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Maintenance and Service

Section 5: Maintenance and Service

Reference Manual

January 2019

00809-0100-4892

FIGURE 5-11. DR Board Wiring, Left-Hand Side

Use the Up/Down keys to select “1-Get From Probe”. Press <ENTER> twice.

vi.

When transfer is complete, press <EXIT> twice to return to the main menu.

Summary of Contents for 6888Xi

Page 1: ...Reference Manual 00809 0100 4892 Rev AB January 2019 Rosemount 6888Xi Advanced Electronics for Zirconium Oxide Flue Gas O2 Probes ...

Page 2: ...B Table of Contents ...

Page 3: ...riate Reference Manual and per applicable local and national codes Connect all products to the proper electri cal and pressure sources To ensure proper performance use qualified personnel to install operate update program and maintain the product When replacement parts are required ensure that qualified people use replacement parts spec ified by Emerson Unauthorized parts and procedures can affect...

Page 4: ...II Table of Contents ...

Page 5: ...nsiderations 12 2 2 Mechanical Installation 12 2 3 Electrical Installation 15 Section 3 Configuration Startup and Operation 3 1 Overview 25 3 2 Startup 25 3 2 1 Configuration 26 3 2 2 Operation 26 3 2 3 Startup Display 26 3 2 4 Error Conditions 27 3 2 5 Keypad 27 3 2 6 Password Protection 34 3 3 Optional Advanced Features 34 3 3 1 Extended Temperature 35 3 3 2 Stoichiometer 35 3 3 3 Programmable R...

Page 6: ...n 67 3 9 D A Trim 68 Section 4 Troubleshooting 4 1 Overview of Operating Principles 71 4 2 General 72 4 2 1 Grounding 72 4 2 2 Electrical Noise 72 4 2 3 Electrostatic Discharge 72 4 3 Alarm Indications 72 4 4 Identifying and Correcting Fault Indications 73 4 5 Calibration Passes But Still Reads Incorrectly 74 4 5 1 Probe Passes Calibration O2 Still Reads High 75 4 5 2 Probe Passes Calibration O2 S...

Page 7: ...essories 7 1 HART Handheld 375 475 Field Communicator 95 7 2 Asset Management Solutions AMS 95 7 3 By Pass Packages 95 7 4 SPS 4001B Single Probe Autocalibration Sequencer 96 7 5 IMPS 4000 Intelligent Multiprobe Test Gas Sequencer 97 7 6 O2 Calibration Gas 98 7 7 OxyBalance Display and Averaging System 99 Appendix A Safety Data A 1 Safety Instructions 100 Appendix B Return of Material B 1 Returnin...

Page 8: ...VI Table of Contents Table of Contents Reference Manual January 2019 00809 0100 4892 ...

Page 9: ...ng it Read this instruction manual completely Definitions The following definitions apply to WARNINGS CAUTIONS and NOTES Section i Introduction WARNING Highlights an operation or maintenance procedure practice condition statement etc If not strictly observed could result in injury death or long term health hazards of personnel CAUTION Highlights an operation or maintenance procedure practice condi...

Page 10: ... to flow two calibration gases into the probe and with the calibration gases flowing automatically adjusts the O2 signal With the addition of a Single Probe Sequencer SPS the 6888Xi Advanced Electronics can also switch the calibration gases on and off 4 Diagnostics Multiple alarms are available for display The alarm displays are intended to assist a technician in locating where an instrument probl...

Page 11: ...ions specified by your order number are on or included with the unit 1 2 System Overview 1 2 1 Power Supply Current Loop Wiring This Reference Manual is designed to supply details needed to install start up operate and maintain the Rosemount 6888Xi Advanced Electronics Signal conditioning electronics outputs a 4 20 mA signal representing an O2 value This information plus additional details can be ...

Page 12: ...mmable reference and plugged diffusor These additional features will be discussed in other sections of this manual The 6888Xi can be purchased to operate a single probe or as a dual channel unit to run two probes Traditional Architecture HART and 6888Xi Communications Some customers prefer not to mount electronics onto the probe so a traditional architecture version is offered This probe sends raw...

Page 13: ... electronics can make automatic adjustments to the O2 readings to match the bottled gas value 0 4 O2 and 8 O2 balance nitrogen gases are recommended Never use nitrogen as a calibration gas Flowmeters for calibration gases and regulators and flowmeters for reference air are available as loose components mounted into an optional manual calibration switching panel or as a fully automatic calibration ...

Page 14: ...ut line transmits an analog signal pro portional to the oxygen level The HART output is superimposed on the 4 20 mA output line This information can be accessed through the following Rosemount Model 375 475 Field Communicator The handheld communicator requires Device Description DD software specific to the 6888Xi The DD software will be sup plied with many Model 375 475 units but can also be progr...

Page 15: ...te with a 6888A FOUNDATION Fieldbus probe Refer to section 3 2 1 Configuration to set up for FOUNDATION Fieldbus communications Optional OxyBalance Display and Averaging System Receives up to eight 4 20 mA signals from individual 6888Xi units Trends individual outputs and calculates four programmable averages as additional 4 20 mA outputs OxyBalance graphic dis plays are shown in Figure 1 5 See IM...

Page 16: ... F to 131 F General Purpose Certifications Installation Specifications Mounting Panel wall or pipe Reference Air 2 scfh 1L min clean dry instrument quality air 20 95 O2 regulated to 5 psi 34 kPa Calibration Semi automatic or automatic Cal Gases 0 4 O2 and 8 O2 balance N2 recommended Traditional Architecture Cable 200 ft 61 m maxmum length Transmitter Electrical Power 12 24 VDC loop powered from co...

