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Emerson Rosemount Oxymitter 4000 Reference Manual Download Page 166

9.3.9

Replace cell

Do not attempt to replace cell until you have eliminated all other possibilities for poor
performance.

 WARNING

The transmitter, probe tube, and flame arrestor hub can be hot (up to 572 °F [300 °C]) in
the region of the probe heater. This can cause severe burns.

Wear heat resistant gloves and clothing when removing probe.
Do not attempt to work on the probe until it has cooled to room temperature.

 CAUTION

Removing the cell may damage the cell and platinum pad.

Do not remove the cell unless it needs to be replaced. Go through the complete
troubleshooting procedure to eliminate other possible causes before removing the cell.

If you need to replace the cell, order the cell replacement kit. See 

Table 10-3

. The cell

replacement kit (

Figure 9-7

) contains a cell and flange assembly, corrugated seal,

setscrews, socket head cap screws, and anti-seize compound. Emerson carefully packages
the items to preserve precise surface finishes. Do not remove items from the packaging
until you are ready to use them. A special tools kit contains spanner and hex wrenches. See

Table 10-3

.

Maintenance and service

Reference Manual

October 2019

00809-0100-4340

166

Emerson.com/Rosemount

Summary of Contents for Rosemount Oxymitter 4000

Page 1: ...Reference Manual 00809 0100 4340 Rev AB October 2019 Rosemount Oxymitter 4000 Hazardous Area Oxygen Transmitter ...

Page 2: ...d by qualified people to prevent electrical shock and personal injury Note The information contained in this document is subject to change without notice CAUTION If a Model 275 375 HART Communicator is used with this product the software within the Model 275 375 may require modification If a software modification is required please contact your local Emerson Service Group or National Response Cent...

Page 3: ...ontroller is set up at least to the point where it is controlling the sensor heater This will ensure that should there be a delay between installation and full commissioning that the sensor being supplied with ac power and reference air will not be subjected to component deterioration Definitions The following definitions apply to Warnings Cautions and Notes found throughout this publication WARNI...

Page 4: ...4 ...

Page 5: ...nics 58 2 4 Pneumatic installation 65 2 5 Rosemount IMPS 4000 connections 68 2 6 Rosemount SPS 4001B connections 68 Chapter 3 Configure transmitter with membrane keypad 69 3 1 Verify installation 69 3 2 Mechanical installation 69 3 3 Wire terminal block 69 3 4 Configuration 70 3 5 Logic I O 73 3 6 Recommended configuration 74 Chapter 4 Configure transmitter with LOI 77 4 1 Verify installation 77 4...

Page 6: ...e with HART 113 7 9 D A trim 113 Chapter 8 Troubleshoot 115 8 1 Overview 115 8 2 Factors to consider when troubleshooting 116 8 3 Alarm indications 117 8 4 Alarm contacts 118 8 5 Identify and correct alarm indications 119 8 6 Heater not open but unable to reach 1357 F 736 C setpoint 145 8 7 Calibration passes but still reads incorrectly 146 Chapter 9 Maintenance and service 149 9 1 Overview 149 9 ...

Page 7: ...European Directive information 189 E 2 Ordinary location certification 189 E 3 Installing equipment in North America 189 E 4 Rosemount OXT4A Oxymitter for general purpose locations and OXT4C hazardous locations certification 189 E 5 Rosemount Xi X Stream Xi Remote Interface for general locations certification 191 Appendix F Declaration of Conformity 193 Appendix G China RoHS table 197 Reference Ma...

Page 8: ...Contents Reference Manual October 2019 00809 0100 4340 viii Emerson com Rosemount ...

Page 9: ...he approval label The general purpose version does not If you received the general purpose version ensure you do not install it in a potentially explosive atmosphere Also use Table 1 1 through Table 1 4 to compare your order number against your unit The title of the table defines the model The rest of the table defines the various options and features of the Rosemount Oxymitter 4000 Ensure the fea...

Page 10: ... Autocalibration Sequencer optional safe area only E HART Communicator package optional F Mounting plate with mounting hardware and gasket G Rosemount Oxymitter 4000 with remote electronics optional H Reference air set used if Rosemount SPS 4001B without reference air option or Rosemount IMPS 4000 is not supplied Description and specifications Reference Manual October 2019 00809 0100 4340 10 Emers...

Page 11: ...ing plate with Model 218 shield removed 3 Adapter plate required must reference adapter plate part number Code Mounting adapter probe side 0 No adapter plate 1 Probe only ANSI 4 Probe only DIN Code Electronic housing filtered customer termination NEMA 4X IP66 12 HART integral electronics transient protected filtered termination ATEX certification 14 HART remote electronics requires cable transient...

Page 12: ...0 ft 45 m cable 16 200 ft 61 m cable 1 Membrane keypad only Note 1 Recommended uses High velocity particulates in flue stream installation within 11 5 ft 3 5 m of soot blowers or heavy salt cake buildup Applications pulverized coal recovery boilers or lime kiln 2 Where possible specify ANSI or DIN designation otherwise provide details of existing mounting plate as follows Plate with studs Bolt cir...

Page 13: ...er diffusion element ANSI 44 V heater C Ceramic diffusion element probe DIN 44 V heater D Snubber diffusion element DIN 44 V heater Code Probe assembly 0 18 in 457 mm probe 3 3 ft 0 91 m probe 5 6 ft 1 83 m probe Code Mounting adapter stack side 0 No adapter plate 1 Probe only ANSI 4 Probe only DIN Code Electronic housing filter customer termination NEMA 4X IP66 12 Transient protected filtered ter...

Page 14: ...probe Code Mounting adapter stack side 0 No adapter plate 0 must be chosen under Mounting adapter probe side below 1 New installation square weld plate with studs 2 Model 218 mounting plate with Model 218 shield removed 3 Adapter plate required must reference adapter plate part number Code Mounting adapter probe side 0 No adapter plate 1 Probe only ANSI 4 Probe only DIN Code Electronics housing fi...

Page 15: ...lator Code Electronics to probe cable 00 No cable integral electronics or reusing existing cable 10 20 ft 6 m cable 11 40 ft 12 m cable 12 60 ft 18 m cable 13 80 ft 24 m cable 14 100 ft 30 m cable 15 150 ft 45 m cable 16 200 ft 60 m cable Table 1 4 Rosemount OXT4CDRNF Oxymitter 4000 In Situ Oxygen Transmitter DR Probe Optional Rosemount Xi Electronics Safe Area Only Code Sensing probe type without...

Page 16: ...te 1 Probe only ANSI 4 Probe only DIN Code Electronics housing and filtered customer termination NEMA 4X IP66 12 Transient protected filtered termination Code Arrangement 03 No hardware For use with 218 analog electronics world class IFT electronics or Rosemount Oxymitter electronics Xi electronics 04 1A Digital 07 1A Model 132 digital 08 Yokogawa Electronics 09 Other competitive electronics speci...

Page 17: ...IMPS with 220 V heater 3 probes 3D39695G12 IMPS with 220 V heater 4 probes 1 2 Overview A typical Rosemount Oxymitter 4000 should contain the items shown in Figure 1 1 Record the part number serial number and order number of each component of your system The transmitter comes with the following Signal conditioning electronics that output a 4 20 mA signal representing an O2 value A membrane keypad ...

Page 18: ...tion Therefore the output signal increases as the oxygen concentration of the sample gas decreases This characteristic enables the transmitter to provide exceptional sensitivity at low oxygen concentrations The transmitter measures net oxygen concentration in the presence of all the products of combustion including water vapor Therefore it may be considered an analysis on a wet basis In comparison...

Page 19: ...semount IMPS 4000 Intelligent Multiprobe Test Gas Sequencer The Rosemount IMPS 4000 provides automatic calibration gas sequencing for up to four Rosemount Oxymitter 4000 units and accommodates autocailibrations based on the CALIBRATION RECOMMENDED signal from the transmitter a timed interval set up in HART or the Rosemount IMPS 4000 or whenever a calibration request is initiated For systems with o...

Page 20: ...d The membrane keypad and HART communications are standard Figure 1 3 Membrane Keypad WARNING Accessing the probe keypad requires opening the electronics housing Opening the electronics housing will cause the loss of all hazardous permits Opening the electronics housing in hazardous areas may cause an explosion resulting in loss of property severe personal injury or death You may need to get a hot...

Page 21: ...option is not protected by energy limiting barriers Do not interface with the HART option from within the hazardous area Route the 4 20 mA cables and make the connections outside the hazardous area This is the case even when using the intrinsically safe version of the handheld communicator You can access HART information through the following Handheld communicator Requires device description DD so...

