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Emerson 4000 O2 CALIBRATION GAS, CATALYST REGENERATION

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Oxymitter 4000

Instruction Manual

IB-106-340 Rev. 3.0 December 2003

O2 CALIBRATION GAS

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.

CATALYST REGENERATION

Measure O2 in regenerators at pressures up to 50 psi. In-situ design resists plugging due to catalyst fines Class I, Div. I, Group B, C and D.

Optional pressure balancing arrangement. Optional isolation valving system permits installation and withdrawal while the process is running. Specified by UOP.

See Application Data Sheet ADS 106-300F.A01,

Isolation Valving System.

26170021

OXYMITTER 4000 ISOLATION

PROBE IN VALVING

RETRACTED SYSTEM

POSITION

INTEGRAL

PRESSURE

BALANCING

ASSEMBLY

37260042

Rosemount Analytical Inc. A Division of Emerson Process Management

Optional Accessories 12-3

Contents

Instruction Manual ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING MUST properly install, use, and maintain them MUST be adhered to Read all instructions HIGHLIGHTS OF CHANGES HIGHLIGHTS OF CHANGES (CONTINUED) TABLE OF CONTENTS Page LIST OF ILLUSTRATIONS LIST OF TABLES PREFACE DEFINITIONS NOTE TO USERS IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS BELANGRIJK VIGTIGT Page TÄRKEÄÄ IMPORTANT Wichtig Sicherheitshinweise für den Anschluß und die Installation dieser Geräte IMPORTANTE VIKTIG Page Page VIKTIGT Page CERAMIC FIBER PRODUCTS MATERIAL SAFETY DATA SHEET JULY 1 PRODUCT NAME CHEMICAL FAMILY APPEARANCE AND ODOR SPECIFIC WEIGHT: 12-25LB./CUBIC FOOT BOILING POINT: VOLATILES (% BY WT.): N.A MATERIAL, QUANTITY, AND THRESHOLD/EXPOSURE LIMIT VALUES THRESHOLD LIMIT VALUE EFFECTS OF OVER EXPOSURE EXPOSURE TO USED CERAMIC FIBER PRODUCT SPECIAL TOXIC EFFECTS EMERGENCY FIRST AID PROCEDURES STABILITY/CONDITIONS TO AVOID HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID INCOMPATIBILITY/MATERIALS TO AVOID HAZARDOUS DECOMPOSITION PRODUCTS STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED WASTE DISPOSAL METHODS RESPIRATORY PROTECTION PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING CONCENTRATION Page WHAT YOU NEED TO KNOW REMOTE ELECTRONICS WITH INTEGRAL SPS OPTION WALL-MOUNTEDSPS OPTION Figure 2. Installation Options – Oxymitter 4000 with Remote Electronics CAN YOU USE THE FOLLOWING QUICK START GUIDE QUICK START GUIDE FOR OXYMITTER 4000 SYSTEMS Figure 3. Oxymitter 4000 with SPS 4000 Wiring Diagram Figure 4. Oxymitter 4000 without SPS 4000 Wiring Diagram QUICK REFERENCE GUIDE MANUAL CALIBRATION INSTRUCTIONS HART COMMUNICATOR FAST KEY SEQUENCES SECTION DESCRIPTION AND SPECIFICATIONS Figure 1-1.Typical System Package c.System Configuration d.System Features INTEGRALLY MOUNTED SPS Figure 1-3.Membrane Keypad Figure 1-4.Local Operator Interface (LOI) Figure 1-5.Model 751 LCD Display Panel e. Handling the Oxymitter Figure 1-6.Oxymitter 4000 HART Communications and AMS Application f.System Considerations Instruction Manual STANDARD IMPS 4000 