Emerson Process Management OXYMITTER 4000 SECTION 2 INSTALLATION

Instruction Manual

IB-106-340C Rev. 4.1

July 2004

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

Hazardous Area Oxymitter 4000

SECTION 2INSTALLATION

The Hazardous Area Oxymitter 4000

and probe abrasive shield are heavy.

Use proper lifting and carrying proce-

dures to avoid personal injury.

Install all protective equipment covers

and safety ground leads after installa-

tion. Failure to install covers and

ground leads could result in serious

injury or death.

2-1 MECHANICAL INSTALLATION

a. Selecting Location

1. The location of the Hazardous Area

Oxymitter 4000 in the stack or flue is

most important for maximum accuracy

in the oxygen analyzing process. The

Hazardous Area Oxymitter 4000 must

be positioned so the gas it measures

is representative of the process. Best

results are normally obtained if the

Hazardous Area Oxymitter 4000 is

positioned near the center of the duct

(40 to 60% insertion). Longer ducts

may require several Hazardous Area

Oxymitter 4000 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 proc-

ess gas temperature falls within a

range of 0° to 704°C (32° to 1300°F).

Figure 2-1 through Figure 2-5 provide

mechanical installation references.

The ambient temperature of the elec-

tronics housing must not exceed 70°C

(150°F). For higher ambient tempera-

tures, we recommend the remote

mounted electronics option.

NOTE

At temperatures up to 85°C (185°F)

inside the housing, the infrared keypad

will cease to function, but the transmit-

ter will continue to operate properly.

2. Check the flue or stack for holes and

air leakage. The presence of this con-

dition will substantially affect the accu-

racy of the oxygen reading. Therefore,

either make the necessary repairs or

install the Hazardous Area Oxymitter

4000 upstream of any leakage.

3. Ensure the area is clear of internal and

external obstructions that will interfere

with probe installation and access to

the membrane keypad or LOI. Allow

adequate clearance for removal of the

Hazardous Area Oxymitter 4000

(Figure 2-1 or Figure 2-3).

Do not allow the temperature of the

Hazardous Area Oxymitter 4000 elec-

tronics to exceed 85°C (185°F) or dam-

age to the unit may result.

b. Probe Installation

1. Ensure all components are available to

install the Hazardous Area Oxymitter

4000. If equipped with a ceramic dif-

fuser, make sure the diffuser is not

damaged.

2. The Hazardous Area Oxymitter 4000

probe 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 coal-

fired boilers, kilns, and recovery

boilers).

3. Weld or bolt mounting plate (Figure

2-5) onto the duct.

2

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.