Page 22: ...eat each component of the system with care to avoid physical damage After verifying that you have all the components select mounting locations and determine how each component will be placed in terms of available line voltage ambient temperatures environmental considerations convenience and serviceability WARNING The HART option is not protected by energy limiting barriers Do not interface with th...

Page 23: ...ral electronics B 4 20 mA output twisted pairs C HART handheld interface D Asset Management Solutions E Termination in control room F Line voltage G Two calibration gas lines by customer 300 ft 90 m maximum Reference Manual Description and specifications 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 23 ...

Page 24: ...rument air supply reference air C Pressure regulator D Calibration gas E Flow meter F 4 to 20 mA signal G Logic I O H Line voltage I Rosemount Oxymitter 4000 J Stack K Gases L Duct Description and specifications Reference Manual October 2019 00809 0100 4340 24 Emerson com Rosemount ...

Page 25: ...ral Electronics A Duct B Calibration gas C Rosemount IMPS 4000 D Reference air E Logic I O F 4 to 20 mA signal G Line voltage H Rosemount Oxymitter 4000 I Adapter plate J Stack K Gases Reference Manual Description and specifications 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 25 ...

Page 26: ... gas C Rosemount SPS 4001B D Reference air E Logic I O F 4 to 20 mA signal G Line voltage H Rosemount Oxymitter 4000 I Adapter plate J Stack K Gases WARNING Install the Rosemount IMPS 4000 and SPS 4001B in a non hazardous explosive free environment Description and specifications Reference Manual October 2019 00809 0100 4340 26 Emerson com Rosemount ...

Page 27: ... air supply reference air D Pressure regulator E Flow meter F Calibration gas G Line voltage H 4 to 20 mA signal I Logic I O J Remote electronics K Rosemount Oxymitter 4000 L Stack M Gases Reference Manual Description and specifications 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 27 ...

Page 28: ... Duct B Calibration gas C Reference air D Rosemount IMPS 4000 E Line voltage F 4 to 20 mA signal G Logic I O H Line voltage I Remote electronics J Rosemount Oxymitter 4000 K Adapter plate L Stack M Gases Description and specifications Reference Manual October 2019 00809 0100 4340 28 Emerson com Rosemount ...

Page 29: ...eck valve next to the calibration fittings on the integral electronics The check valve is to prevent breathing of the calibration gas and subsequent flue gas condensation and corrosion The check valve is in addition to the stop valve in the calibration gas kit and solenoid valves in the Rosemount IMPS 4000 or SPS 4001B Note The integral electronics is rated NEMA 4X IP66 and is capable of operation...

Page 30: ...ent For further information refer to the Rosemount SPS 4001B Single Probe Autocalibration Sequencer Reference Manual 1 9 Rosemount 751 remote powered loop LCD display The optional Rosemount 751 remote mounted LCD display panel is loop driven by the 4 20 mA output signal representing the O2 percentage The display provides a simple economical means to obtain accurate reliable and remote indication o...

Page 31: ...ame Arrestor Ceramic Diffusion Assembly Flame arrestor snubber diffusion assembly The snubber diffusion assembly is satisfactory for most applications This element is also available with a dust seal for use with an abrasive shield Figure 1 14 Flame Arrestor Snubber Diffusion Assembly 1 10 2 Abrasive shield assembly The abrasive shield assembly is a stainless steel tube that surrounds the probe ass...

Page 32: ...eld on both sides with expanding chill block E On inside Ø break for smooth rounded edge on both ends of chamber F Skin cut face for 90 G Ø 0 75 in 19 mm through four places equally spaced on Ø 4 75 in 120 65 mm B C Note In highly abrasive applications rotate the shield 90 degrees at normal service intervals to present a new wear surface to the abrasive flow stream Description and specifications R...

Page 33: ... conditions 0 75 of reading or 0 05 of O2 whichever is greater Process temperature effect on repeatability Less than 05 O2 from 212 to 1292 F 100 to 700 C Lowest detectable limit 0 02 O2 System speed of response to calibration gas Tintial 3 seconds T90 8 seconds Response to process gas changes will vary depending on process gas velocity and particulate loading of the diffuser Calibration Manual se...

Page 34: ...e 1 11 2 Electrical specifications Rosemount Oxymitter power requirements and consumption Probe heater electrical power 100 to 240 V 10 50 60 Hz Power consumption of probe heater 776 VA maximum during warm up Electrical power of Rosemount Oxymitter or optional Xi electronics 120 to 240 V 10 50 60 Hz Power consumption of Rosemount Xi 10 watts maximum Transmitter electrical power 12 to 42 Vdc loop p...

Page 35: ...using integral to probe or remote mounted Low copper aluminum IP66 NEMA 4X with reference air exhaust port piped to clean area Optional Rosemount Xi Electronics NEMA 4X polycarbonite material Process connections 2 in 150 4 75 in 121 mm bolt circle DIN 5 71 in 145 mm bolt circle Note Flanges are flat faced and for mounting only Flanges are not pressure rated Spool piece part numbers are available t...

Page 36: ... 457 mm 16 lb 7 3 kg 3 ft 0 91 m 21 lb 9 5 kg 6 ft 1 83 m 27 lb 12 2 kg 9 ft 2 74 m 33 lb 15 0 kg 12 ft 3 66 m 39 lb 17 7 kg 15 ft 4 57 m 45 lb 20 5 kg 18 ft 5 49 m 51 lb 23 kg Description and specifications Reference Manual October 2019 00809 0100 4340 36 Emerson com Rosemount ...

Page 37: ...be considered a potential source if an explosive gas mixture is present All cable entry devices and blanking elements for unused apertures must be certified flameproof and suitable for conditions of use They must also be properly installed Do not open when an explosive atmosphere may be present Do not open while energized Process temperature at mounting flange location shall not exceed 239 F 115 C...

Page 38: ...abrasive applications rotate the shield 90 degrees at normal service intervals to present a new wear surface to the abrasive flow stream 2 Check the flue or stack holes for air leakage Make any necessary repairs or install the transmitter upstream of any leakage Holes and leakage substantially affect the accuracy of the oxygen reading 3 Ensure that the area is clear of internal and external obstru...

Page 39: ...e if exposed to ambient weather conditions E Certification approved label F External earth G Internal earth H Electrical connection NPT I See Table 2 1 J Cover removal and access K Bottom view L Vent reference air M See Table 2 2 Table 2 1 Calibration Gas and Reference Air Calibration gas Reference air ANSI 6 34 tube DIN 6 35 tube Table 2 2 Mounting Flange Gasket Included ANSI DIN Flange diameter ...

Page 40: ...71 4 holes equally spaced on BC 152 4 6 00 170 6 69 Figure 2 2 Remote Electronics with Membrane Keypad and Blind Cover Note All dimensions are in millimeters with inches in parentheses A Pipe mount configuration Install Reference Manual October 2019 00809 0100 4340 40 Emerson com Rosemount ...

Page 41: ...Figure 2 3 Remote Electronics with LOI and Window Cover Wall Mount Configuration Reference Manual Install 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 41 ...

Page 42: ...ector assembly E Diffuser dust seal assembly F 91 3 6 diameter nominal G NPT electrical connection Table 2 3 Installation Removal Probe Dimension A Dimension B 18 in 387 15 3 912 35 9 3 ft 842 33 2 1367 53 8 6 ft 1762 69 4 2287 90 0 Table 2 4 Abrasive Shield 3D390003 Flange ANSI DIN Flange diameter 229 9 0 235 9 25 Hole diameter 19 0 75 24 0 94 8 holes equally spaced on BC 191 7 50 190 7 48 Ref ai...

Page 43: ...t numbers for adapter plates include attaching hardware Dimensions mm in ANSI PN 4512C34G01 DIN PN 4512C36G01 JIS PN 451235G01 A 153 6 00 191 7 5 165 5 50 B thread 0 625 11 M 16 x 2 M 12 x 1 75 C diameter 121 4 75 145 5 708 130 4 118 Table 2 6 Mounting Plate Dimensions for Rosemount Oxymitter 4000 Dimensions in mm in ANSI DIN A 197 7 75 216 8 5 B stud size 0 625 11 M16 x 2 C diameter B C 142 4 6 0...

Page 44: ... field bolting of plate to outside wall service E Eight threaded holes equally spaced on D diameter B C F Abrasive shield flange O D Table 2 7 Adapter Plate Dimensions for Rosemount Oxymitter 4000 with Abrasive Shield Dimensions in in mm ANSI PN 3536B58G02 DIN PN 3535B58G08 A 9 0 229 9 25 235 B diameter 4 75 121 3 94 100 C thread 0 625 11 M 16 x 2 D diameter B C 7 50 191 7 48 190 Install Reference...