MULTIPROBE AUTOCALIBRATION OPTION SPS 4000 SINGLE PROBE (WITH REFERENCE AIR OPTION)REMOTE ELECTRONICS Figure 1-8.Typical System Installation – Oxymitter 4000 with Remote Electronics 1-3IMPS 4000 (Optional) 1-4SPS 4000 (Optional) a.Mounting b.Components (Figure 1-9) c.Operation FRONT VIEW REAR VIEW (OF MANIFOLD ONLY) Figure 1-9.SPS Figure 1-10.Model 751 Remote Powered Loop LCD Display 1-5MODEL 751 REMOTE POWERED LOOP LCD DISPLAY 1-6PROBE OPTIONS a.Diffusion Elements Figure 1-13.Hastelloy Cup-Type Diffusion Assembly b.Abrasive Shield Assembly Figure 1-14.Abrasive Shield Assembly In highly abrasive applications, rotate the shield 90 degrees at normal service intervals to present a new wear surface to the abrasive flow stream 1-7SPECIFICATIONS Oxymitter Page Table 1-1.Product Matrix Table 1-1.Product Matrix (Continued) Table 1-2.Calibration Components Part Number Description Table 1-3.Intelligent Multiprobe Test Gas Sequencer Versions Number of Part Oxymitter Number INSTALLATION Figure 2-1.Oxymitter 4000 Probe Installation REMOTE ELECTRONICS WITH MEMBRANE KEYPAD AND BLIND COVER WITH LOI AND WINDOW COVER Figure 2-2.Oxymitter 4000 Remote Electronics Installation HORIZONTAL MOUNTED SPS 4000 A VERTICAL MOUNTED SPS 4000 A Figure 2-3.Oxymitter 4000 Installation (with SPS 4000) Figure 2-4.Oxymitter 4000 with Abrasive Shield Figure 2-5.Oxymitter 4000 Adapter Plate Dimensions Figure 2-6.Oxymitter 4000 Adapter Plate Installation Figure 2-7.Oxymitter 4000 Abrasive Shield Bracing Installation Figure 2-8.Orienting the Optional Vee Deflector c.Remote Electronics Installation Figure 2-9.Installation with Drip Loop and Insulation Removal Disconnect and lock out power before connecting the power supply b.Connect Line Voltage c.Connect 4-20mA Signal and Calibration Handshake/Logic I/O Leads INTEGRAL ELECTRONICS WITHOUT SPS WITH SPS WITH IMPS Figure 2-10.Electrical Installation – Oxymitter 4000 with Integral Electronics c.Connect 4-20mA Signal and Calibration Handshake/Logic I/O Leads (Figure 2-11) e.Install Interconnecting Cable Page Page 2-4ELECTRICAL INSTALLATION (FOR OXYMITTER 4000 WITH SPS 4000) Disconnect and lock out power before connecting the unit to the power supply Figure 2-12.SPS 4000 Electrical Connections f. Connect Remote Contact Input Wiring Connect Relay Output Wiring 2-5PNEUMATIC INSTALLATION (FOR OXYMITTER 4000 WITHOUT SPS 4000) Reference Air Package Connect 4-20mA Signal Wiring Figure 2-13.Air Set, Plant Air Connection Figure 2-14.Oxymitter 4000 Gas Connections Calibration Gas Connections 2-6PNEUMATIC INSTALLATION (FOR a. Reference Air Connection (Optional) OXYMITTER 4000 WITH SPS 4000) 2-7IMPS 4000 CONNECTIONS Page CONFIGURATION OF OXYMITTER WITH MEMBRANE KEYPAD c.Verify Oxymitter 4000 Configuration d.SW1 e.SW2 Page 3-2LOGIC I/O a.Alarm b.Calibration Handshake Signal Table 3-1.Logic I/O Configuration (as set at HART/AMS or LOI) Mode 3-3RECOMMENDED CONFIGURATION a.4-20mA Signal Upon Critical Alarm b.Calibration Page CONFIGURATION OF OXYMITTER 4000 WITH LOI Page Figure 4-2.Defaults – Oxymitter 