Page 17: ...hitecture for 120V Probes Code Cable 00 No Cable 10 20 6m Cable 11 40 12m Cable 12 60 18m Cable 13 80 24m Cable 14 100 30m Cable 15 150 45m Cable 16 200 60m Cable Code Stoichiometer Function 00 No 01 Single Channel 02 Dual Channel Code Extended Temperature Function 00 None 01 Single Channel 02 Dual Channel Code Plugged Diffuser Diagnostic Function 00 None 01 Single Channel 02 Dual Channel Code Mou...

Page 18: ...be 06 IMPS two probe 115V heated general purpose NEMA 4X includes check valve for probe 07 IMPS three probe 115V heated general purpose NEMA 4X includes check valve for probe 08 IMPS four probe 115V heated general purpose NEMA 4X includes check valve for probe 09 IMPS single probe 220V heated general purpose NEMA 4X includes check valve for probe 10 IMPS two probe 220V heated general purpose NEMA ...

Page 19: ...ructions could result in serious injury or death CAUTION If external loop power is used the power supply must be a safety extra low voltage SELV type WARNING Install all protective equipment covers and safety ground leads after installation Failure to install covers and ground leads could result in serious injury or death WARNING The 6888Xi Advanced Electronics can be installed in general purpose ...

Page 20: ... the 6888Xi at a height convenient for viewing and operating the interface Approximately 5 ft 1 5 m is recommended 4 The keypad window on the 6888Xi may have interior and exterior protective membranes Remove the protective membranes prior to use of the 6888Xi enclosure Failure to remove the protective membranes may cause the display to appear distorted The membrane may be difficult or impossible t...

Page 21: ...Installation 13 Reference Manual Section 2 Installation 00809 0100 4892 January 2019 FIGURE 2 2 6888XI Advanced Electronics Panel Mounting Details ...

Page 22: ...14 Installation Section 2 Installation Reference Manual January 2019 00809 0100 4892 FIGURE 2 3 6888XI Advanced Electronics Wall Surface and Pipe Mounting Details ...

Page 23: ...past the shield NOTE Installation of the ferrite clamp over the 4 20 mA OUT wires is required for compliance with the European EMC Directive 4 Terminate the shield of the 4 20 mA signal wires at the designated ground terminal of the 6888Xi Do not allow bare shield wires to contact the circuit boards Insulate the shield wires prior to termination 5 Connect the signal wires from the SPS or IMPS if u...

Page 24: ...t the AC line input to the J1 connector 4 Connect the AC power to the 6888A probe to the J2 connector 5 Reinstall connector J1 and J2 to the AC relay board Traditional Architecture Cable Connections A traditional architecture configuration is used to provide for remote location of the transmitter electronics All electronics are housed inside the 6888Xi A multi conductor power signal cable connects...

Page 25: ... circumference of the insert and not extend beyond the narrow diameter portion g Carefully press the gray insert into the gland body The grooves on the insert should align with similar grooves inside the gland body Press the insert in until it bottoms out in the gland body h Slide the locking nut up and thread it onto the gland body Tighten the locking nut so the rubber grom met inside the plastic...

Page 26: ...18 Installation Section 2 Installation Reference Manual January 2019 00809 0100 4892 6888 STANDARD PROBE HOUSING 6888 STANDARD PROBE HOUSING FIGURE 2 5 Single Dual Channel Wiring Diagram ...

Page 27: ...Installation 19 Reference Manual Section 2 Installation 00809 0100 4892 January 2019 FIGURE 2 5 cont Single Dual Channel Wiring Diagram CHANNEL 2 CHANNEL 1 CHANNEL 2 CHANNEL 2 CHANNEL 1 CHANNEL 1 ...

Page 28: ...20 Installation Section 2 Installation Reference Manual January 2019 00809 0100 4892 51 6888Xi 6888 STANDARD PROBE HOUSING FIGURE 2 6 Single Channel with Flame Safety Wiring Diagram ...

Page 29: ...Installation 21 Reference Manual Section 2 Installation 00809 0100 4892 January 2019 LOSS OF FLAME OUTPUT TO BURNER MANAGEMENT SYSTEM FIGURE 2 6 cont Single Channel with Flame Safety Wiring Diagram ...

Page 30: ...22 Installation Section 2 Installation Reference Manual January 2019 00809 0100 4892 FIGURE 2 7 Traditional Architecture Wiring Diagram ...

Page 31: ...Installation 23 Reference Manual Section 2 Installation 00809 0100 4892 January 2019 FIGURE 2 7 cont Traditional Architecture Wiring Diagram ...

Page 32: ...24 Installation Section 2 Installation Reference Manual January 2019 00809 0100 4892 ...

Page 33: ... board depends on the system design and system components used in your installation The setting of switch SW4 and the configuration of jumpers JP1 through JP8 must be verified on the I O board in the 6888Xi Refer to figures 2 5 2 6 and 2 7 in Section 2 for additional details If necessary the I O Board can be reset to factory default settings in order to configure the fol lowing parameters Sensor T...

Page 34: ...the System menu appears 3 Select CONFIGURE IOB 4 Press the ENTER key to continue 5 Select I O BOARD 1 Note With a dual channel 6888XI either or both I O boards may be reset and reconfigured 6 Press the ENTER key to continue 7 Select RESET I O BOARD Press the ENTER key to continue 8 When the reset menu appears select FACTORY DEFAULTS Press the ENTER key to contin ue 3 2 2 Operation The following pr...

