Emerson 4000 manual Section Description and Specifications, System Overview

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Oxymitter 4000

Instruction Manual

IB-106-340 Rev. 3.0 December 2003

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1-1 COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS)

A typical Rosemount Oxymitter 4000 Oxygen Transmitter should contain the items shown in Figure 1-1.Record the part number, serial num- ber, and order number for each component of your system in the table located on the first page of this manual.

Also, use the product matrix in Table 1-1at the end of this section to compare your order num- ber against your unit. The first part of the matrix defines the model. The last part defines the various options and features of the Oxymitter 4000. 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 4000. Signal conditioning electronics outputs a 4-

20 mA signal representing an O2 value and provides a membrane keypad or fully func- tional Local Operator Interface (optional) for setup, calibration, and diagnostics. This same information, plus additional details, can be accessed with the HART Model 275/375 handheld communicator or Asset Manage- ment Solutions (AMS) software.

b.System Description

The Oxymitter 4000 is designed to measure the net concentration of oxygen in an indus- trial 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 percent- age by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous

metal electrodes. When operated at the proper temperature, the millivolt output volt- age of the cell is given by the following Nernst equation:

EMF = KT 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.

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, in- strument air (20.95% oxygen) as the reference air.

When the cell is at operating temperature and there are unequal oxygen concentra- tions across the cell, oxygen ions will travel from the high oxygen partial pressure side to the low oxygen partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade. The output is proportional to the inverse logarithm of the oxygen concentration. Therefore, the output signal increases as the oxygen con- centration of the sample gas decreases. This characteristic enables the Oxymitter 4000 to provide exceptional sensitivity at low oxygen concentrations.

The Oxymitter 4000 measures net oxygen concentration in the presence of all the prod- ucts 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, indi- cate a lower percentage of oxygen. The dif- ference will be proportional to the water content of the sampled gas stream.