4000 with LOI 4-2LOGIC I/O Table 4-1.Logic I/O Configuration (as set at HART/AMS or LOI) 4-3RECOMMENDED CONFIGURATION Page STARTUP AND OPERATION OF OXYMITTER 4000 WITH MEMBRANE KEYPAD Figure 5-2.Calibration Keys Refer Section 9, MAINTENANCE AND SERVICE, for calibration instructions b.Model 751 Remote Powered Loop LCD Display (Optional) OF OXYMITTER 4000 WITH LOI b. Lockout Figure LOI Features 6-3NAVIGATING THE LOCAL OPERATOR 6-4LOI KEY DESIGNATIONS 6-5LOI MENU TREE 6-6OXYMITTER 4000 SETUP AT THE LOI a.SYSTEM/Calibration Setup Refer to Section 9, MAINTENANCE AND SERVICE, for calibration instructions Rosemount Analytical recommends 0.4% O2 and 8% O2 for calibration gases b.SYSTEM/Input/Output c.SYSTEM/Parameters d.SYSTEM/Status e.SYSTEM/Software f.SENSOR DATA 6-7LOI INSTALLATION Figure 6-5.LOI Module Connectors 6-8OXYMITTER 4000 TEST POINTS 6-9MODEL 751 REMOTE POWERED LOOP LCD DISPLAY (OPTIONAL) Figure 6-6.Oxymitter 4000-TestPoints Figure 7-1.Signal Line Connections, ≥ 250 Ohms Load Resistance Figure 7-2.Signal Line Connections, < 250 Ohms Load Resistance SECTION 7 HART/AMS 7-3HART COMMUNICATOR PC CONNECTIONS 7-4 OFF-LINEAND ON-LINEOPERATIONS If the HART Communicator is turned on while connected to the 4-20mA 7-5LOGIC I/O CONFIGURATIONS 7-6MENU TREE FOR HART COMMUNICA- TOR/OXYMITTER 4000 APPLICATIONS Figure 7-3.Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 1 of 3) Figure 7-3.Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 2 of 3) Figure 7-3.Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 3 of 3) 7-7HART COMMUNICATOR MANUAL O2 CAL METHOD 7-8DEFINING A TIMED CALIBRATION VIA HART Page TROUBLESHOOTING d. Electrostatic Discharge Install all protective equipment covers and safety ground leads after trouble shooting. Failure to install covers and ground leads could result in serious 8-4ALARM CONTACTS The 4-20mA signal can be configured to respond normally during any cali bration, or can be configured to hold the last O2 value upon the initiation of Table 8-1.Diagnostic/Unit Alarm Fault Definitions – Membrane Keypad Only Self LED Flashes Status Alarms O2 T/C Open Figure 8-3.Fault 1, Open Thermocouple LOI b. Fault 2, Shorted Thermocouple O2 T/C Shorted Figure 8-4.Fault 2, Shorted Thermocouple c. Fault 3, Reversed Thermocouple Wiring or Faulty PC Board O2 T/C Reversed Figure 8-5.Fault 3, Reversed Thermocouple d.Fault 4, A/D Comm Error ADC Error Figure 8-6.Fault 4, A/D Comm Error e. Fault 5, Open Heater O2 Heater Open Figure 8-7.Fault 5, Open Heater f. Fault 6, High High Heater Temp Very Hi O2 Temp Figure 8-8.Fault 6, High High Heater Temp g. Fault 7, High Case Temp Board Temp Hi Figure 8-9.Fault 7, High Case Temp h. Fault 8, Low Heater Temp O2 Temp Low Figure 8-10.Fault 8, Low Heater Temp i. Fault 9, High Heater Temp O2 Temp Hi Figure 8-11.Fault 9, High Heater Temp j. Fault 10, High Cell mV O2 Cell Open Figure 8-12.Fault 10, High Cell mV k. Fault 11, Bad Cell O2 Cell Bad Figure 8-13.Fault 11, Bad Cell l. Fault 12, EEPROM Corrupt EEprom Corrupt Figure 8-14.Fault 12, EEPROM Corrupt