Page 35: ...he selected main menu is displayed DIAG toggles between the Alarms list of the three main menus All faults and warnings related to the selected main menu device are displayed ENTER saves newly entered data and returns you to previous menu level EXIT returns you to the previous menu level without saving newly entered data When navigating the menu tree pressing EXIT returns you to the Main menu UP D...

Page 36: ...K171 2O 4P312A4 5 K171 28 2B 45E A 8K 28 B 4Q G62 R 2B 45E 8 R 2B K 29 N5 P12 G 102 C129 R 2B K 2 2L 129M N5 P12 G 102 C129 2 NJ R I NK B 2A K J 29 1 15 L 12 M J 2 1 15 J 2S J1T K QD J 2U J1T K QD K1015 2 61 J4 QG4Q1 547 K171 2 547 A347D2 3456 8K N477V 5E L G1EM 4P312N477V 5E 28 Configuration Startup and Operation Section 3 Configuration Startup and Operation Reference Manual January 2019 00809 01...

Page 37: ...0 6 7 6 3 301 A BC D 3087 1 2 56 E BA D E F G76 H B IE 7 DJ K 7LM G 2MBE N7 6 E7O3 6 E739078 M 390780 6 7P7 1 E 7 6 3 301 A BC D 3087 1 2 56 E BA D E F G76 H B IE 7 DJ K 7LM G 2MBE N7 6 E7O3 6 E739078 M 1RWH Visible if the device is configured for 2 I O boards 1RWH Label differently based on one or two I O boards Figure 3 3 6888Xi Menu Sheet 2 of 6 ...

Page 38: ...FG H HI63 2345 2345 3 31 45 3 F A 2 IJK3 6 14L 2 28 8 2 F G E4E G E4E G1 3 MED3 7013 GL 06 1 NO P QO3 F3K M E6G13 M F 73401H M E6 0 1 2345 EOP M I 01H 70 3 3 31 45 3 7 2 3QL01 53Q 2 53Q 2345 0R 2345 EOP 2 P01 3 2 3K31L3 3 31 M E6G13 S 0QJQG3 T S 0QJQG3 T S 0QJQG3 T S 0QJQG3 T G1Q31 M6 430G 30 Configuration Startup and Operation Section 3 Configuration Startup and Operation Reference Manual January...

Page 39: ...4 M 03 N 3 E H OI 30P 6A 3 6 Q 6A 3 8 0 6 R7 NK S 6K6 5I 6 Q A G3 6 Q A B A01 6 R D67S S0 T3 3 G0 I0 1 3 G0 6 R BB N6 7 7S 56 78 767 H I 7I D6 8 0P 0 0P 8 67I5 88 H03 U 6 H03 676K S O8 O8 83 6 C 68 7S I868OI B 3V 5 10 BA 0 I 6 A 0P 0 0A V 0P 0 0A V 4 0P 0 6 0P 0 U I868 I U I868 I S I A0 1 S 4 I A0 1 U I868 I 4 BA 0 I B 3V 5 10 0A V 0A V 4 I IU 5 I I IU 5 I I868OI 9 3 H A 0 H A 0 I 8 9 3 0 3 0 3 0 ...

Page 40: ...N 4 5 6 4 0 0O G0 42 P Q 70 R 5 6 G0 S2 P0 G03 6 G0 S2 P0 G03 I GCQ T G0 S2 578 6 6G CQ 0G03 3 0O030 C0 UG0 101 70 R 9 T E03 V 3 5 5I J 87 87 4 I H 4 8 H 5 0 5 3 I0B0 I5W I5W 8 G 5 3 I N 4 0C 0 101 A3 I5W 4 8 G 5 3 I N 4 0C 0 101 A3 P0 G03 0 X 5I 57 5 73 CY 7 Q0CY 0C 0 1 5CY N 01 0 J E J E 4 J E 7 0 3 0 7 0 9 86 G0 K2 01 9 T E03 5 G 51B C0 587 5I 57 EKd ϲͿ A 0 5 G 6G 3G 0C G03B 0UG 7 0 6 8 5 GR G ...

Page 41: ... 0 0A 3 C0AA 0A 3 C0AA 4 9 0 D9 E0 G I 7JK 3E0 7 B0 L G I M93 8 0 2 N 0 30AA 30 N 0 30AA 30 4 0 30AA 30 0 30AA 30 4 1RWH 9LVLEOH LI WKH GHYLFH LV FRQILJXUHG IRU 636 XWRFDO 1RWH Visible if the Programmable Reference software feature is enabled 1RWH Visible if the Extended Temperature software feature is enabled 1RWH Visible if the Diffuser Warning software feature is enabled 1RWH Visible if the Fac...

Page 42: ... protection feature i e the password protection will fall back to a disabled condition after a reset 3 3 Optional Advanced Features Advanced features are typically ordered factory programmed However these advanced fea tures are also available for field retrofit A 6888Xi is shipped from the factory with the optional enhanced software features enabled based on the model configuration 3 3 1 Extended ...

Page 43: ...ture between 750 C and 850 C However a heater temperature above this level will cause an alarm but will not force the analog output signal level to either 3 5 mA or 21 5 mA When the heater turns off the oxygen reading is adjusted continuously to compensate for the varying process temperatures It should be noted that cell life will be reduced by continuous operation at temperatures above 736 C 1357...