Page 45: ...nry stack work and joints except adapter are not furnished by Emerson A Minimum diameter hold in wall B Stack or duct metal wall C Weld or bolt mounting plate to metal wall of stack or duct joint must be airtight D Mounting holes shown rotated 45 out of true position Reference Manual Install 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 45 ...

Page 46: ...e 101 6 mm 4 00 in in sched 40 pipe sleeve not by Emerson length by customer B Masonry stack wall C Outside wall surface D Joint must be airtight E Mounting holes shown rotated 45 out of true position F Field weld pipe to mounting plate G Bolt mounting plate to outside wall surface Install Reference Manual October 2019 00809 0100 4340 46 Emerson com Rosemount ...

Page 47: ...nt must be airtight Figure 2 10 Probe Mounting for Masonry Wall Stack Construction A Field weld pipe to mounting plate B Pipe 88 9 mm 3 5 in sched 40 pipe sleeve not by Emerson length by customer C Masonry stack wall D Outside wall surface E Joint must be airtight F Bolt mounting plate to outside wall surface Reference Manual Install 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 47 ...

Page 48: ...h as those in coal fired boilers kilns and recovery boilers Procedure 1 Weld or bolt mounting plate onto the duct 2 If using the optional ceramic diffusion element make sure to correctly orient the vee deflector Before inserting the transmitter check the direction of the flow of gas in the duct Orient the vee deflector so the apex points upstream towards the flow a Loosen the setscrews b Rotate th...

Page 49: ...0 C For higher ambient temperatures Emerson recommends the remote mounted electronics option 3 In vertical installations ensure the system cable drops vertically from the transmitter and the conduit is routed below the level of the electronics housing This drip loop minimizes the possibility that moisture will damage the electronics Reference Manual Install 00809 0100 4340 October 2019 Rosemount O...

Page 50: ... that the gaskets are in the hub grooves as the transmitter slides into the 15 degree forcing cone in the abrasive shield Note If process temperatures will exceed 392 F 200 C use anti seize compound on the stud threads to ease future removal of the transmitter 5 Insert probe through the opening in the mounting plate and bolt the unit to the plate Note To maintain CE compliance ensure a good connec...

Page 51: ...warnings on the housing covers 2 1 3 Install remote electronics For a Rosemount Oxymitter 4000 with the remote electronics option install the probe according to the instructions in Install probe Install the remote electronics unit on a wall stand pipe or similar structure see Figure 2 2 and Figure 2 13 Figure 2 13 Remote Electronics Mounting 2 2 Electrical installation with integral electronics Al...

Page 52: ...ernal means of disconnecting the power supply close by Circuit breakers or switches must comply with a recognized standard such as IEC 60947 WARNING The instrument is heavy Use proper lifting and carrying procedures to avoid personal injury WARNING To maintain explosion proof protection all cable entry devices and blanking elements for unused apertures must be certified flameproof and suitable for...

Page 53: ...24 Gasket 1A Window cover 13 Lock washer 25 Corrugated seal 2 Electronic assembly 1 14 Cable clamp 26 Cell and flange assembly 3 Screw 15 Terminal block 27 Retainer screw 4 Membrane keypad 16 Captive screw 28 Flame arrestor with snubber diffuser Reference Manual Install 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 53 ...

Page 54: ... 35 Strut pressure clamp 11 Housing 23 Probe tube assembly 1 The electronic assembly Item 2 consists of items 3 through 10 2 Connect the line or L1 wire to the L1 terminal and the neutral or L2 wire to the N terminal Figure 2 15 Integral Electronics without Rosemount SPS 4001B A 4 20 mA signal B Calibration handshake logic I O C Line voltage D Terminal block E Ground lugs F 90 250 Vac 50 60 Hz lin...

Page 55: ...0 Vac 50 60 Hz line voltage input B Calibration handshake Refer to Rosemount IMPS 4000 Reference Manual The transmitter will automatically configure itself for 90 to 250 Vac line voltage and 50 60 Hz WARNING Electrical shock Install the power terminal cover AC wiring should be rated for 240 Vac and be at least 14 gauge or greater 3 Connect 4 20 mA signal and calibration handshake logic I O leads R...

Page 56: ...le 2 8 Diagnostic LEDs LED Flashes Status 4 20 mA line Fault Recoverable Heater C T 1 Open Dependent on position 3 of SW2 1 1 No 2 Shortened Dependent on position 3 of SW2 1 2 No 3 Reversed Dependent on position 3 of SW2 1 3 No 4 A D Comm Error Dependent on position 3 of SW2 1 4 No Heater 1 Open Dependent on position 3 of SW2 1 5 No 2 High High Temp Dependent on position 3 of SW2 1 6 No 3 High Cas...

Page 57: ...O2 4 The unit is configured for a High AC Impedance CALIBRATION RECOMMENDED 5 1 The unit is configured for both a Unit alarm and a High AC Impedance CALIBRATION RECOMMENDED 6 The unit is configured for both a Low O2 and High AC Impedance CALIBRATION RECOMMENDED 7 The unit is configured for a Unit alarm a low O2 and a High AC Impedance CALIBRATION RECOMMENDED 8 2 The unit is configured for a calibr...

Page 58: ... power supply through a circuit breaker minimum 10 A which will disconnect all current carrying conductors during a fault situation This circuit breaker should also include a mechanically operated isolating switch If there is no switch locate another external means of disconnecting the supply from the equipment close by Circuit breakers or switches must comply with a recognized standard such as IE...

Page 59: ...al and the neutral or L2 wire to the N terminal The transmitter will automatically configure itself for 90 250 Vac line voltage and 50 60 Hz WARNING Electrical shock Install the power terminal cover Figure 2 18 Electrical Installation Rosemount Hazardous Area Oxymitter 4000 with Remote Electronics Reference Manual Install 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 59 ...

Page 60: ... Note Refer to Figure 2 14 for component parts of probe 3 Connect 4 20 mA signal and calibration handshake logic I O leads 2 3 2 4 20 mA signal The 4 20 mA signal represents the O2 value and can also operate the Rosemount 751 Loop LCD Display or any other loop powered display Superimposed on the 4 20 mA signal is HART information that is accessible through a handhedl communicator or AMS software 2...

Page 61: ...he voltage from heater power supply and analog electronics if used before changing jumpers Line voltage selection Jumper install 100 120 Vac 1 JM4 JM1 220 240 Vac JM5 1 100 Vac operation requires transformer part number 1M02961G02 Heater power Jumper Remote Remove JM2 On Install JM2 Probe heater voltage selection Jumper install Rosemount World Class probe 44 V JM7 218 probe 115 V JM8 Rosemount Dir...

Page 62: ...Rosemount Oxymitter DR Probe to work with the Yokogawa ZA8C and AV8C Converters Connect the cabling from the Yokogawa ZA8C or AV8C terminal to the probe terminal in the junction box as shown below Install Reference Manual October 2019 00809 0100 4340 62 Emerson com Rosemount ...

Page 63: ...an error because the probe has not reached temperature setup in the normal time Remove power from the Yokogawa Electronics or probe module to clear the error and restore power You may have to do this a couple of times before the transmitter reaches the operating temperature A ZA8C or AV8C terminal B Cell C Thermocouple D Cold junction E Ground shield F ZA8C or AV8c G Probe heater H ZA8C or AV8C co...

Page 64: ...tance An interposing relay is required if the logic contact will annunciate a higher voltage device such as a light or horn An interposing relay may also be required for certain DCS input cards A Potter Brumfield model R10S E1Y1 OK 3 2 mA DC or equal interposing relay will be mounted where the contact wires terminate in the control relay room Install cover Figure 2 14 and secure with captive washe...

Page 65: ... WARNING Electrical shock Install the heater power terminal cover 4 Install covers and secure with captive washers cover locks and screws 2 4 Pneumatic installation 2 4 1 Reference air package After the Rosemount Oxymitter 4000 is installed connect the reference air set to the transmitter Refer to Figure 2 20 Reference Manual Install 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 65 ...

Page 66: ...2 0 312 diameter through bolts F Drain valve G Outlet H 0 125 27 NPT outlet I Flow set point knob Table 2 10 Replacement Parts 1 Flow meter 0 006 0 057 scmh 0 1 2 0 scfh 771B635H02 2 Pressure gage 0 103 kPa gage 0 15 psig 275431 006 3 Combination filter regulator 0 207 kPa gage 0 30 psig 4505C21G01 Instrument air reference air 68 95 kPa gage 10 psig minimum 1551 38 kPa gage 225 psig maximum at 0 2...

Page 67: ... for the low zero be between 0 4 percent and 2 0 percent O2 Do not use gases with hydrocarbon concentrations of more than 40 parts per million Use two calibration gas concentrations with the transmitter low gas 0 4 percent O2 and high gas 8 percent O2 See Figure 2 21 for connections WARNING If using a Rosemount IMPS 4000 or SPS 4001B install it in a non hazardous explosive free environment Referen...

