Emerson manual Oxymitter 4000 Repair, Replace

Page 134

Instruction Manual

IB-106-340 Rev. 3.0 December 2003

Oxymitter 4000

9-4 OXYMITTER 4000 REPAIR

2. Replace.

Refer to Figure 9-3or Figure 9-4to view the component parts of the Oxymitter 4000.

It is recommended that the Oxymitter 4000 be removed from the stack for all service activities. The unit should be allowed to cool and be taken to a clean work area. Failure to comply may cause severe burns.

Disconnect and lock out power before working on any electrical components. There is voltage up to 115 VAC.

a.Removal and Replacement of Oxymitter 4000 Probe (without Integrally Mounted SPS 4000)

1.Remove.

(a)Turn off power to the system.

(b)Shut off the calibration gases at the cylinders and the instrument air.

(c)Disconnect the calibration gas and instrument air lines from the probe.

(d)While facing the Oxymitter 4000 and looking at the Rosemount la- bel, remove screw (32, Figure 9-3or Figure 9-4), gasket (33) and cover lock (34) securing left hous- ing cover (27). Remove the cover to expose the terminal block.

(e)Remove all signal and power wir- ing to the probe.

(f)Remove insulation to access the mounting bolts. Unbolt the Oxy- mitter 4000 from the stack and take it to a clean work area.

(g)Allow the unit to cool to a comfort- able working temperature.

(a)Bolt the Oxymitter 4000 probe to the stack and install insulation.

(b)Connect all signal and power leads at the probe. Refer to Section 2 for detailed wiring instructions.

(c)Install left housing cover (27, Figure 9-3or Figure 9-4)and en- sure it is tight. Secure the cover using cover lock (34), gasket (33), and screw (32).

(d)Connect the calibration gas and in- strument air lines to the probe.

(e)Turn on the calibration gases at the cylinders and turn on instru- ment air.

(f)Restore power to the system.

b.Removal and Replacement of Oxymitter 4000 Probe with Integral Electronics and Integrally Mounted SPS 4000

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, dis- connect the instrument air directly at the Oxymitter 4000 probe.

(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.