m. Fault 13, Invalid Slope Figure 8-15.Fault 13, Invalid Slope n. Fault 14, Invalid Constant Figure 8-16.Fault 14, Invalid Constant o. Fault 15, Last Calibration Failed Calib Failed Figure 8-17.Fault 15, Last Calibration Failed 8-6OXYMITTER 4000 PASSES CALIBRATION BUT STILL READS INCORRECTLY a.Probe passes calibration, but still appears to read high Figure 8-18.Probe Leakage Paths b.Probe passes calibration, but still appears to read low Can I calibrate a badly plugged diffuser 8-7SPS 4000 TROUBLESHOOTING Table 8-3.SPS 4000 Fault Finding Symptom Check Remedy SYMPTOM — NO TEST GAS FLOW Figure 8-19.SPS 4000 Troubleshooting Flowchart (Sheet 1 of 2) SYMPTOM — NO TEST GAS FLOW (CONTINUED) Figure 8-19.SPS 4000 Troubleshooting Flowchart (Sheet 2 of 2) MAINTENANCE AND SERVICE Figure 9-1.Membrane Keypad ALARMS MANUAL CALIBRATION Figure 9-2.Inside Right Cover Page 9-3CALIBRATION – OXYMITTER 4000 WITH A LOCAL OPERATOR INTERFACE (LOI) a.CALIBRATION/ Start Calibration Hit E when ready Flow Gas 1xxxxs Read Gas 1xxxxs Done Gas Flow Gas 2xxxxs 9-4OXYMITTER 4000 REPAIR Figure 9-3.Oxymitter 4000 with Integral Electronics, Exploded View Page c.Replace Entire Integral Electronics (with Housing) Figure 9-5.Electronic Assembly Figure 9-6.J8 Connector d.Electronic Assembly Replacement (Figure 9-5) e.Terminal Block Replacement f.Fuse Replacement (Figure 9-7) Figure 9-7.Fuse Location g.Entire Probe Replacement (Excluding Probe Head) h.Heater Strut Replacement Figure 9-8.Heater Strut Assembly Figure 9-9.Probe to Probe Head Assembly – Remote Electronics Only i.Cell Replacement Figure 9-10.Cell Replacement Kit To determine if the diffusion element needs to be replaced, refer to paragraph j.Ceramic Diffusion Element Replacement This refers to the ceramic diffusion element only Figure 9-11.Ceramic Diffusion Element Replacement Page Figure 9-12.Termination Housing Connections for Remote Electronics Probe Head 9-5SPS 4000 MAINTENANCE AND COMPONENT REPLACEMENT a.Fuse Replacement Disconnect and lock out power before working on any electrical components b.Board Replacement Figure 9-13.SPS 4000 Manifold Assembly c.Solenoid Replacement d.Pressure Switch Replacement POWER SUPPLY BOARD INTERFACE BOARD Figure 9-14.Power Supply Board and Interface Board Connections e.Check Valve Replacement f.Pressure Regulator (Optional) Maintenance g.Flowmeter Adjustments h.Flowmeter Replacement Figure 9-15.Calibration Gas and Reference Air Components Calibration Record For Rosemount Analytical In Situ O2 Probe Probe Serial Number: Probe Tag Number: RETURN OF MATERIAL Page REPLACEMENT PARTS Table 11-1.Replacement Parts for Probe (Continued) Figure and Index No Figure 11-1.Cell Replacement Kit Page Figure 11-2.Probe Disassembly Kit Table 11-2.Replacement Parts for Electronics Table 11-3.Replacement Parts for SPS Table 11-4.Replacement Parts for Calibration Components Page OPTIONAL ACCESSORIES IMPS 4000 INTELLIGENT MULTIPROBE TEST GAS SEQUENCER SPS 4000 SINGLE AUTOCALIBRATION SEQUENCER O2 CALIBRATION GAS CATALYST REGENERATION Page INDEX Page WARRANTY