Page 68: ...nt SPS 4001B Single Probe Autocalibration Sequencer Reference Manual CAUTION Upon completing installation ensure that the Rosemount Oxymitter 4000 is turned on and operating prior to firing up the combustion process Damage can result from having a cold Rosemount Oxymitter 4000 exposed to the process gases During outages if possible leave all Rosemount Oxymitter 4000 units running to prevent conden...

Page 69: ... to get a hot work permit from your company safety officer before you open the housing 3 3 Wire terminal block See Figure 2 14 or Figure 2 18 Procedure 1 Remove screw cover lock and captive washer that secure cover on left side of housing Remove the cover 2 Check the terminal block wiring Be sure the 4 20 mA signal and the logic outputs are properly connected and secure For units with remote elect...

Page 70: ...roprocessor board the top board are two switches that configure outputs for the transmitter WARNING The HART option is not protected by energy limiting barriers Do not interface with the HART option from within the hazardous area Route the 4 20 mA cables and make the connections outside the hazardous area This is the case even when using the intrinsically safe version of the handheld communicator ...

Page 71: ...t SW1 determines if the 4 20 mA signal is internally or externally powered SW2 determines Transmitter status HART or LOCAL Oxygen range 0 to 10 O2 or 0 to 25 O2 0 to 40 O2 is also configurable only through HART AMS 4 20 mA signal at fault or power up 3 5 mA or 21 6 mA Reference Manual Configure transmitter with membrane keypad 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 71 ...

Page 72: ...O2 range from 0 to 40 percent O2 To select values within this range set SW2 position 1 to HART and then enter the range via HART AMS Do not change SW2 position 1 to LOCAL unless you want to operate in the range specified by SW2 position 2 WARNING Typically the probe s sensing cell in direct contact with the process gases is heated to approximately 1357 F 736 C The external temperature of the probe...

Page 73: ...nsically safe version of the handheld communicator 3 Rosemount 751 the loop driven LCD display 3 5 Logic I O You can configure the two terminal logic contact either as a solid state relay activated alarm or as a bi directional calibration handshake signal to a Rosemount IMPS 4000 or SPS 4001B The configuration of this signal depends on the setting of the Logic I O PIN MODE via HART AMS or LOI The ...

Page 74: ...lways accurate and eliminates many unnecessary calibrations based on calendar days or weeks since previous calibration When using the Rosemount SPS 4001B or IMPS 4000 consider wiring some or all associated alarm contacts 1 CALIBRATION INITIATE Contact from the control room to a Rosemount SPS4001B or IMPS 4000 one per probe provides the ability to manually initiate a calibration at any time from th...

Page 75: ... be useful if several probes are being averaged for the purpose of automatic control Unless you are averaging several probes always place control loops that are using the O2 signal into the Manual mode prior to starting the calibration Reference Manual Configure transmitter with membrane keypad 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 75 ...

Page 76: ...Configure transmitter with membrane keypad Reference Manual October 2019 00809 0100 4340 76 Emerson com Rosemount ...

Page 77: ... permit from your company safety officer before you open the housing 4 3 Wire terminal block See Figure 2 14 or Figure 2 18 Procedure 1 Remove screw cover lock and captive washer that secure cover on left side of housing Remove the cover to expose the terminal block 2 Check the terminal block wiring Be sure the power 4 20 mA signal and the logic outputs are properly connected and secure For units ...

Page 78: ...electronics housing B LOI C Terminal block D Ground lugs E Logic I O F 4 20 mA signal 3 Install the cover over terminal block and secure with captive washer cover lock and screw Configure transmitter with LOI Reference Manual October 2019 00809 0100 4340 78 Emerson com Rosemount ...

Page 79: ...semount Hazardous Area Oxymitter 4000 with LOI Note The 115 V option at switch SW2 position 4 is active only when the heater voltage option is set to manual in the software A 4 20 mA is internally powered default B 4 20 mA requires external power C Default position ex factory Reference Manual Configure transmitter with LOI 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 79 ...

Page 80: ...al The factory setting is to internally power the 4 20 mA signal 4 4 2 SW2 setting The factory sets this switch as follows 1 Position 1 is HART LOCAL This switch setting controls the configuration of the transmitter The defaults cannot be changed via HART AMS or the LOI unless the switch is in the HART position Placing SW2 position 1 in the LOCAL position forces the O2 range to the setting of posi...

Page 81: ...ture you can read the O2 percentage Procedure 1 To access TP5 and TP6 under the LOI module Figure 4 2 power down the transmitter and remove the LOI module 2 Attach alligator leads from a multimeter across TP5 and TP6 3 Install the LOI module and power up the transmitter Allow time for the cell to reach operating temperature You can now monitor the calibration and process gases When you have initia...

Page 82: ...or calibration handshaking Of the 10 modes in Table 2 9 only modes 8 and 9 are configured for calibration handshaking For a transmitter with a Rosemount IMPS 4000 or an SPS 4001B the factory sets the default to mode 8 In this mode the logic I O is used to communicate between the transmitter and the sequencer 4 6 Recommended configuration 4 6 1 4 20 mA signal on critical alarm Emerson recommends us...

Page 83: ...s being used in an automatic control loop use this contact to place the control loop into Manual during calibration 3 CALIBRATION FAILED One contact per probe from a Rosemount SPS 4001B or IMPS 4000 to the control room for notification that the calibration procedure has failed A pressure switch which indicates when the calibration gas bottles are empty is grouped with this alarm 4 4 20 mA SIGNAL D...

Page 84: ...Configure transmitter with LOI Reference Manual October 2019 00809 0100 4340 84 Emerson com Rosemount ...

Page 85: ...ION LED the LEDS light in ascending order until all four LEDs are on At this point all four turn off and the cycle starts again This ramp cycle continues until the cell is up to operating temperature 5 1 2 Operating display The ramp cycle turns into a cycle where the diagnostic LEDs light in sequence from the top to the bottom one at a time After the bottom LED turns on the sequence starts again a...

Page 86: ...g normal operation operating display 5 1 3 Error If there is an error condition at start up one of the diagnostics LEDs will be blinking Refer to Troubleshoot to determine the cause of the error Clear the error and cycle power the operating display should return Start up and operate transmitter with membrane keypad Reference Manual October 2019 00809 0100 4340 86 Emerson com Rosemount ...

Page 87: ...mbrane keyapd to adjust the high and low gas and to initiate the calibration sequence Figure 5 2 Calibration Keys A Diagnostic LEDs B Membrane keys Reference Manual Start up and operate transmitter with membrane keypad 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 87 ...

Page 88: ... Calibration LED 5 2 1 Diagnostic alarm LEDs If there is an error in the system one of these LEDs will flash various blink codes In the case of multiple errors only one LED will flash based on a priority system Correct the problem and cycle power The operating display will return to normal or the next error will be displayed The alarms are HEATER T C HEATER O2 CELL CALIBRATION Start up and operate...

Page 89: ...P3 and TP4 monitor the heater thermocouple TP5 and TP6 monitor the process gas or the calibration gas procedures Figure 5 4 Test Points 5 2 4 Cal LED The Cal LED is on steady or flashing during calibration Keys Use the INC and DEC keys to set the values of the calibration gases Attach a multimeter across TP5 and TP6 You can now monitor the calibration and process gases Press the INC or DEC once to...

Page 90: ...as seen on the multimeter are 8 0 O2 8 0 Vdc 0 4 O2 0 4 Vdc 5 2 5 Cal The Cal key can Initiate a calibration Sequence through calibration Abort the calibration Keys Refer to the Remote Powered Loop LCD Reference Manual for calibration and operation Start up and operate transmitter with membrane keypad Reference Manual October 2019 00809 0100 4340 90 Emerson com Rosemount ...

Page 91: ...perature This condition is indicated by a Warm up display on the LOI The message will continue to display until the cell is up to operating temperature Figure 6 1 Start up Display 6 1 2 Operating display The normal operating display is the O2 concentration The normal display is shown in Figure 6 2 Reference Manual Start up and operate transmitter with LOI 00809 0100 4340 October 2019 Rosemount Oxy...

Page 92: ...the cause of the error Clear the error and cycle the power the O2 display should return 6 1 4 LOI You can use the local operator interface to adjust the high and low gas settings and to initiate the calibration sequence Refer to Figure 6 3 Start up and operate transmitter with LOI Reference Manual October 2019 00809 0100 4340 92 Emerson com Rosemount ...

Page 93: ...Figure 6 3 Local Operator Interface Menu Tree Reference Manual Start up and operate transmitter with LOI 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 93 ...

Page 94: ...Start up and operate transmitter with LOI Reference Manual October 2019 00809 0100 4340 94 Emerson com Rosemount ...