Page 44: ...3 4 Plugged Diffusion Element Diagnostic In situ analyzers do very well in high particulate flue gases resulting from processes as such coal or biofuel boilers or lime and cement kilns because the passive filter or diffusion element does not foul or plug off easily Since the probe sensing cell is inserted entirely into the flue gas stream the process gasses can diffuse migrate into the cell area w...

Page 45: ...rning to the user when the return to process time has exceeded 75 of the configured purge time Default purge time is 300 seconds but it s important for the user to configure the actual purge time for their process conditions A purge time that is too long will prevent a plugged diffuser alarm from triggering until the diffuser pluggage is very bad If the purge time is set too short and probe has no...

Page 46: ...the 6888Xi menu Setup parameters are located at Menu Detailed Setup Calibration Diffuser Diagnostic results parameters are located at Menu Calibration Diffuser Each parameter is described below Menu Detailed Setup Calibration Diffuser Plugged Diffuser Disabled The plugged diffuser diagnostic is disabled Rate The plugged diffuser diagnostic is enabled with the rate mode algorithm With this mode the...

Page 47: ...ized as opposed to manually applying calibration test gasses Rtn Process Return to process time Tfinal which is also the actual purge time This may also be defined as the time it takes to get back to the initial process reading or the time for the rate of the sensor output change to reach near zero or both depend ing on which mode of the diagnostic has been enabled O2 Rate Change The rate of chang...

Page 48: ... an extended period of time which could also indicate that calibration test gas is causing excessive pressurization of the sensing cell during the calibration 3 4 System Parameter Descriptions Among the parameters available through the 6888Xi and 375 475 Field Communicator menus are a number of System Parameters The system parameters define variables that configure the 6888Xi in the transmitter sy...

Page 49: ...n display Line 2 data for one probe configuration 0 displays PV O2 1 displays SV O2 Temp Y One Probe Format Line3 Left Main display Line 3 left hand side data for one probe configuration 0 displays PV O2 1 displays SV O2 Temp 2 displays TV Cell Imp 3 displays 4V Cell mV 4 displays CJC Temp 5 displays AO 6 displays OP Mode 7 displays Tag Y One Probe Format Line 3 Right Main display Line 3 right han...

Page 50: ...3 Right Main display Line 3 right hand side data for two probe configuration 0 displays PV O2 1 displays SV O2 Temp 2 displays TV Cell Imp 3 displays 4V Cell mV 4 displays CJC Temp 5 displays AO 6 displays OP Mode 7 displays Tag Line 1 Line 3 are dedicated for probe 1 in a two probe configuration Y Two Probe Format Line4 Left Main display Line 4 left hand side data for two probe configuration 0 di...

Page 51: ... number for licensed feature code generation N Features Available advanced licensed features for the I O board ON Feature supported OFF Feature not supported N Factory Mode I O board factory mode Always OFF internal use only N Resource Analog Output I O board analog output resource mapping One for each probe Index 0x00000001 contains IOB AO Index 0x00000002 contains TX AO N Resource Auto Cal I O b...

Page 52: ...2 sensor temperature reached since last reset Y Y Temperature CJC Max C This is the highest temperature reached at the cold junction since last reset Y Y Temperature CJC Max Time Days ago Time stamp of the highest temperature reached at the cold junction since last reset N Y Temperature Board Max C This is the highest temperature reached at the IO board since last reset N Y Temperature Board Max T...

Page 53: ...EE Val Transmitter board nonvolatile memory diagnostic N Y IOB EE Val I O board nonvolatile memory diagnostic Y Y Xmtr Restart Software restarts count for the Transmitter N Y IOB Restart Software restarts count for the IO board Y Y HART Device Rev HART Device Revision number Y Y Transmitter Version Software version number for the Transmitter N Y I O Board Version Software version number for the I ...

Page 54: ...actual value of the gas being applied during the Test Gas 2 phase of a calibration Y Y Gas Time sec Test Gas application time This is the length of time test gases are applied to the O2 probe during low or high Test Gas phase of a calibration Y Y Purge Time sec Test Gas purge time This is the length of time before the output will be returned to the process reading after a calibration N Y Plugged D...

Page 55: ...ce last calibration N Y Cal Step This represents the step of the calibration cycle is in 0 Idle 1 Reserved 2 Apply Gas 1 3 Flow Gas 1 4 Read Gas 1 5 Apply Gas 2 6 Flow Gas 2 7 Read Gas 2 8 Cal Abort 9 Stop Gas 10 Purge N Y Time Remain sec Time remaining in the present calibration cycle state N Y Process mV Cell mV reading just prior to start of calibration Diagnostic parameter for Diffuser Warning...

Page 56: ...ections When working at the 6888Xi the 375 475 Field Communicator can be connected directly to test points TP21 and TP22 on the 6888Xi I O Board as shown in Figure 3 5 The AM and AM test points are provided to monitor the 4 20 mA signal without breaking into the loop 3 6 2 Field Communicator Menu Trees Connect the 375 475 Field Communicator in the 6888Xi 6888Xi to DCS 4 20 mA signal loop or to the...

Page 57: ... F K F 9 A23 24L93 F EM24 952 26 4L 5 4 2669 2 21L 2 F J F 8L124693 KL23A 21L 2 J94AN942 ON942 K F 4986ELP24 8 5I 5 5 94A FK Q Q B 8R 42 286 4 8R 42 893 5 5 8R 42 239D 8R 42 93LM490 8 8R 42 5 93LM490 8 F B F K F 9 24L93 F EM24 KL893 662EM3D F E 952 26 4L 5 4 2669 2 F F B 33 AA4266 F E 2S B429EM326 BTD6L 93 L 893 A2 F UV KL3524 N 7 394E B 7 233 2W2428 2 JL T 2E 394E B J29524 25 B L85 J29524 95 T X ...

