Emerson Process Management OXYMITTER 4000 - page 116

Instruction Manual

IB-106-340C Rev. 4.1

July 2004

8-20 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Hazardous Area Oxymitter 4000

8-6 HAZARDOUS AREA OXYMITTER 4000

PASSES CALIBRATION, BUT STILL

READS INCORRECTLY

There are a few fault conditions where no alarm

indication is present and the probe passes cali-

bration, but the O2 reading may still be incorrect:

a. Probe passes calibration, but still ap-

pears to read high.

1. There ma y be a leak that is permitting

ambient air to mix with the process

gases. Since many combustion proc-

esses are slightly negative in pressure,

ambient air can be sucked into the cell

area, biasing the O2 reading upward.

(a) Make sure that the calibration gas

line is capped tightly between cali-

brations. If autocal is used, make

sure the check valve is seating

properly.

(b) If an abrasive shield is installed

to protect the entire probe from

particulate erosion, a leak in the

probe flange gasket can allow

ambient air to migrate down the

annular space between the probe

and shield, and then into the cell.

Always install a new probe flange

gasket when re-installing a probe.

2. T here may be a leak inside the probe

itself, permitting the reference air

(20.95% O2) to mix with the process

gases at the cell. To confirm this leak

condition, instrument air will need to be

connected for reference. Pressurize

the inside (reference side) of the probe

by plugging the reference air exhaust

port with your finger for 1 minute. The

O2 reading should decrease slightly. If

the O2 reading increases during this

test, there is a leak inside the probe.

(a) Acid condensation inside the probe

can degrade the red silicon tube

(item 38, Figure 9-3) that carries the

cal gas to the cell. Remove the

housing (11) to inspect this hos e.

(See Section 9, MAINTENANCE

AND SERVICE).

BOTTOM VIEW

37260045

PROBE HEAD

CORRUGATED

SEAL

REFERENCE AIR

EXHAUST PORT

PROBE

FLANGE

GASKET

Figure 8-18. Probe Leakage Path s

(b) The sensing cell is bolted to the

end of the probe, and uses a cor-

rugated metallicseal (item 25,

Figure 9-3) to separate the process

gases from the ambient reference

air. This seal can be used only one

time, so always replace this seal

when a cell is replaced. Always

apply anti-seize compound on both

sides of the corrugations.

b. Probe passes calibration, but still

appears to read low.

The diffusion element at the end of the

probe is a passive filter. It plugs very slowl y,

since there is no active flow being drawn

across it. In applications that have a heav y

particulate loading (coal or wood fired boil-

ers, cement and lime kilns, catal yst regen-

eration, recovery boilers, etc.), this diffus ion

element will eventually plug.

It is important not to pressurize the sensing

cell during calibrations by flowing excess ive

cal gas against a plugged diffuser. Calibra-

tion flow rates should be set only when a

new diffuser is installed. As the diffuse r

plugs, do not adjust the flow rates upward.

How do I detect a plugged diffuser?

1. The O2 signal's speed of response will

degrade. The O2 trend in the control

room will become smoother.

2. W hen calibrating, the calibration gas

flow rate will be noted to be lower.

Never readjust this flow upwards.

Adjust this flow only when a new

diffuser is installed.