Page 95: ...play There is an infrared LED source and a detector for each key The detectors can detect a finger placed above the button through the glass window There is no need to open the instrument in bad weather or in hazardous areas in order to access the electronics The transmitter also uses HART communications permitting access to all instrument functionality anywhere the 4 20 mA signal terminates via a...

Page 96: ...ons to occur Always clean the dust and soil away from the LOI screen each time you use the LOI 6 3 LOI key designations The gray key top left moves one level higher in the menu structure When entering numbers this key moves the cursor to the left This key also doubles as an Enter key once numbers are entered and when the cursor is moved to its leftmost position The new data entry value appears in ...

Page 97: ...e Z pattern touch command to unlock menu B For this menu column the selections in italics are user configurable All other parameters are display only Reference Manual Start up and operate transmitter with LOI 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 97 ...

Page 98: ... Setup menu SYSTEM Calibration Setup O2 Gas 1 Enter the high or low cal gas value the order is not important O2 Gas 2 Enter the second cal gas value Note See Maintenance and service for calibration instructions Note Emerson recommends 0 4 O2 and 8 O2 for calibration gases Start up and operate transmitter with LOI Reference Manual October 2019 00809 0100 4340 98 Emerson com Rosemount ...

Page 99: ...g O2 O2 Type 4 20 mA signal may be configured to increase with increasing O2 or the reverse O2 Range Upper O2 range is user selectable O2 Alarm Level Operator can configure the digital output to alarm at a given O2 level Do O2 Trim Procedure for calibrating the 4 20 mA signal to a precision mA source Procedure is intuitive Digital The operator may configure a bi directional logic signal as an alar...

Page 100: ... the normal process reading and the 4 20 mA signal can be released Luminance Gas fluorescence brightness is user adjustable 6 7 SYSTEM Status Alarms Diagnostic alarms See Troubleshoot PID Parameter Displays the line voltage powering the transmitter and infers the temperature control algorithm used to control heater temperature Reset Device The operator can reset the device here as opposed to re po...

Page 101: ...6 9 Test points Test points 1 through 6 allow you to monitor the following with a multimeter the heater thermocouple the O2 cell millivolt value and the process O2 TP1 and TP2 monitor the oxygen cell millivolt output which equates to the percentage of oxygen present TP3 and TP4 monitor the heater thermocouple TP5 and TP6 monitor the process gas or the calibration gas procedures Reference Manual St...

Page 102: ... Remote powered loop LCD display optional Refer to the Remote Powered Loop LCD manual for calibration and operation Start up and operate transmitter with LOI Reference Manual October 2019 00809 0100 4340 102 Emerson com Rosemount ...

Page 103: ...HART Communicator accomplishes its task using a frequency shift keying FSK technique With FSK high frequency digital signals are superimposed on the transmitter s 4 20 mA current loop The HART Communicator does not disturb the 4 20 mA signal since no net energy is added to the loop You can interface to the HART Communicator with a personal computer PC after installing the special software To conne...

Page 104: ... WARNING Explosions Explosions can result in death or serious injury Do not make connections to the HART Communicator s serial port 4 20 mV signal line or NICad recharger jack in an explosive atmosphere A 4 20 mA signal line B Analog output device C Lead set D HART Communicator E HART Communicator rear panel F Loop connectors G Terminal block HART AMS Reference Manual October 2019 00809 0100 4340 ...

Page 105: ...nce 250 ohms Refer to the following steps to connect the HART Communicator to a signal line with 250 ohms of load resistance WARNING Explosions Explosions could result in death or serious injury Do not make connections to the HART Communicator s serial port 4 20 mV signal line or NiCad recharger jack in an explosive atmosphere Reference Manual HART AMS 00809 0100 4340 October 2019 Rosemount Oxymit...

Page 106: ...G Terminal block Procedure 1 At a convenient point break the analog output 4 20 mA line signal and install the optional 250 ohm load resistor 2 Plug the load resistor into the loop connectors located on the rear panel of the HART Communicator 1 The signal loop must be broken to insert the optional 250 ohm load resistor HART AMS Reference Manual October 2019 00809 0100 4340 106 Emerson com Rosemoun...

Page 107: ...stor Note If the HART Communicator is turned on while connected to the 4 20 mA analog output signal line an undefined status indicator appears while the communicator warms up Wait until the warming period ends The opening menu displayed on the LCD is different for on line and off line operations When powering up a disconnected off line communicator the LCD will display the Main Menu When powering ...

Page 108: ...B Calibration recommended will initiate the calibration cycle 9 The unit is configured for a calibration handshake Calibration recommended will not intiate the calibration cycle with the Rosemount IMPS 4000 or SPS 4001B 1 The default condition for a Rosemount Hazardous Area Oxymitter 4000 without a Rosemount IMPS 4000 or SPS 4001B 2 The default condition for a Rosemount Hazardous Area Oxymitter 40...

Page 109: ...menu tree This menu tree is specific to the Rosemount Hazardous Area Oxymitter 4000 applications Figure 7 3 HART AMS Menu Tree Reference Manual HART AMS 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 109 ...

Page 110: ...HART AMS Reference Manual October 2019 00809 0100 4340 110 Emerson com Rosemount ...

Page 111: ...e 7 3 for reference Note To select a menu item either use the Up or Down arrow keys to scroll to the menu item and press the Right arrow key or use the number keypad to select the menu item number To return to a preceding menu press the Left arrow key Reference Manual HART AMS 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 111 ...

Page 112: ...S CAL STATE TIME REMAIN PRESENT O2 6 When CALSTATE displays APPLY GAS 2 return to the O2 calibration procedure 7 When the Loop should be removed from automatic control warning appears press OK 8 At the APPLY GAS 2 status prompt select menu item 2 NEXT CAL STEP 9 When the status displays GAS 2 FLOW select menu item 4 EXIT to leave the O2 calibration procedure 10 To monitor the transmitter s calibra...

Page 113: ...u item 6 CAL MODE Set the CAL MODE to AUTO 4 Return to the O2 CALIBRATION screen and select menu item 7 CAL INTRVL 5 At the prompt input a time interval in hours at which you want the automatic calibration to occur then press ENTER 7 9 D A trim Use the D A trim procedure to calibrate the 4 20 mA output signal to a precision mA measurement device such as a calibrated digital ammeter The procedure i...

Page 114: ...HART AMS Reference Manual October 2019 00809 0100 4340 114 Emerson com Rosemount ...

Page 115: ...t represents the difference between the process O2 percentage and the reference O2 percentage inside the probe 20 95 percent O2 ambient air Test points Figure 8 1 are provided to read the raw millivolt value generated by the thermocouple that controls both the cell temperature and the raw cell signal Figure 8 1 O2 Sensor mV Readings vs Percent O2 at 1357 F 736 C Reference Air 20 95 Percent O2 Tabl...

Page 116: ...tors to consider when troubleshooting This chapter describes how to identify and isolate faults that may develop in the transmitter When troubleshooting consider the following 8 2 1 Grounding It is essential to take adequate grounding precautions when installing the system Thoroughly check both the probe and electronics to ensure the grounding quality has not degraded during fault finding The syst...

Page 117: ...cted to severe vibration the ICs could work loose Before troubleshooting the system ensure all ICs are fully seated 8 2 4 Electrostatic discharge Electrostatic discharge can damage the ICs used in the electronics Before removing or handling the processor board of the ICs ensure you are at ground potential 8 3 Alarm indications The majority of the fault conditions for the transmitter will be indica...

Page 118: ...000 and is unavailable for alarming purposes The autocalibration systems provide the following additional contacts 8 4 1 Rosemount SPS 4001B and IMPS 4000 1 to 4 probes One contact closure per probe from the control room to the Rosemount SPS 4001B or IMPS 4000 for calibration initiate One contact output per probe from the Rosemount SPS 4001B or IMPS 4000 to the control room for in calibration noti...

Page 119: ...ucouple open 1 No O2 T C Shorted Heater thermocouple shorted 2 No O2 T C Reversed Heater thermocouple polarity reversed 3 No ADC Error A D communications error 4 No O2 Heater Open O2 heater open 5 No Very Hi O2 Temp Very high process temperature 6 No Board Temp Hi Electronics overheated 7 Yes O2 Temp Low Low process temperature 8 Yes O2 Temp Hi High process temperature 9 Yes O2 Cell Open O2 cell o...

Page 120: ...f the reading is 1 2 Vdc 0 1 Vdc the thermocouple is open 3 Remove power Disconnect J1 Measure the resistance across the red and yellow thermocouple leads The resistance should be approximately 1 ohm 4 If the thermocouple is open see Fault 1 LOI When Fault 1 is detected the LOI displays the O2 T C Open message Troubleshoot Reference Manual October 2019 00809 0100 4340 120 Emerson com Rosemount ...