Page 58: ...B 4 G5 50 H BB 5 FIA J A50 K 34 L037 99999 3 5 57A HM 7 A H 5 N HM 50 H BB 53HM G O5E O5 O57FB 8 A 57FB PFQ O A 99999 8 5PFQ O A 3 53 C H 5 3 7 5 34 L037 99999 1 I 53 5 6 A 5 5 50 H FIA 5 AC R 5 57FB 016 0 1 99999 3 5 3 5 FIA 0 K5E 0 K5 6 3 5P1 1 34 L037 99999 34 L037 99999 5 FIA 6 A S6 5 FIA 3I A 5 FIA 67371 99999 FIA 56 7FB 50 B F 5 016 476 99999 FIA 50 O P 5 B H P 610 99999 PFQ O A57TU 8 A 57FB...

Page 59: ...33333 1K 7 6 1G 1K 0L 1G 1K 0 EG 6 6 2 M 1K 0 EG 6 6 H I8 1K 0L 8 6 1K 0L 67 H 6 9 6 F 6 6 9 E 4 D0 D4D K 33333 06 7E N 6 B 7 9 O6 EE 9 O6 9 99 EG H I8 P6 O 7E 8 Q B 7 4B 1 R 33333 9 O6 8 I H 6 9 I 2 M P6 O 8 I 2 M 1K B S 7 6 T 6 I P 1C 33333 P6 7 49 6E7 4 U 49 6E 0 E 4 VD1T2 BW 33333 4 U 9 O6 4 U 9 O6 9 4 U B S 7 6 T 6 I 4 U P6 O 8 I 4 4F2 33333 P 1 4 4F2 33333 P 0 X P6 E 6A 6 O9 6A 6 O9 0 6 6A 6...

Page 60: ... C H C 6 0IE1 55555 8 FJ G C 89 6 H C D J 8 CH C 2 I60I I 0 55555 6 8I 55555 89 D K 1C CL1C H D K K C D K 16 60 55555 D K 1C H 6 89 89 DD 014 6 55555 D K M DC E DC H G E NN410 55555 E O M 6PQ 7 J 6 R E O M S I 8A 846746 55555 6 8 CH C H 6 MC 870 6 IA 16 641 55555 N GC F 2 ND 1C C M C D E T G D F U E T G D F 9 E T G D J 8 CH C E T G I746L846746 16 601 55555 L8 16 601 U 55555 A M U 1 D A M 9 1 D L8 ...

Page 61: ...rn to the main menu 8 Repeat steps 1 through 7 for PROBE 2 if configured for dual channel Setting Test Gas Values Using Field Communicator in Manual Configure Mode 1 Use the 375 475 Field Communicator to access the main HART menu 2 From the main menu select CONFIGURE 3 From the CONFIGURE menu select MANUAL SETUP 4 From the MANUAL SETUP menu select CALIBRATION 5 From the CALIBRATION menu select GAS...

Page 62: ...e during the calibration cycle This same process must be performed any time an I O Board is replaced Setting Output Tracking Using the 6888Xi Keypad Display 1 Press the MENU button repeatedly until the IOB1 Probe 1 menu displays 2 From the main menu select DETAILED SETUP then press ENTER 3 From the DETAILED SETUP menu select CALIBRATION then press ENTER 4 From the CALIBRATION menu select AO TRACK ...

Page 63: ... the IOB1 Probe 1 menu displays 2 From the main menu select DETAILED SETUP then press ENTER 3 From the DETAILED SETUP menu select CALIBRATION then press ENTER 4 From the CALIBRATION menu select TOL CHECK then press ENTER 5 Press the RIGHT arrow key to edit the value No Tolerance Check active Yes Tolerance Check inactive Use the UP and DOWN arrow keys to change the value from NO to YES or YES to NO...

Page 64: ...igured with the optional Flame Safety Interlock Heater Relay is not valid and cannot be chosen for Alarm 2 Configuring the Alarm Relays Using the 6888Xi Keypad Display 1 Press the MENU button repeatedly until the IOB1 Probe 1 menu displays 2 From the main menu select DETAILED SETUP then press ENTER 3 From the DETAILED SETUP menu select RELAY then press ENTER 4 From the RELAY menu select RELAY 1 th...

Page 65: ...A 6888Xi shipped from the factory has the analog outputs set to a 4 to 20 mA range with a 3 5 mA alarm level This same process must be performed any time an I O Board is replaced Configuring the Analog Output Using the 6888Xi Keypad Display 1 Press the MENU button repeatedly until the IOB1 Probe 1 menu displays 2 From the main menu select DETAILED SETUP then press ENTER 3 From the DETAILED SETUP m...

Page 66: ...s same process must be performed any time an I O Board is replaced Activating the Autocalibration Menu if not available 1 Apply power to 6888XI 2 Press MENU until the System menu appears 3 Select CONFIGURE IOB 4 Press the ENTER key to continue 5 Select I O BOARD 1 Note With a dual channel 6888XI either or both I O boards may be reset and reconfigured 6 Press the ENTER key to continue 7 Select RESE...

Page 67: ...ed alarm This alarm advises the user that the calibration is out of date and should be recalibrated A 6888Xi is shipped from the factory with the calibration recommended alarm enabled This same process must be performed any time an I O Board is replaced Configuring Calibration Recommended Using the 6888Xi Keypad Display 1 Press the MENU button repeatedly until the IOB1 Probe 1 menu displays 2 From...