9-6 Maintenance and Service

Rosemount Analytical Inc. A Division of Emerson Process Management

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Contents Oxymitter IB-106-340 Rev DecemberEssential Instructions Summary Highlights of ChangesEffective December, 2003 Rev Highlights of Changes Table of Contents OxymitterStartup and Operation of Oxymitter 4000 with LOI List of Illustrations Oxymitter 4000 Gas Connections Calibration Gas Connections11-5 List of Tables11-3 11-1Preface DefinitionsOxymitter Belangrijk Vigtigt Oxymitter Tärkeää Oxymitter Wichtig Importante Viktig Oxymitter Oxymitter Viktigt Oxymitter Ceramic Fiber Products Material Safety Data Sheet July 1Section II. Physical Data Section V. Health Hazard Data Section VI. Reactivity Data Section VII. Spill or Leak Procedures Section IX. Special Precautions Oxymitter What YOU Need to Know Oxymitter 4000 with Remote Imps 4000 OptionOxymitter Remote Electronics with Integral SPS Option Can YOU USE the Following Quick Start GUIDE? Use this Quick Start Guide ifQuick Start Guide For Oxymitter 4000 Systems Oxymitter 4000 with SPS 4000 Wiring Diagram Quick Reference Guide Manual Calibration Instructions Performing a Manual Calibration with a Membrane KeypadHart Communicator Fast KEY Sequences Technical Support HotlineSystem Overview Section Description and SpecificationsComponent Checklist of Typical System Package Contents Typical System Package Oxymitter Integrally Mounted Remote MountedMembrane Keypad Model 751 LCD Display Panel Control Room Asset Management Solutions Line Voltage Autocalibration Option StandardImps 4000 Multiprobe SPS 4000 Single Probe Autocalibration OptionCalibra Mounting Imps 4000 OptionalSPS 4000 Optional Components FigureFront View Rear View of Manifold onlyDiffusion Elements Model 751 Remote Powered Loop LCD DisplayProbe Options 13. Hastelloy Cup-Type Diffusion Assembly Abrasive Shield AssemblyView a Specifications Oxymitter In. NPT 100% relative humidityNema 4X IP56 90 to 250 VAC, 50/60 HzProduct Matrix Code Sensing Probe TypeCalibration Components Part Number Description3D39695G03 3D39695G013D39695G02 3D39695G04Selecting Location Section InstallationMechanical Installation Oxymitter 4000 Probe Installation Oxymitter 4000 Remote Electronics Installation Horizontal Mounted SPS 4000 a Vertical Mounted SPS 4000 aOxymitter 4000 with Abrasive Shield Oxymitter 4000 Adapter Plate Dimensions Oxymitter 4000 Adapter Plate Installation Oxymitter 4000 Abrasive Shield Bracing Installation Remote Electronics Installation Installation with Drip Loop and Insulation RemovalAll wiring must conform to local and national codes Connect Line VoltageIntegral Electronics Install Interconnecting Cable Probe WALL-MOUNTED Electrical Installation for Oxymitter 4000 with SPS Not Used Line Pneumatic Installation for Oxymitter 4000 Without SPS Connect Relay Output WiringConnect 4-20 mA Signal Wiring Reference Air Package13. Air Set, Plant Air Connection Imps 4000 Connections Pneumatic Installation forOxymitter 4000 with SPS Oxymitter Verify Terminal Block Wiring Section Configuration of Oxymitter With Membrane KeypadVerify Mechanical Installation GeneralModel 751. The loop-driven LCD display Verify Oxymitter 4000 ConfigurationSW2 Heater T/C Diagnostic Logic I/O Configuration as set at HART/AMS or LOI Mode AlarmCalibration Handshake Signal Logic I/OCalibration Recommended ConfigurationMA Signal Upon Critical Alarm Oxymitter Section Configuration of Oxymitter 4000 with LOI Electronics Housing Terminals and LOIVerify Oxymitter 4000 Configuration Defaults Oxymitter 4000 with LOI Logic I/O Recommended Configuration Oxymitter Power UP General OperationTROUBLESHOOTING. Diagnostic Alarm LEDS. If thereIs an error in the system, one of these Case of multiple errors, only oneO2 2.59% LK normal Section Startup and Operation Oxymitter 4000 with LOIO2 0.00% LK warm up 367dgC Start UP Oxymitter 4000 CalibrationLOI Features LockoutLOI Menu Tree DataOxymitter 4000 Setup AT the LOI SYSTEM/Calibration SetupSYSTEM/Input/Output SYSTEM/ParametersSYSTEM/Software LOI InstallationSYSTEM/Status Sensor DataTP3 and TP4 monitor the heater thermo Model 751 Remote Powered LoopOxymitter 4000 Test Points TP1 and TP2 monitor the oxygen cellSignal Line Connections, ≥ 250 Ohms Load Resistance Overview Hart Communicator Signal Line ConnectionsHART/AMS Method 1, For Load Resistance ≥ 250 OhmsHart Communicator PC Connections Logic I/O ConfigurationsLogic I/O Configuration Mode OFF-LINE and ON-LINE OperationsMenu Tree for HART/AMS on the Oxymitter 4000 Sheet 1 Menu Tree for HART/AMS on the Oxymitter 4000 Sheet 2 Menu Tree for HART/AMS on the Oxymitter 4000 Sheet 3 Hart Communicator Manual O2 CAL Method Complete CAL Recommended Apply GAS GAS 1 FlowDefining a Timed Calibration VIA Hart From the Device Setup screen, selectFrom the Detailed Setup screen, select Oxymitter EMFmV Section Troubleshooting100 16.1 18.4 21.1 23.8 27.2 31.2 36.0Alarm Indications Indications with Membrane Keypad Alarm ContactsIdentifying and Correcting Alarm Flashes Status MA Line Fault Clearing LEDKeypad Alarms O2 T/C OpenFault 1, Open Thermocouple LOIAlarms O2 T/C Shorted Fault 2, Shorted ThermocoupleFaulty PC Board Alarms O2 T/C ReversedFault 3, Reversed Thermocouple Wiring or Alarms ADC Error Fault 4, A/D Comm ErrorAlarms O2 Heater Open Fault 5, Open HeaterAlarms Very Hi O2 Temp Fault 6, High High Heater TempAlarms Board Temp Hi Fault 7, High Case TempAlarms O2 Temp Low Fault 8, Low Heater TempAlarms O2 Temp Hi Fault 9, High Heater TempAlarms O2 Cell Open Fault 10, High Cell mVAlarms O2 Cell Bad Fault 11, Bad CellAlarms EEprom Corrupt Fault 12, Eeprom CorruptFault 13, Invalid Slope Fault 14, Invalid Constant Alarms Calib Failed Fault 15, Last Calibration FailedHow do I detect a plugged diffuser? Probe passes calibration, but still appears to read highProbe passes calibration, but still appears to read low SPS 4000 Troubleshooting Can I calibrate a badly plugged diffuser?SPS 4000 Fault Finding Symptom Check Remedy Symptom no Test GAS Flow 19. SPS 4000 Troubleshooting Flowchart Sheet 119. SPS 4000 Troubleshooting Flowchart Sheet 2 Section Maintenance and Service Calibration Oxymitter 4000 with a Membrane KeypadStart Calib from the Calibra Tion menuAlarms Manual CalibrationOxymitter Flow Gas 1xxxxs Read Gas 1xxxxs Done Gas Apply Gas Hit E when readyCALIBRATION/ Start Calibration PurgexxxxsOxymitter 4000 Repair ReplaceOxymitter 4000 with Integral Electronics, Exploded View Remote Electronics Oxymitter Electronic Assembly Terminal Block Replacement Electronic Assembly ReplacementFuse Replacement Figure Entire Probe Replacement Excluding Probe Head Heater Strut ReplacementHeater Strut Assembly Probe to Probe Head Assembly Remote Electronics Only Cell ReplacementOxymitter 11. Ceramic Diffusion Element Replacement Oxymitter SPS 4000 Maintenance and Component Replacement Board Replacement 13. SPS 4000 Manifold Assembly Solenoid Replacement Pressure Switch ReplacementPower Supply Board Interface BoardFlowmeter Adjustments Check Valve ReplacementPressure Regulator Optional Maintenance Flowmeter Replacement 15. Calibration Gas and Reference Air Components Calibration Record For Rosemount Analytical In Situ O2 Probe Value to begin migrating back to the process valueSection Return of Material Oxymitter Section Replacement Parts Replacement Parts for ProbeReplacement Parts for Probe Part Number Figure and Index No No Dust Seal DescriptionCell Replacement Kit Oxymitter Probe Disassembly Kit Replacement Parts for Electronics Replacement Parts for SPS Replacement Parts for Calibration ComponentsOxymitter Hart Handheld 275/375 Communicator Section Optional AccessoriesAsset Management Solutions AMS BY-PASS PackagesOxymitter Imps 4000 Intelligent Multiprobe Test GAS SequencerSPS 4000 Single Autocalibration Sequencer O2 Calibration GAS Catalyst RegenerationOxymitter Section Index Fuse, 8-22, 8-23, 9-18 Warranty Oxymitter Serial no Order no
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