Page 121: ...embrane keypad 8 5 2 Fault 2 Shorted Thermocouple The figure below show the electronic assembly for a transmitter with a membrane keypad and a transmitter with an LOI The transmitter with the membrane keypad also shows J1 and test points TP1 through TP6 located on the microprocessor bard below the membrane keypad on the LOI module Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemoun...

Page 122: ...is likely 2 Remove power and disconnect J1 3 Measure the resistance from TP3 to TP4 The reading should be approximately 20 K ohms If it is the short is not on the PC board The thermocouple wiring or the thermocouple is shorted See Replace heater strut Fault 2 LOI When Fault 2 is detected the LOI displays the O2 T C Shorted message Recommended actions 1 Remove power Unscrew and remove the LOI modul...

Page 123: ...brane keypad or the LOI module Fault 3 membrane keypad When Fault 3 is detected the HEATER T C LED flashes three times pauses for three seconds and repeats Figure 8 6 HEATER T C LED Alarm on Membrane Keypad Recommended actions 1 Using a multimeter measure the voltage from TP3 to TP4 If the reading is negative the thermocouple wiring is reversed 2 Check red and yellow wires in the J1 connector for ...

Page 124: ...the LOI module from the electronic assembly 2 Reconnect power to the transmitter 3 Perform the recommended actions in Fault 3 membrane keypad 8 5 4 Fault 4 A D Comm Error Fault 4 membrane keypad When Fault 4 is detected the HEATER T C LED flashes four times pauses for three seconds and repeats Troubleshoot Reference Manual October 2019 00809 0100 4340 124 Emerson com Rosemount ...

Page 125: ...Membrane Keypad Recommended action Call the factory for assistance Fault 4 LOI When Fault 4 is detected the LOI displays the ADC Error message Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 125 ...

Page 126: ...The figures below show the electronic assembly for the transmitter with a membrane keypad and the transmitter with an LOI Fault 5 membrane keypad When Fault 5 is detected the HEATER LED flashes once pauses for three seconds and repeats Troubleshoot Reference Manual October 2019 00809 0100 4340 126 Emerson com Rosemount ...

Page 127: ...er measure the resistance across the terminals of heater connector J8 The measurement should be approximately 72 ohms If the heater is open see Replace heater strut Fault 5 LOI When Fault 5 is detected the LOI displays the O2 Heater Open message Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 127 ...

Page 128: ...er Temp The figures below show the electronic assembly for a transmitter with a membrane keypad and a transmitter with an LOI Fault 6 membrane keypad When Fault 6 is detected the HEATER LED flashes twice pauses for three seconds and repeats The high high heater temp alarm will activate when the thermocouple produces a voltage of 37 1 mV 1652 F 900 C Troubleshoot Reference Manual October 2019 00809...

Page 129: ...s Restore power 2 If the condition repeats replace the electronic assembly per Replace electronic assembly Fault 6 LOI When Fault 6 is detected the LOI displays the Very Hi O2 Temp message The very high O2 temperature alarm will activate when the thermocouple produces a voltage of 37 1 mV 1652 F 900 C Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 129 ...

Page 130: ...ssembly 8 5 7 Fault 7 High Case Temp The figures below show the electronic assembly for a transmitter with a membrane keypad and a transmitter with an LOI Fault 7 membrane keypad When Fault 7 is detected the HEATER LED flashes three times pauses for three seconds and repeats If the case temperature exceeds 185 F 85 C the temperature control will shut off and the 4 20 mA signal output will go to th...

Page 131: ...to convection is causing case temperature to rise above the limit Recommended actions 1 Place a spool piece between the stack flange and the transmitter flange 2 Relocate the transmitter to a cooler area Fault 7 LOI When Fault 7 is detected the LOI displays the Board Temp Hi message Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 131 ...

Page 132: ...re 8 15 Board Temp Hi Message on LOI A LOI Recommended action Refer to the recommended actions in Fault 7 membrane keypad Troubleshoot Reference Manual October 2019 00809 0100 4340 132 Emerson com Rosemount ...

Page 133: ...ding has dropped below 28 6 mV If the thermocouple reading continues to ramp downward for one minute and does not return to the temperature set point of approximately 29 3 mV than an Open Heater fault will be displayed Recommended actions 1 Power down the electronics Remove the electronic assembly per Replace electronic assembly Using a multimeter measure the resistance across the terminals of hea...

Page 134: ...e produces a voltage in excess of approximately 30 7 mV the high heater temp alarm activates The 4 20 mA signal returns to the default value 4 or 20 mA Figure 8 17 HEATER LED on Membrane Keypad Recommended action This alarm is self clearing When temperature control is restored and the thermocouple voltage returns to the normal range the alarm clears If the temperature continues to rise the next al...

Page 135: ... for three seconds and then repeats Figure 8 18 O2 Cell LED on Membrane Keypad Potential causes The orange or green wire has come loose from the crimped connection in connector J1 Recommended actions 1 Using a multimeter measure across TP1 to TP2 If you measure 104 mV to 1 volt DC the cell reading is due to high combustibles This is a self clearing alarm If you measure 1 2 Vdc the cell wires eithe...

Page 136: ... power Unscrew and remove the LOI module from the electronic assembly 2 Reconnect power to the transmitter 3 Perform the Recommended actions in Fault 10 membrane keypad 8 5 11 Fault 11 Bad Cell Fault 11 membrane keypad When Fault 11 is detected the O2 CELL LED flashes three times pauses for threee seconds and repeats Potential cause The bad cell alarm activates when the cell exceeds the maximum re...

Page 137: ...essage Figure 8 20 O2 Cell Bad Message on LOI Recommended action See the recommended action in Fault 11 membrane keypad 8 5 12 Fault 12 EEprom Corrupt Fault 12 membrane keypad When Fault 12 is detected the O2 CELL LED flashes four times pauses for three seconds and repeats Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 137 ...

Page 138: ...2 Restore power Potential cause If the alarm occurs while the unit is running there is a hardware problem on the microprocessor board Recommended action Replace the electronic assembly See Replace electronic assembly Fault 12 LOI When Fault 12 is detected the LOI displays the EEprom Corrupt message Troubleshoot Reference Manual October 2019 00809 0100 4340 138 Emerson com Rosemount ...

Page 139: ...on Refer to Fault 12 membrane keypad 8 5 13 Fault 13 Invalid Slope Fault 13 keypad When Fault 13 is detected the CALIBRATION LED flashes once pauses for three seconds and repeats Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 139 ...

Page 140: ...rge cycle Recommended actions 1 Ensure the calibration gases match the calibration gas parameters See Replace cell If you attach a multimeter to TP1 and TP2 sample gas measurements are 8 O2 23 mV 0 4 O2 85 mV 2 Power down the transmitter and remove it from the stack 3 Replace the cell per Fault 13 LOI When Fault 13 is detected the LOI displays the O2 Cell Bad message Troubleshoot Reference Manual ...

Page 141: ...ee Fault 13 keypad 8 5 14 Fault 14 Invalid Constant Fault 14 membrane keypad When Fault 14 is detected the CALIBRATION LED flashes twice pauses for three seconds and repeats Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 141 ...

Page 142: ...he alarm activates See Calibrate with keypad and verify the last calibration was performed correctly Recommended actions 1 Power down the transmitter and remove it from the stack 2 Replace the cell per Replace cell Fault 14 LOI When Fault 14 is detected the LOI displays the O2 Cell Bad message Troubleshoot Reference Manual October 2019 00809 0100 4340 142 Emerson com Rosemount ...

Page 143: ... membrane keypad 8 5 15 Fault 15 Last Calibration Failed Fault 15 membrane keypad When Fault 15 is detected the CALIBRATION LED flashes three times pauses for three seconds and repeats Reference Manual Troubleshoot 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 143 ...

Page 144: ...nt values calculated are out of range and the unit reverts to using the previous calibration values Recommended action Replace the cell See Replace cell Fault 15 LOI When Fault 15 is detected the LOI displays the Calib Failed message Troubleshoot Reference Manual October 2019 00809 0100 4340 144 Emerson com Rosemount ...

Page 145: ...ause the transmitter has an Auto Tune function for establishing heater control parameters Probes mounted into processes that operate at above 1112 F 600 C may have a hard time controlling the temperature with the Auto Tune function enabled Recommended actions 1 Go to System Parameters Auto Tune 2 Select No to disable the Auto Tune function Reference Manual Troubleshoot 00809 0100 4340 October 2019...

Page 146: ...lar space between the probe and shield and then into the cell Always install a new probe flange gasket when reinstalling a probe 3 Check calibration gas hoses or tubing for leaks Repair leaks in hose or tubing 4 Check cell flange corrugated seal for leaks Replace seal Potential cause There may be a leak inside the probe itself permitting the reference air 20 95 percent O2 to mix with the process g...