Page 68: ...ANUAL SETUP menu select CALIBRATION 5 From the CALIBRATION menu select the CAL ACKNOWLEDGE parameter 6 Press the RIGHT arrow key to edit Use the stylus on the screen keypad to select YES or NO then press ENTER when finished 7 Use the stylus on the screen to select SEND to update the 6888Xi 3 7 10 Plugged Diffuser Diagnostic Use a Field Communicator or the 6888Xi to configure the plugged diffuser d...

Page 69: ...CALIBRATION menu select DIFFUSER 6 From the DIFFUSER menu select PLUGGED DIFFUSER 7 Press the RIGHT arrow key to edit the value Use the UP and DOWN arrow keys to select the mode Disable Disables this feature Rate Uses rate of change of gas value during purge to determine when purge is complete Proximity Uses comparison of pre calibration measurement versus post calibration meas urement purgeto det...

Page 70: ... be between 750 C and 850 C Press ENTER to save the new value Press the LEFT arrow key to return to the SENSOR menu 8 From the SENSOR menu select HEATER LATCH OFF then press ENTER 9 Press the RIGHT arrow key to edit the value No Heater turns off above set point then turns back on if process falls below set point Yes Heater turns off above set point but does not then turn back on if process falls b...

Page 71: ...urn back on if process falls below set point 14 Use the stylus on the screen keypad to press ENTER when finished 15 Use the stylus on the screen to select SEND to update the 6888Xi 3 8 Calibration 3 8 1 General New O2 cells may operate for more than a year without requiring calibration but older cells may require recalibration every few weeks as they near the end of their life A CALIBRATION RECOMM...

Page 72: ...he diffuser O2 Calibration with 6888Xi For systems with configuration 1 shown in Figure 3 5 use the following procedure to perform a calibration using the 6888Xi If necessary use the 6888Xi menu tree in Figure 3 2 for refer ence Multiprobe Test Gas Sequencer 1 Press the MENU button repeatedly until the IOB1 Probe 1 menu displays 2 From the main menu select CALIBRATION then press ENTER 3 From the C...

Page 73: ...perform the following steps Otherwise proceed to the next step a From the final calibration screen press EXIT twice to return to the main display screen The screen should indicate an alarm condition b Press DIAG to view the alarms A CAL CHANGED alarm should be shown c Press EXIT to return to the DIAGNOSTIC menu d From the DIAGNOSTIC menu select ACKNOWLEDGE ALARMS then press ENTER e From the ACKNOW...

Page 74: ...CTION menu 10 At the SELECT ACTION menu select STEP CALIBRATION then ENTER to continue the calibra tion with Flow Gas 2 11 When Flow Gas 2 and Read Gas 2 are complete and the step shows STOP GAS press OK to return to the SELECT ACTION menu 12 At the SELECT ACTION menu select STEP CALIBRATION then ENTER to continue the calibra tion with Purge 13 When the step shows IDLE press OK to return to the SE...

Page 75: ...ress HOME to return to the main menu b From the main menu select SERVICE TOOLS c From the OVERVIEW menu select ALERTS d From the ALERTS menu select ACTIVE ALERTS e The ACTIVE ALERTS menu should contain an M CALIBRATION CHANGED alarm Press the left arrow key to return to the ALERTS menu f From the ALERTS menu select DEVICE STATUS g From the DEVICE STATUS menu select ACKNOWLEDGE h From the ACKNOWLED...

Page 76: ...pad Display IOB 1 Probe 1 or 2 Calibration Cal Constants Cal Logs Using the Field Communicator Configure Calibration Calibration Constants Calibration Logs When first entering the log the screen will display calibration 1 This is the most recent previous calibration not the current calibration Calibration 0 displays the current calibration Use the keypad or communicator keys to navigate through th...

Page 77: ...A Trim The D A trim procedure is used to calibrate the 4 20 mA output signal to a precision mA meas urement device Only the signal to the DCS needs to be trimmed D A Trim with 6888Xi 1 Press the MENU button repeatedly until the IOB1 Probe 1 menu displays 2 From the main menu select DIAGNOSTICS then press ENTER 3 From the DIAGNOSTICS menu select MAINTENANCE then press ENTER 4 From the MAINTENANCE m...

Page 78: ...l D A Trim with 6888Xi and Field Communicator 1 Use the 375 475 Field Communicator to access the main HART menu 2 From the main menu select SERVICE TOOLS 3 From the SERVICE TOOLS menu select MAINTENANCE 4 From the MAINTENANCE menu select ANALOG OUTPUT 5 From the ANALOG OUTPUT menu select TRIM mA OUTPUT 6 In the first screen a Loop should be removed from automatic control warning occurs Remove the ...

Page 79: ...ents the difference between the process O2 and the reference O2 inside the probe 20 95 O2 instrument or ambient air When flowing calibration gases the raw cell millivolt value should represent the levels on the chart in Figure 4 1 Note that the raw cell millivolt value increases logrithmically as the O2 con centration decreases FIGURE 4 1 O2 Sensor mV Reading vs O2 at 736 C 1357 F Reference Air 20...

Page 80: ...rge Electrostatic discharge can damage the ICs used in the electronics Before removing or handling the circuit boards ensure you are at ground potential 4 3 Alarm Indications The first indication of a problem at the O2 measuring system usually comes from the operators running the process Critical alarms that render the O2 measurement unusable will force the 4 20 mA analog output signal representin...