Contents

Main ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! 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 BELANGRIJK TRKE IMPORTANT Wichtig Sicherheitshinweise fr den Anschlu und die Installation dieser Gerte. Page VIKTIG Page Page VIKTIGT Page SECTION I. IDENTIFICATION SECTION II. PHYSICAL DATA SECTION III. HAZARDOUS INGREDIENTS SECTION IV. FIRE AND EXPLOSION DATA SECTION V. HEALTH HAZARD DATA THRESHOLD LIMIT VALUE EFFECTS OF OVER EXPOSURE EXPOSURE TO USED CERAMIC FIBER PRODUCT SPECIAL TOXIC EFFECTS SECTION VI. REACTIVITY DATA STABILITY/CONDITIONS TO AVOID HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID INCOMPATIBILITY/MATERIALS TO AVOID HAZARDOUS DECOMPOSITION PRODUCTS SECTION VII. SPILL OR LEAK PROCEDURES SECTION VIII. SPECIAL PROTECTION INFORMATION SECTION IX. SPECIAL PRECAUTIONS PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING CONCENTRATION Page GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS SECTION 1 DESCRIPTION AND SPECIFICATIONS Figure 1-1. Typical System Package HAZARDOUS AREA OXYMITTER 4000 IMPS 4000 REMOTE MOUNTED SPS 4000 Page Page Page STANDARD IMPS 4000* MULTIPROBE AUTOCALIBRATION OPTION REMOTE MOUNTED SPS 4000* SINGLE PROBE AUTOCALIBRATION OPTION (WITH REFERENCE AIR OPTION) Figure 1-6. Typical System Installation O xymitter 4000 with Integral Electronics STANDARD IMPS 4000* MULTIPROBE AUTOCALIBRATION OPTION Figure 1-7. Typical System Installation O xymitter 4000 with Remote Electronics REMOTE MOUNTED SPS 4000* SINGLE PROBE AUTOCALIBRATION OPTION (WITH REFERENCE AIR OPTION) Page Hazardous Area Oxymitter 4000 VIEW A VIEW B A A B B Page Page Table 1-1. Product Matrix Table 1-1. Product Matrix (Continued) Page SECTION 2 INSTALLATION 2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management AMBIENT WEATHER CONDITIONS Figure 2-1. Hazardous Area Oxymitter 4000 Probe Installation INSULATE IF EXPOSEDTO PROCESS FLOW MUST BE IN THIS DIRECTIONWITH RESPECT TO DEFLECTOR 3534B48G01 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3 PIPE MOUNT CONFIGURATION REMOTE ELECTRONICS WITH LOI AND WINDOW COVER REMOTE ELECTRONICS WITH MEMBRANE KEYPAD AND BLIND COVER WALL MOUNT CONFIGURATION Figure 2-2. Hazardous Area Oxymitter 4000 Remote Electronics Installation Figure 2-3. Hazardous Area Oxymitter 4000 Probe with Abrasive Shield 2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5 MOUNTING PLATE OUTLINE Figure 2-4. Hazardous Area Oxymitter 4000 Mounting Plate Dimensions 2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION INSTALLATION FOR METAL WALL STACK OR DUCT CONSTRUCTION Figure 2-5. Hazardous Area Oxymitter 4000 Mounting Plate Installation PROBE MOUNTING ABRASIVE SHIELD MOUNTING Page Page Page 2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management WITHOUT SPS 4000 WITH REMOTE SPS 4000 Figure 2-9. Electrical Installation Hazardous Area Oxymitter 4000 with Integral Electronics WITH REOMTE IMPS 4000 Page 2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management WIRING DIAGRAM Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-13 WIRING DIAGRAM Page Page ! SECTION 3 CONFIGURATION OF HAZARDOUS AREA OXYMITTER 4000 WITH MEMBRANE KEYPAD Page Page Page Page Page SECTION 4 CONFIGURATION OF HAZARDOUS AREA OXYMITTER 4000 WITH LOI Page Page Page Page Page SECTION 5 START UP AND OPERATION OF HAZARDOUS AREA OXYMITTER 4000 WITH MEMBRANE KEYPAD Page Page Page SECTION 6 START UP AND OPERATION OF HAZARDOUS AREA OXYMITTER 4000 WITH LOI O2: 0.00% LK warm up 367dgC O2: 2.59% LK normal Page Figure 6-4. Local Operator Interface M enu Tree (Sheet 1 of 2) Page Page Page Page Page SECTION 7 HART/AMS Page Page Page Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 7-5 Figure 7-3. HART/AMS Menu Tree (Sheet 1 o f 3) Figure 7-3. HART/AMS Menu Tree (Sheet 2 o f 3) 7-6 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 7-7 Figure 7-3. HART/AMS Menu Tree (Sheet 3 o f 3) Page Page Page SECTION 8 TROUBLESHOOTING 150 EMF (mV) 100 50 Page Page Page Alarms O2 T/C Open KEYPAD LOI Alarms O2 T/C Shorted KEYPAD LOI Alarms O2 T/C Reversed LOI KEYPAD Alarms ADC Error LOI KEYPAD LOI KEYPAD Alarms O2 Heater Open LOI KEYPAD Alarms Very Hi O2 Temp LOI KEYPAD Alarms Board Temp Hi LOI KEYPAD Alarms O2 Temp Low Alarms O2 Temp Hi KEYPAD LOI Alarms O2 Cell Open KEYPAD LOI Alarms O2 Cell Bad KEYPAD LOI Alarms O2 Cell Bad KEYPAD LOI Alarms O2 Cell Bad LOI KEYPAD Alarms O2 Cell Bad LOI KEYPAD Alarms Calib Failed LOI KEYPAD Page Page Calibration Record For Rosemount Analytical In Situ O2 Probe SECTION 9 MAINTENANCE AND SERVICE Page Page ALARMS MANUAL CALIBRATION * * Page Page Page Figure 9-3. Hazardous Area Oxymitter 4000 with Integral Electronics Exploded View 9-8 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 9-9 REMOTE ELECTRONICS PROBE HEAD PROBE INTERCONNECTING CABLE Figure 9-4. Hazardous Area Oxymitter 4000 with Remote Electronics Exploded View Page Page Page Page Page Page Page Page Page SECTION 10 RETURN OF MATERIAL Page SECTION 11 REPLACEMENT PARTS Page Page Page SECTION 12 OPTIONAL ACCESSORIES ASSET MANAGEMENT SOLUTIONS Page Page Page SECTION 13 INDEX A B C D Page WARRANTY Hazardous Area Oxymitter 4000 Part no. Serial no. Order no.