Page 147: ... etc the diffusion element will eventually plug This may cause a calibration shift Recommended actions 1 Do not pressurize the sensing cell during calibrations by flowing excessive cal gas against a plugged diffuser 2 Only set calibration flow rates when a new diffuser is installed 3 As the diffuser plugs do not adjust the flow rates upward Detecting a plugged diffuser When a diffuser is plugged t...

Page 148: ...nstall covers and ground leads could result in serious injury or death Install all protective equipment covers and safety ground leads after installation Procedure 1 Adjust the flow of cal gas downward until the reading begins to migrate from eight percent to lower values indicating that process gases are now mixing with the calibration gases 2 Adjust the flow rate back up until this mixing is jus...

Page 149: ...e aware that the transmitter probe tube and flame arrestor hub can be hot up to 572 F 300 C in the region of the probe heater WARNING Failure to install covers and ground leads could result in serious injury or death Install all protective equipment covers and safety ground leads after installation 9 2 Calibrate Reference Manual Maintenance and service 00809 0100 4340 October 2019 Rosemount Oxymit...

Page 150: ... Calibrate with keypad To calibrate apply two calibration gases with known O2 concentrations to the transmitter The tranamitter calculates slope and constant values from the two calibration gases to determine if it is correctly measuring the net concentration of O2 in the industrial process See Calibration record to track transmitter performance Before calibrating verify that the calibration gas p...

Page 151: ...time you change the diffusion element reset the calibration gas flow meter to 5 scfh and calibrate the transmitter To change the diffusion element refer to Replace ceramic diffusion element Three types of calibration methods are available automatic semi automatic and manual WARNING The HART option is not protected by energy limiting barriers Do not interface with the handheld communicator option f...

Page 152: ... LOI If using a Rosemount IMPS 4000 enter a time interval via the Rosemount IMPS 4000 keypad that will initiate an automatic calibration at a scheduled time interval in hours Once an automatic calibration is initiated by any of the above three methods the transmitter s CALIBRATION RECOMMENDED alarm signals a Rosemount IMPS 4000 or SPS 4001B to initiate a calibration The sequencer sends an in cal s...

Page 153: ...Rosemount IMPS 4000 or SPS 4001B Refer to the documentation available for the control system in use for more information Once you have initiated a semi automatic calibration by any of the above methods the transmitter s CALIBRATION RECOMMENDED alarm signals a Rosemount IMPS 400 or SPS 4001B to initiate a calibration The sequencer sends an in cal signal to the control room so that any automatic con...

Page 154: ... multimeter is attached across TP5 and TP6 the reading displays the percentage of oxygen the cell sees 4 Press the CAL key The CALIBRATION RECOMMENDED LED turns off and the CAL LED flashed continuously You can configure the transmitter so that the 4 20 mA signal holds the last value The default condition is for the output to track A flashing LED indicates that the transmitter is ready to accept th...

Page 155: ...ashing CAL LED indicates the calibration is done See Troubleshoot for an explanation of the two pattern and three pattern flashes 9 Remove the second calibration gas and cap off the calibration gas port 10 Press the CAL key The CAL LED turns solid as the unit purges The default purge time is three minutes When the purge is complete the CAL LED turns off and the transmitter unlocks from its held va...

Page 156: ...s completion 4 Remove the first calibration gas and apply the second calibration gas Electronics will abort the calibration if this step is not done within 30 minutes The LOI displays Apply Gas 2 Hit E when ready 5 Press ENTER to start the Gas 2 flow The transmitter activates the timer The LOI displays Flow Gas 2 xxxxs Read Gas 2 xxxxs Done Gas 2 xxxxs Stop Gas Hit E when ready 6 Remove the second...

Page 157: ...duled calibration 9 3 Repair Each of the following procedures details how to remove and replace a specific component of the transmitter WARNING The transmitter is hot and may cause severe burns Remove the transmitter from the stack for all service activities Allow the transmitter to cool and take it to a clean work area WARNING Electrical shock Disconnect and lock out power before working on any e...

Page 158: ... cover 17 and ensure it is tight Secure the cover using captive washer 20 cover lock 19 and screw 18 4 Connect the calibration gas and instrument air lines to the probe 5 Turn on the calibration gases at the cylinders and turn on instrument air 6 Restore power to the system Refer to Start up and operate transmitter with membrane keypad or Start up and operate transmitter with LOI 7 When the probe ...

Page 159: ... gas ports Install four washers 21 and screws 22 Tighten screws 5 Follow the instructions in Replace probe to replace the probe in the stack or duct 9 3 4 Replace electronic assembly WARNING Opening the electronics housing will cause the loss of all hazardous permits Opening the electronics housing in hazardous areas may cause an explosion resulting in loss of property severe personal injury or de...

Page 160: ...bly 2 partially out of housing 11 4 Squeeze the sides of the J8 connector and carefully remove the J8 connector heater leads from the power supply board See Figure 9 4 Figure 9 4 J8 Connector A Power supply board Maintenance and service Reference Manual October 2019 00809 0100 4340 160 Emerson com Rosemount ...

Page 161: ...ng will cause the loss of all hazardous permits Opening the electronics housing in hazardous areas may cause an explosion resulting in loss of property severe personal injury or death You may need to get a hot work permit from your company safety officer before opening the electronics housing Refer to Figure 2 14 if you are using integral electronics or Figure 2 18 if you are using remote electron...

Page 162: ...and captive washer 20 securing cover 1 Remove the cover 2 Depress and remove the J1 cell and T C connector from the J1 socket See Figure 9 3 3 Loosen the three captive screws 10 Slide electronic assembly 2 partially out of housing 11 4 Squeeze the sides of the J8 connector and carefully remove the J8 connector heater leads from the power supply board See Figure 9 4 5 Remove the electronic assembly...

Page 163: ...15 Install and tighten cover 1 Make sure it is tight Secure the cover using captive washer 20 cover lock 19 and screw 18 9 3 7 Replace entire probe Do not attempt to replace the probe until you have eliminated all other possibilities for poor performance WARNING The transmitter probe tube and flame arrestor hub can be hot up to 572 F 300 C in the region of the probe heater This can cause severe bu...

Page 164: ...ng can occur Do not force the probe housing when installing or removing it from the integral electrical barrier feed through Figure 2 14 3 Remove four screws 22 Figure 2 14 and washers 21 from the probe tube assembly 23 Remove the probe tube assembly from the housing 11 Once you have separated the probe and housing spring tension releases and the heater strut assembly 32 moves up 4 Remove strut pr...

Page 165: ...trut will slide in the rest of the way 10 Install the guide rod into the calibration gas tube to assist in guiding the calibration gas tube through the hole in the end of the strut 11 Push down on the back plate of the strut to make sure you have spring tension and then install the strut pressure clamp 34 on the back plate 12 Install gas port fittings 29 in the CAL REF and VENT ports 13 Replace th...

Page 166: ... the cell unless it needs to be replaced Go through the complete troubleshooting procedure to eliminate other possible causes before removing the cell If you need to replace the cell order the cell replacement kit See Table 10 3 The cell replacement kit Figure 9 7 contains a cell and flange assembly corrugated seal setscrews socket head cap screws and anti seize compound Emerson carefully packages...

Page 167: ...ng set screw from the flame arrestor Use spanner wrenches from the probe disassembly kit Table 10 4 to turn the flame arrestor hub free from the probe flange If equipped with the flame arrestor with ceramic diffuser remove and discard the setscrews and remove the vee deflector Figure 9 8 Inspect the ceramic diffuser If damaged replace using the element Note The flame arrestor and flame arrestor hu...

Page 168: ...th the optional ceramic diffusion assembly remove and discard the setscrews and remove the vee deflector Figure 9 8 Use spanner wrenches from the probe disassembly kit Table 10 4 to turn the hub free from the retainer Inspect the diffusion element If damaged replace the element 5 Loosen the four socket head cap screws from the cell and flange assembly 6 Remove the assembly and the corrugated cell ...

Page 169: ... flange and flame arrestor hub 16 Apply a light coating of anti seize compound to both sides of the new corrugated seal 17 Assemble the cell and flange assembly and corrugated seal to the probe tube Make sure the calibration tube lines up with the calibration gas passage in each component Apply a small amount of anti seize compound to the screw threads and use the screws to secure the assembly Tor...

Page 170: ...l set screws coated with anti seize compound 3 On systems equipped with abrasive shield remove dual dust seal gaskets 4 Use spanner wrenches from the probe disassembly kit Table 10 4 to turn hub free from retainer 5 Put hub in vise Break out old ceramic diffusion element with chisel along cement line and in 9 5 mm pin punch through cement port 6 Break out remaining ceramic diffusion element by tap...