Rosemount Analytical Inc. A Division of Emerson Process Management

Description and Specifications 1-1

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Contents IB-106-340 Rev December OxymitterEssential Instructions Effective December, 2003 Rev Highlights of ChangesSummary Highlights of Changes Oxymitter Table of ContentsStartup and Operation of Oxymitter 4000 with LOI Oxymitter 4000 Gas Connections Calibration Gas Connections List of Illustrations11-3 List of Tables11-5 11-1Definitions PrefaceOxymitter Belangrijk Vigtigt Oxymitter Tärkeää Oxymitter Wichtig Importante Viktig Oxymitter Oxymitter Viktigt Oxymitter July 1 Ceramic Fiber Products Material Safety Data SheetSection II. Physical Data Section V. Health Hazard Data Section VI. Reactivity Data Section VII. Spill or Leak Procedures Section IX. Special Precautions Oxymitter Oxymitter 4000 with Remote Imps 4000 Option What YOU Need to KnowOxymitter Remote Electronics with Integral SPS Option Use this Quick Start Guide if Can YOU USE the Following Quick Start GUIDE?Quick Start Guide For Oxymitter 4000 Systems Oxymitter 4000 with SPS 4000 Wiring Diagram Performing a Manual Calibration with a Membrane Keypad Quick Reference Guide Manual Calibration InstructionsTechnical Support Hotline Hart Communicator Fast KEY SequencesComponent Checklist of Typical System Package Contents Section Description and SpecificationsSystem Overview Typical System Package Remote Mounted Oxymitter Integrally MountedMembrane Keypad Model 751 LCD Display Panel Control Room Asset Management Solutions Line Voltage Imps 4000 Multiprobe StandardAutocalibration Option SPS 4000 Single Probe Autocalibration OptionCalibra SPS 4000 Optional Imps 4000 OptionalMounting Components FigureRear View of Manifold only Front ViewProbe Options Model 751 Remote Powered Loop LCD DisplayDiffusion Elements Abrasive Shield Assembly 13. Hastelloy Cup-Type Diffusion AssemblyView a Specifications Oxymitter Nema 4X IP56 100% relative humidityIn. NPT 90 to 250 VAC, 50/60 HzCode Sensing Probe Type Product MatrixPart Number Description Calibration Components3D39695G02 3D39695G013D39695G03 3D39695G04Mechanical Installation Section InstallationSelecting Location Oxymitter 4000 Probe Installation Oxymitter 4000 Remote Electronics Installation Vertical Mounted SPS 4000 a Horizontal Mounted SPS 4000 aOxymitter 4000 with Abrasive Shield Oxymitter 4000 Adapter Plate Dimensions Oxymitter 4000 Adapter Plate Installation Oxymitter 4000 Abrasive Shield Bracing Installation Installation with Drip Loop and Insulation Removal Remote Electronics InstallationConnect Line Voltage All wiring must conform to local and national codesIntegral Electronics Install Interconnecting Cable Probe WALL-MOUNTED Electrical Installation for Oxymitter 4000 with SPS Not Used Line Connect 4-20 mA Signal Wiring Connect Relay Output WiringPneumatic Installation for Oxymitter 4000 Without SPS Reference Air Package13. Air Set, Plant Air Connection Oxymitter 4000 with SPS Pneumatic Installation forImps 4000 Connections Oxymitter Verify Mechanical Installation Section Configuration of Oxymitter With Membrane KeypadVerify Terminal Block Wiring GeneralSW2 Verify Oxymitter 4000 ConfigurationModel 751. The loop-driven LCD display Heater T/C Diagnostic Calibration Handshake Signal AlarmLogic I/O Configuration as set at HART/AMS or LOI Mode Logic I/OMA Signal Upon Critical Alarm Recommended ConfigurationCalibration Oxymitter Electronics Housing Terminals and LOI Section Configuration of Oxymitter 4000 with LOIVerify Oxymitter 4000 Configuration Defaults Oxymitter 4000 with LOI Logic I/O Recommended Configuration Oxymitter General Operation Power UPIs an error in the system, one of these Diagnostic Alarm LEDS. If thereTROUBLESHOOTING. Case of multiple errors, only oneO2 0.00% LK warm up 367dgC Section Startup and Operation Oxymitter 4000 with LOIO2 2.59% LK normal Start UP Oxymitter 4000 CalibrationLockout LOI FeaturesData LOI Menu TreeSYSTEM/Calibration Setup Oxymitter 4000 Setup AT the LOISYSTEM/Parameters SYSTEM/Input/OutputSYSTEM/Status LOI InstallationSYSTEM/Software Sensor DataOxymitter 4000 Test Points Model 751 Remote Powered LoopTP3 and TP4 monitor the heater thermo TP1 and TP2 monitor the oxygen cellSignal Line Connections, ≥ 250 Ohms Load Resistance HART/AMS Hart Communicator Signal Line ConnectionsOverview Method 1, For Load Resistance ≥ 250 OhmsLogic I/O Configuration Mode Logic I/O ConfigurationsHart Communicator PC Connections 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 Complete CAL Recommended Apply GAS GAS 1 Flow Hart Communicator Manual O2 CAL MethodFrom the Detailed Setup screen, select From the Device Setup screen, selectDefining a Timed Calibration VIA Hart Oxymitter 100 Section