “Bad” or a Status of “Not
Invited”. See the appropriate
upstream block diagnostics for
corrective action.
1. Target mode not set.
1. Set target mode to something other
than OOS.
2. Cascade input
2. CAS_IN
a. The link is not configured (the status
would show “Not Connected”).
Configure the CAS_IN link to
the block.
b. The upstream block is sending back
a Quality of “Bad” or a Status of “Not
Invited”. See the appropriate up
stream block diagnostics for
corrective action.
1. Remote Cascade Value
1. Host system is not writing RCAS_IN
with a quality and status of “good
cascade” within shed time (see 2 below).
2. Shed Timer
2. The mode shed timer, SHED_RCAS in
the resource block is set too low. Increase
the value.
Mode will not
change to CAS
Mode sheds from
RCAS to AUTO
C-16
Possible Causes
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
Symptom
Mode sheds from
ROUT to MAN
Process and/or
block alarms will not
work.
Possible Causes
Corrective Action
1. Remote output value
1. Host system is not writing ROUT_IN
with a quality and status of “good
cascade” within shed time (see 2 below).
2. Shed timer
2. The mode shed timer, SHED_RCAS, in
the resource block is set too low. Increase
the value.
1. Features
1. FEATURES_SEL does not have Alerts
enabled. Enable the Alerts bit.
2. Notification
2. LIM_NOTIFY is not high enough. Set
equal to MAX_NOTIFY.
3. Status Options
3. STATUS_OPTS has Propagate Fault
Forward bit set. This should be cleared to
cause an alarm to occur.
C
C-17
Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications
C-18
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
SECTION 10
INDEX
This index is an alphabetized listing of parts, terms, and procedures having to do with the Hazardous Area Oxygen/Combustibles Transmitter. Every item listed in this index refers to a location
in the manual by one or more page numbers.
A
F
Abrasive Shield, 2-1, 2-4, 2-8
Absolute Temperature, 1-2
Accuracy, 1-8
Adaptor Plate, 1-0, 1-5, 2-1
Alarms, Diagnostic, 3-8, 4-6, 5-2
Alarms, Unit, 4-6, 5-2
Arithmetic Constant, 1-2
Autocalibration, 5-1
Automatic Calibration, 4-1
Fieldbus, 1-1, 1-2, 2-9, 2-13, 3-1, 4-3, 4-5
Fuse, 4-11, 5-19
B
Bracing, 2-7
By-Pass Packages, 6-1
C
Calibration, 4-1, 5-15, 5-16, 5-17, 5-19
Calibration Gas, 1-4, 1-5, 1-6, 1-8, 1-11, 2-2, 2-3,
2-4, 2-14, 4-1, 5-18, 5-19, 6-1, 6-2
CALIBRATION RECOMMENDATION, 3-4
CALIBRATION RECOMMENDED, 1-2, 1-7, 3-8, 4-3,
4-4, 4-6, 6-1
Cell, 1-2, 3-2, 4-11, 5-2, 5-12, 5-13, 5-14, 5-18
Cell Constant, 1-2
Cell Replacement Kit, 4-14
Check Valve, 1-4, 4-22, 5-19
D
Diffusion Element, 1-3, 4-1, 4-22
Drip Loop, 2-7, 2-8
E
EEPROM, 5-14
Electrical Noise, 5-1
Electronic Noise, 1-8
Electronics, 1-0, 1-3, 1-4, 1-8, 4-10
ELECTRONICS, 4-9
Electronics Temperature, 1-8
Electrostatic Discharge, 5-1
G
Grounding, 5-1
H
Heater, 5-2, 5-7, 5-8, 5-9, 5-10, 5-11
Heater Strut, 4-12, 4-13
Heater Thermocouple, 5-2, 5-3, 5-4, 5-5
I
IMPS 4000, 1-0, 1-2, 1-3, 1-4, 1-5, 1-12, 2-9, 2-14,
3-4, 3-7, 4-3, 6-1
Installation, Mechanical, 2-1
Instrument Air, 1-4, 1-5, 1-7, 2-13
Insulation, 2-8
Integrated Circuits, 5-1
K
Keypad , Membrane, 1-2
Keypad, Membrane, 1-3, 2-1, 3-2, 3-6, 4-3
L
Length, Probe, 1-8
Line Voltage, 1-8
Logic I/O, 1-9, 5-19
M
Mounting, 1-6, 1-8
Mounting Flange, 2-6
N
Nernst Equation, 1-1
10
Rosemount Analytical Inc.