Page 171: ...sion hub and probe tube 14 On systems equipped with abrasive shield install dust seal gaskets with joints 180 apart 15 Reinstall vee deflector orienting apex towards gas flow 16 Apply anti seize compound to set screws and tighten with hex wrench 17 Reinstall probe on stack flange 9 3 11 Replace contact and thermocouple assembly See Figure 9 9 Figure 9 9 Contact and Thermocouple Assembly Replacemen...

Page 172: ...pring clips held open by squeezing the tabs tube supports and heater support of the heater strut assembly until the spring clip reaches the pencil mark 7 Install the cell per the instructions in Replace cell steps Step 12 through Step 25 8 Slide the heater strut assembly into the probe per the instructions in Replace heater strut steps Step 9 throughStep 14 9 On systems equipped with an abrasive s...

Page 173: ...rut assembly Figure 2 14 32 3D39744G03 6 ft 1 8 m heater strut assembly Table 10 3 Cell Replacement Kits Figure Part number Description Figure 10 1 4847B61G25 DIN 18 in 457 2 mm cell replacement kit 1 Figure 10 1 4847B61G20 DIN 3 ft 0 9 m cell replacement kit 1 Figure 10 1 4847B61G21 DIN 6 ft 1 8 m cell replacement kit 1 Figure 10 1 4847B61G27 ANSI 18 in 457 2 mm cell replacement kit 1 Figure 10 1...

Page 174: ... G Teflon tubing H M16 1 x 6 mm socket head cap screws I Cell and flange assembly J Corrugated seal K Probe tube not included in kit L Calibration gas passage Table 10 4 Tool Kits Figure Part number Description Figure 10 2 3535B42G03 Probe disassembly kit Replacement parts Reference Manual October 2019 00809 0100 4340 174 Emerson com Rosemount ...

Page 175: ...e 2 14 2 3D39861G01 Electronic board assembly HART Figure 2 14 4 and Figure 2 18 4 4849B72H01 Membrane keypad English Figure 2 14 4A and Figure 2 18 4A 6A00115G01 Local operator interface LOI module Figure 2 18 31 6A00122G01 Cable assembly 20 ft 6 m Figure 2 18 31 6A00122G02 Cable assembly 40 ft 12 m Figure 2 18 31 6A00122G03 Cable assembly 60 ft 18 m Figure 2 18 31 6A00122G04 Cable assembly 80 ft...

Page 176: ...art number Description Figure 2 18 31 6A00122G05 Cable assembly 100 ft 30 m Figure 2 18 31 6A00122G06 Cable assembly 150 ft 46 m Figure 2 18 31 6A00122G07 Cable assembly 200 ft 61 m Replacement parts Reference Manual October 2019 00809 0100 4340 176 Emerson com Rosemount ...

Page 177: ...Place the new Rosemount Oxymitter electronic assembly D near the right side of the termination housing 5 Plug the white connector with the two black wires into the white socket on the bottom power supply card 6 Insert the electronics assembly into the termination housing Ensure the black four wire connector remains outside the housing and in the slot provided in the top card of the electronics ass...

Page 178: ...shake H Line voltage 90 to 250 Vac I AC terminal cover You can reuse the existing wires from the transmitter to the electronics However the wires will be carrying new signals as noted by the new labels 10 Remove the 4 20 mA wires from the old electronics and re terminate them to the wires carrying the 4 20 mA signal to the control room 11 Convert the wires carrying the heater to power to carry AC ...

Page 179: ...nt SPS or IMPS autocalibration gas sequencers 3 Calibration recommended diagnostic The new ambient temperature specification for the electronics is 185 F 85 C You can read this temperature with HART communications To upgrade to FOUNDATION Fieldbus you must change out the entire blue electronics housing with the Fieldbus version PN 4850B10G11 Reference Manual Upgrade Rosemount Oxymitter DR to full ...

Page 180: ...Upgrade Rosemount Oxymitter DR to full Oxymitter Reference Manual October 2019 00809 0100 4340 180 Emerson com Rosemount ...

Page 181: ...fective resistance to corrosion and the package uses no moving parts air pumps or other components common to other sampling systems Figure B 1 By pass Package Mounting B 2 Rosemount IMPS 4000 Intelligent Multiprobe Test Gas Sequencer The Rosemount IMPS 4000 Intelligent Multiprobe Test Gas Sequencer is housed within an IP56 NEMA 4X enclosure and has the intelligence to provide calibration gas seque...

Page 182: ... probe is out of calibration calibration gases are on or calibration pressure is low B 3 Rosemount SPS 4001B Single Probe Autocalibration Sequencer Emerson specifically designed the Rosemount SPS 4001B Single Probe Autocalibration Sequencer to perform automatic or on demand calculations The Rosemount SPS 40001B system must be installed in a remote safe area if the Rosemount Oxymitter 4000 is insta...

Page 183: ...tion and relay outputs to indicate when a calibration is in progress or the Rosemount Oxymitter 4000 is out of calibration Figure B 3 Rosemount SPS 4001B A Rosemount Oxymitter 4000 B Rosemount SPS 4001B in a safe area Reference Manual Optional accessories 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 183 ...

Page 184: ...Optional accessories Reference Manual October 2019 00809 0100 4340 184 Emerson com Rosemount ...

Page 185: ...ade through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation The circuit breaker may also include a mechanically operated isolating switch If not then another means of disconnecting the equipment from the supply must be provided and clearly marked as such Circuit breakers or switches must comply with a recognized standard such as IEC947 All wiring m...

Page 186: ...r there is a danger of ignition in areas where an explosive atmosphere is present This equipment should only be opened when the power is removed and adequate time as specified on the label or in the instruction manual has been allowed for the equipment to cool down and then only by trained service personnel Safety instructions Reference Manual October 2019 00809 0100 4340 186 Emerson com Rosemount...

Page 187: ...sible cancer hazard based on tests with laboratory animals May be irritating to skin eyes and respiratory tract May be harmful if inhaled Cristobalite crystalline silica formed at high temperatures above 1800 F 982 C can cause severe respiratory disease D 2 Physical data Appearance and odor Cream to white colored fiber shapes With or without optional white to gray granular surface coating and or o...

Page 188: ...Safety data sheet for ceramic fiber products Reference Manual October 2019 00809 0100 4340 188 Emerson com Rosemount ...

Page 189: ...ment in Divisions The marking must be suitable for the area classification gas and temperature class This information is clearly defined in the respective codes E 4 Rosemount OXT4A Oxymitter for general purpose locations and OXT4C hazardous locations certification Rosemount Oxymitter Oxygen Transmitters Series 4000 DR OXT4A OXT4ADR OXT4C OXT4CDR OXT4CNF and OXT4CDRNF and Rosemount Oxymitter 4000 s...

Page 190: ...sure higher than 1 1 times the atmospheric pressure these calibration lines shall not contain pure oxygen acetylene or combustible gases other than the gases for which this Zone 1 classified application has been investigated for Group IIB H2 gases 3 There are no interchangeable components 4 Contact the original manufacturer for information of flameproof joint dimensions 5 Fastener property class m...

Page 191: ...mbustible gases other than the gases for which this application has been investigated for Group IIB H2 gases 4 There are no interchangeable enclosure components 5 Contact the original manufacturer for information of flameproof joint dimensions 6 Fastener property class must be A2 70 E 5 Rosemount Xi X Stream Xi Remote Interface for general locations certification E 5 1 USA Canada CSA Certificate 1...

Page 192: ...Rosemount Oxymitter product certifications Reference Manual October 2019 00809 0100 4340 192 Emerson com Rosemount ...

Page 193: ...F Declaration of Conformity Reference Manual Declaration of Conformity 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 193 ...

Page 194: ...Declaration of Conformity Reference Manual October 2019 00809 0100 4340 194 Emerson com Rosemount ...

Page 195: ...Reference Manual Declaration of Conformity 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 195 ...

Page 196: ...Declaration of Conformity Reference Manual October 2019 00809 0100 4340 196 Emerson com Rosemount ...

Page 197: ...G China RoHS table Reference Manual China RoHS table 00809 0100 4340 October 2019 Rosemount Oxymitter 4000 197 ...

Page 198: ...EAST AND AFRICA Emerson Automation Solutions Emerson FZE Jebel Ali Free Zone Dubai United Arab Emirates P O Box 17033 971 4 811 8100 971 4 886 5465 gas csc emerson com ASIA PACIFIC Emerson Automation Solutions 1 Pandan Crescent Singapore 128461 Singapore 65 777 8211 65 777 0947 gas csc emerson com Linkedin com company Emerson Automation Solutions twitter com rosemount_news Facebook com Rosemount y...

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