TroubleshootingEMFmV 16.1 18.4 21.1 23.8 27.2 31.2 36.0Alarm Indications Identifying and Correcting Alarm Alarm ContactsIndications with Membrane Keypad LED Flashes Status MA Line Fault ClearingFault 1, Open Thermocouple Alarms O2 T/C OpenKeypad LOIFault 2, Shorted Thermocouple Alarms O2 T/C ShortedFault 3, Reversed Thermocouple Wiring or Alarms O2 T/C ReversedFaulty PC Board Fault 4, A/D Comm Error Alarms ADC ErrorFault 5, Open Heater Alarms O2 Heater OpenFault 6, High High Heater Temp Alarms Very Hi O2 TempFault 7, High Case Temp Alarms Board Temp HiFault 8, Low Heater Temp Alarms O2 Temp LowFault 9, High Heater Temp Alarms O2 Temp HiFault 10, High Cell mV Alarms O2 Cell OpenFault 11, Bad Cell Alarms O2 Cell BadFault 12, Eeprom Corrupt Alarms EEprom CorruptFault 13, Invalid Slope Fault 14, Invalid Constant Fault 15, Last Calibration Failed Alarms Calib FailedProbe passes calibration, but still appears to read low Probe passes calibration, but still appears to read highHow do I detect a plugged diffuser? Can I calibrate a badly plugged diffuser? SPS 4000 TroubleshootingSPS 4000 Fault Finding Symptom Check Remedy 19. SPS 4000 Troubleshooting Flowchart Sheet 1 Symptom no Test GAS Flow19. SPS 4000 Troubleshooting Flowchart Sheet 2 Calibration Oxymitter 4000 with a Membrane Keypad Section Maintenance and ServiceTion menu Start Calib from the CalibraManual Calibration AlarmsOxymitter CALIBRATION/ Start Calibration Apply Gas Hit E when readyFlow Gas 1xxxxs Read Gas 1xxxxs Done Gas PurgexxxxsReplace Oxymitter 4000 RepairOxymitter 4000 with Integral Electronics, Exploded View Remote Electronics Oxymitter Electronic Assembly Fuse Replacement Figure Electronic Assembly ReplacementTerminal Block Replacement Heater Strut Replacement Entire Probe Replacement Excluding Probe HeadHeater Strut Assembly Cell Replacement Probe to Probe Head Assembly Remote Electronics OnlyOxymitter 11. Ceramic Diffusion Element Replacement Oxymitter SPS 4000 Maintenance and Component Replacement Board Replacement 13. SPS 4000 Manifold Assembly Pressure Switch Replacement Solenoid ReplacementInterface Board Power Supply BoardPressure Regulator Optional Maintenance Check Valve ReplacementFlowmeter Adjustments Flowmeter Replacement 15. Calibration Gas and Reference Air Components Value to begin migrating back to the process value Calibration Record For Rosemount Analytical In Situ O2 ProbeSection Return of Material Oxymitter Replacement Parts for Probe Section Replacement PartsFigure and Index No No Dust Seal Description Replacement Parts for Probe Part NumberCell Replacement Kit Oxymitter Probe Disassembly Kit Replacement Parts for Electronics Replacement Parts for Calibration Components Replacement Parts for SPSOxymitter Asset Management Solutions AMS Section Optional AccessoriesHart Handheld 275/375 Communicator BY-PASS PackagesSPS 4000 Single Autocalibration Sequencer Imps 4000 Intelligent Multiprobe Test GAS SequencerOxymitter Catalyst Regeneration O2 Calibration GASOxymitter Section Index Fuse, 8-22, 8-23, 9-18 Warranty Oxymitter Serial no Order no
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4000 specifications

The Emerson 4000 is a state-of-the-art automation platform designed to enhance industrial processes and improve operational efficiency. This advanced system is recognized for its unparalleled reliability and flexibility, making it suitable for various industries such as oil and gas, chemicals, pharmaceuticals, and power generation.

One of the standout features of the Emerson 4000 is its robust architecture that comprises distributed control systems (DCS) and a comprehensive suite of software applications. This integration allows for real-time monitoring and control of complex processes, ensuring that operators have access to crucial data for informed decision-making. The system supports a wide range of field devices and protocols, facilitating seamless connectivity across various platforms.

The Emerson 4000 employs innovative technologies that elevate its performance. It incorporates advanced analytics and machine learning capabilities, which enable predictive maintenance and reduce downtime. By analyzing historical data and identifying patterns, the system can forecast potential failures, allowing operators to address issues before they escalate. This leads to increased uptime and significant cost savings.

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Overall, the Emerson 4000 stands out as a powerful tool for industrial automation. Its combination of reliability, advanced technology, user-friendliness, security, and scalability makes it an ideal choice for organizations seeking to optimize their operations and drive efficiency in an increasingly competitive landscape.