Page 81: ... Distributed Control System is configured to interpret these signal levels correctly Message Status Alert Self Clearing NV Memory Fail A checksum error was detected in the nonvolatile memory configuration data when the unit was turned on Default values have been loaded Check to see that your configurations have not been changed Cycle the power to clear alarm Failed N Y Board Temp High The electron...

Page 82: ...r and the heater should be turned off Maint Y Y Xmtr Disconnect Communication failures detected between transmitter and the IO board indicat ing the transmitter has been disconnected from the IO board Check the con necting cable Maint Y Y Cal Recommended Probe calibration is recommended The cell impedance has shifted enough above 100 ohms and has shifted 50 ohms since the last calibration that the...

Page 83: ...obe flange gasket can migrate down the annular space between the probe OD and shield ID to the sensing cell causing a false high O2 reading Internal Reference Air Leak See Figure 4 2 There may be a leak inside the O2 Probe itself per mitting the reference air 20 95 O2 to mix with the process gases at the cell To confirm this leak condition pressurize the inside reference side of the probe by plugg...

Page 84: ...diffuser plugs this recovery time will get longer and longer Use the Calibration Record provided to record and track Calibration Response times The 6888Xi Advanced Electronics is available with enhanced software feature to automatically characterize the rate of diffuser pluggage during a calibration cycle 4 5 4 Can I calibrate a badly plugged diffuser It may not be possible to immediately replace ...

Page 85: ...ion Date Placed Into Service Notes Responseinitial When the second calibration gas is turned off note the number of seconds required for the O2 value to begin migrating back to the process value Responsefinal When the second calibration gas is turned off note the number of seconds required for the O2 value to settle out at the process value Date Slope Constant Impedance Reponseinitial Responsefina...

Page 86: ...78 Troubleshooting Section 4 Troubleshooting Reference Manual January 2019 00809 0100 4892 ...

Page 87: ...m the bottle values then a formal calibration should be conducted as noted in Section 3 Configuration Startup and Operation The 6888Xi offers a calibration recommended diagnostic that will indicate when the probe needs to be calibrated Combustion processes that have a high level of ash or other particulate content will cause the diffusion element on the end of the probe to plug off A badly plugged...

Page 88: ...bration Sequencer or the IMPS 4000 Intelligent Multiprobe Test Gas Sequencer 5 3 1 Automatic Calibration The 6888Xi can be used with the SPS 4001B or IMPS 4000 in order to perform an auto semi auto calibration Refer to the SPS 4001B or IMPS 4000 Reference Manual for further details on how to configure and perform an automatic calibration 5 3 2 Manual Calibration Refer to the Calibration General in...

Page 89: ...cific component of the 6888Xi Most of these procedures include component setup instructions that must be performed before returning the related O2 Probe to service Refer to Figure 5 1 and Figure 5 2 for illustrations of the 6888Xi components 5 5 1 I O Board Replacement FIGURE 5 2 6888Xi Components WARNING Disconnect and lock out power before working on any electrical components WARNING The I O Boa...

Page 90: ...t the 4 position plug for the transmitter probe and output wiring Remove the I O Board completely from the 6888Xi enclosure 7 See Figure 5 3 Set jumpers JP1 JP2 JP5 JP7 and JP8 to their proper positions using the old I O Board as a guide 8 Set switch SW4 to their proper positions using the old I O Board as a guide 9 Partially slide the new I O Board into the 6888Xi enclosure Ensure the board is co...

Page 91: ...and Service 83 6888Xi Advanced Electronics Reference Manual Section 5 Maintenance and Service 00809 0100 4892 January 2019 FIGURE 5 4 I O Board Wiring Connections FIGURE 5 5 I O Board Flame Safety Interlock Wiring ...

Page 92: ...on 5 Maintenance and Service Reference Manual January 2019 00809 0100 4892 FIGURE 5 6 I O Board Positions in the 6888Xi Enclosure Part Number Description 6A00269G01 Enhanced Software Option Upgrade Stoichiometric Function 6A00269G02 Enhanced Software Option Upgrade Programmable Reference Function 6A00269G03 Enhanced Software Option Upgrade Extended Temperature Function 6A00267604 Enhanced Software...

Page 93: ... Board 1 Loosen the four screws securing the 6888Xi cover The screws are captive and do not need to be completely removed 2 Swing the 6888Xi cover down to expose the inner components 3 Tag and disconnect wiring for the Relay In 4 Slide the AC Relay Board part way out of the 6888Xi enclosure 5 Tag and disconnect the two 3 position plugs for the AC input and transmitter probe heater wiring Remove th...

Page 94: ...he enclo sure and re install it in the right most slot Ensure the board is correctly aligned within the slots See Figure 5 8 for the correct location of the I O Board 6 If there is not sufficient wiring tag and disconnect all wiring and relocate the board Then reinstall the wiring Section 5 Maintenance and Service Reference Manual January 2019 00809 0100 4892 86 Maintenance and Service FIGURE 5 7 ...

Page 95: ...ls 11 Slide the AC Relay Board completely into the 6888Xi enclosure 12 Swing the cover up in place and tighten the four screws 5 5 3 Power Supply Board Replacement Use the procedure that follows to replace the Power Supply board in the 6888Xi Use this proce dure to replace an original Linear Power Supply board or the current configuration Switching Power Supply board 1 Loosen the four screws secur...