A Division of Emerson Process Management
Index
10-1
Instruction Manual
IB-106-350 Rev. 1.2
April 2001
Oxymitter 5000
Installation, Electrical, 2-9, 2-10
Installation, Pneumatic, 2-13
Interface Board, 4-19, 5-18, 5-19
Line Voltage, 2-11
Manifold, 1-6
Noise, External Electrical, 1-9
Piping Distance, 1-9
Power, 1-9
Power Supply Board, 4-19, 5-19
Pressure Regulator, 1-7
Pressure Switch, 1-7, 5-19
Reference Air Flowmeter, 1-7, 2-3, 4-23
Relay Output, 5-18
Relay Outputs, 1-9, 2-12
Remote Contact, 4-3
Remote Contact Input, 2-12
Shipping Weight, 1-9
Solenoid, 4-21, 5-19
Solenoids, 1-6
Terminal Block, 2-9, 3-1
Terminal Strip, 1-7
P
Packaging, 1-4
Partial Pressure, 1-1
Power Requirements, 1-9
Power Supply, 1-2
Probe, 4-12
Probe Disassembly Kit, 8-5
Process Temperature, 1-8
Product Matrix, 1-1, 1-10, 1-11
R
Range, O2, 1-8, 3-2
Reference Air, 1-1, 1-4, 1-6, 1-7, 1-8, 2-2, 2-4, 2-13,
2-14
Relay Outputs, 1-5
Remote Contact, 1-5
Replacement Parts, Calibration Gas Bottles, 8-8
Replacement Parts, Electronics, 8-6, 8-7
Replacement Parts, Probe, 8-2, 8-5
Replacement Parts, SPS 4000, 8-8
S
Semi-Automatic Calibration, 4-3
Signal, Digital, 1-2, 1-9, 2-9, 2-13
SPS 4000, 1-0, 1-2, 1-4, 1-5, 1-6, 1-9, 1-12, 2-3,
2-10, 3-1, 3-4, 4-8, 5-18, 5-19, 6-2
Ambient Temperature Range, 1-9
Cabling Distance, 1-9
Calibration Gas Flowmeter, 1-6, 2-3, 4-1, 4-22
Contact Input, 1-9
Fuse, 4-17
Handshake, 1-9
Handshake Signal, 3-4
Humidity Range, 1-9
10-2
Index
T
Terminal Block, 4-11
Test Points, 3-8
Thermocouple, 1-3
Troubleshooting, 5-1
V
Vee Deflector, 2-7
Z
Zirconia Disc, 1-1
Rosemount Analytical Inc.
A Division of Emerson Process Management
WARRANTY
Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from
defects in workmanship and material under normal use and service for a period of twelve (12)
months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid
junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and
material under normal use and service for a period of ninety (90) days from date of shipment by
Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or
material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the
goods, part(s) or consumables are returned to Seller's designated factory, transportation charges
prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in
the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in
effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day
warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and
consumables are capable of being renewed, repaired or replaced.
The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly
or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from
any other cause. All other warranties, expressed or implied are hereby excluded.
IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS,
SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED
WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD
WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC
GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER
AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT
ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT.
IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER
NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS
COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO
BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED
HEREUNDER.
Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond
Seller's direct control.
3177
3536/4-01
Instruction Manual
Ib-106-350 Rev.1.2
April 2001
Oxymitter 5000
Oxymitter 5000
Part no. _______________
Serial no. _______________
Order no. _______________
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
E [email protected]
Fisher-Rosemount GmbH & Co.
Industriestrasse 1
63594 Hasselroth
Germany
T 49-6055-884 0
F 49-6055-884209
ASIA - PACIFIC
Fisher-Rosemount
Singapore Private Ltd.
1 Pandan Crescent
Singapore 128461
Republic of Singapore
T 65-777-8211
F 65-777-0947
EUROPE, MIDDLE EAST, AFRICA
Fisher-Rosemount Ltd.
Heath Place
Bognor Regis
West Sussex PO22 9SH
England
T 44-1243-863121
F 44-1243-845354
http://www.processanalytic.com
© Rosemount Analytical Inc. 2001
LATIN AMERICA
Fisher - Rosemount
Av. das Americas
3333 sala 1004
Rio de Janeiro, RJ
Brazil 22631-003
T 55-21-2431-1882