Page 96: ...board A new ribbon cable 7 Figure 5 1 is provided in the replacement kit and should be used if the 6888Xi cable is damaged 11 Connect the AC power plug to the Power Supply board 12 Swing the 6888Xi cover up and tighten the four mounting screws 5 5 4 Front Panel Replacement Use the procedure that follows to replace the front panel on the 6888Xi Replacement kits with and without the CPU board are av...

Page 97: ... 14 pin ribbon cable going to the Power Supply board A new cable is sup plied in the replacement kit and should be used if the old one is damaged 4 Disconnect the 10 pin ribbon cable s going to the I O Board s One new cable is supplied in the replacement kit and should be used if either of the ribbon cables are damaged 5 Remove the wire hinge from the right side of the 6888Xi cover A paper clip or...

Page 98: ...ssary reconfigure the appearance of the main display Refer to Section 3 Configuration Startup and Operation 5 5 5 DR Board Replacement Use the procedure that follows to replace the DR board in the 6888Xi that is connected to a Direct Replacement probe 1 Loosen the four screws securing the 6888Xi cover The screws are captive and do not need to be completely removed 2 Swing the 6888Xi cover down to ...

Page 99: ... When initialization is complete the Probe will begin heating up but an alarm condition will be shown Prior to using the Transmitter for measurement purposes perform one of the following a Recalibrate the O2 Probe according to the applicable calibration instructions in Section 3 b Synchronize the calibration parameters as follows i Press the DIAG button once to view the alarms A Probe Changed alar...

Page 100: ...ance and Service Reference Manual January 2019 00809 0100 4892 FIGURE 5 11 DR Board Wiring Left Hand Side v Use the Up Down keys to select 1 Get From Probe Press ENTER twice vi When transfer is complete press EXIT twice to return to the main menu ...

Page 101: ...anel Mount 6A00243G01 Ribbon Cable 10 Pin CPU Board to I O Board 6A00242G01 Ribbon Cable 14 Pin CPU Board to Power Supply Board 6A00291H01 Insulator 6A00381G01 Kit Hole Plug Gland 6A00285H01 Gasket Panel 6A00287H01 Gasket Cover Note If the existing I O Board has been operated with the Stoichiometric enhanced software feature this feature must be activated in the new board before the 6888Xi is put ...

Page 102: ...94 Replacement Parts Section 6 Replacement Parts Reference Manual January 2019 00809 0100 4892 ...

Page 103: ...e standing in front of the instrument For more information call Rosemount Analytical at 1 800 433 6076 FIGURE 7 1 375 475 Field Communicator 7 2 Asset Management Solutions AMS Asset Management Solutions AMS software works in conjunction with the HART Communication Protocol and offers the capability to communicate with all HART plant devices from a single computer terminal For more information call...

Page 104: ...provide the capability to perform automatic or on demand calibrations The SPS 4001B is fully enclosed in a NEMA cabinet suited for wall mounting This cabinet provides added protection against dust and minor impacts The SPS 4001B works in conjunction with the 6888Xi eliminating out of calibration occurrences and the need to send a technician to the installation site For more information call Rosemo...

Page 105: ...alibration routines This sequencer works in conjunction with the CALIBRATION RECOMMENDED feature eliminat ing out of calibration occurrences and the need to send a technician to the installation site In addition the IMPS 4000 provides a remote contact input to initiate a calibration from a remote location and relay outputs to alert when a calibration is in progress an O2 Probe is out of calibra ti...

Page 106: ... and Service Kits have been carefully designed to pro vide a more convenient and fully portable means of testing calibrating and servicing Rosemount Analytical s oxygen analyzers These lightweight disposable gas cylinders eliminate the need to rent gas bottles For more information call Rosemount Cutsomer Support at 1 855 724 2628 FIGURE 7 4 Calibration Gas Bottles ...

Page 107: ...nce Display And Averaging System Optional OxyBalance Display and Averaging System Reviews up to eight 4 20 mA signals from individual probes Trends individual outputs calculates four programmable averages as addi tional 4 20 mA outputs For more information call Rosemount Cutsomer Support at 1 855 724 2628 FIGURE 7 5 OxyBalance System ...

Page 108: ...o 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 stan dard such as IEC947 All wiring must conform with any local standards 7 Where equipment or covers are marked with the symbol to the right hazardous voltages are likely t...

Page 109: ...needed information or materials The center will ask for product model and serial numbers and will provide a Return Material Authorization RMA number The center will also ask for the process material to which the product was last exposed Emerson Instrument and Valves Response Center representatives will explain the additional information and proce dures necessary to return goods exposed to hazardou...

Page 110: ...tions for Use 1 Mounting option 01 was not certified to provide Type 4X ingress protection through the panel cut out opening The panel mount gasket has not been tested for Type 4X installation Canada CSA Certificate 1913435 Standards CAN CSA C22 2 No 61010 1 04 UL 61010 1 2004 2nd Edition CAN CSA C22 2 No 94 M91 R2001 UL 50 11th Ed Markings Type 4X 102 Appendix C Appendix C Product Certifications ...

Page 111: ...Reference Manual Appendix D EU Declaration of Conformity 00809 0100 4892 January 2019 Appendix D 103 Appendix D EU Declaration of Conformity ...

Page 112: ...Appendix E 104 Appendix E China RoHS Table Reference Manual January 2019 00809 0100 4892 Appendix E China RoHS Table ...

Page 113: ...105 ...

Page 114: ...e of the Emerson family of companies All other marks are the property of their respective owners The contents of this publication are presented for information purposes only and while effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees expressed or implied regarding the products or services described herein or their use or applicability All sales ...

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