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Instruction Manual

IB-106-340AC Rev. 1.3

January 2003

Rosemount Analytical Inc. A Division of Emerson Process Management

Troubleshooting 5-1

SPS 4000

SECTION 5

TROUBLESHOOTING

5-1 OVERVIEW

This section describes the SPS 4000 trouble-
shooting procedures. Additional troubleshooting
information can be found in the Oxymitter 4000
Oxygen Transmitter Instruction Bulletin.

Install all protective equipment covers
and safety ground leads after trouble-
shooting. Failure to replace covers
and ground leads could result in seri-
ous injury or death.

5-2

SPS 4000 TROUBLESHOOTING

Use the CAL FAIL and IN CAL relay outputs to
identify possible SPS faults.

a.

If a calibration was not successfully com-
pleted, the SPS 4000 sends a CAL FAIL
contact indication to the control room. To
determine if the SPS 4000 caused the failed
calibration, go to the Oxymitter 4000 site to
view the keypad. Or, access the HART/AMS
menus. For more information on HART/
AMS, refer to the HART/AMS section in the
Oxymitter 4000 Oxygen Transmitter Instruc-
tion Bulletin.

1. If no alarms are indicated on the key-

pad or in the HART/AMS STATUS sub-
menu, the calibration did not fail be-
cause of an Oxymitter 4000 fault.
Therefore, a calibration gas flow prob-
lem occurred. Refer to Table 5-1 or
Figure 5-1 to troubleshoot the SPS
4000.

2. If the LAST CAL FAILED alarm is indi-

cated on the keypad or in the HART/
AMS STATUS sub-menu, the failure is

due to either a bad Oxymitter 4000 cell
or a calibration gas flow problem.

(a) Verify your calibration setup per

paragraph 2-3 in Section 2, IN-
STAL-LATION; Section 3, OP-
ERATION; and paragraph 4-8 in
Section 4, MAINTENANCE AND
SERVICE.

(b) Perform another calibration and

monitor the process. If the calibra-
tion fails before both calibration
gases finish sequencing, a gas
flow problem exists. Refer to Table
5-1 or Figure 5-1 to troubleshoot
the SPS 4000.

If the calibration setup is correct
and the Oxymitter 4000 indicates
an invalid slope fault (fault 12) be-
fore the gases are purged and a
last calibration failed fault (fault 14)
after the gases are purged, replace
the Oxymitter 4000 cell per the
Oxymitter 4000 Oxygen Transmit-
ter Instruction Bulletin.

b.

If a semi-automatic or manual calibration is
being performed but no 5 - 30 VDC relay
output contact (IN CAL or CAL FAIL) is be-
ing received by the control room, the inter-
face board relays are malfunctioning.
Replace the interface board per paragraph
4-3 in Section 4, MAINTENANCE AND
SERVICE.

NOTE

If the unit is performing frequent auto-
calibrations, investigate at the Oxymit-
ter 4000 site or using HART/AMS. This
condition may indicate an aging cell in
the Oxymitter 4000.

5

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Содержание ROSEMOUNT Analytical SPS 4000 B201110

Страница 1: ...Instruction Manual IB 106 340AC Rev 1 3 January 2003 http www processanalytic com SPS 4000 Single Probe Autocalibration Sequencer ...

Страница 2: ... of the instructions contact your Rosemount Analytical repre sentative for clarification Follow all warnings cautions and instructions marked on and supplied with the product Inform and educate your personnel in the proper installation operation and mainte nance of the product Install your equipment as specified in the Installation Instructions of the appropriate In struction Manual and per applic...

Страница 3: ...sh these components as separate order items because the calibration gas bottles cannot be shipped via airfreight Page 7 1 Added Table 7 2 to list the calibration gas bottles and flow regulators as replacement parts Effective April 2001 Rev 1 1 Page Summary Page 7 1 Table 7 1 changed part number of solenoid items 24 and 30 Effective January 2002 Rev 1 2 Page Summary Page 1 2 and 7 1 Added bottle ra...

Страница 4: ......

Страница 5: ...ons 2 1 2 4 Electrical Connections 2 3 3 0 OPERATION 3 1 3 1 Overview 3 1 3 2 Calibration Requirements 3 1 3 3 Calibration Gas Flow Setup 3 2 3 4 Automatic Calibration 3 2 3 5 Semi Automatic Calibration 3 2 4 0 MAINTENANCE AND SERVICE 4 1 4 1 Overview 4 1 4 2 Fuse Replacement 4 1 4 3 Board Replacement 4 1 4 4 Solenoid Replacement 4 3 4 5 Pressure Switch Replacement 4 5 4 6 Check Valve Replacement ...

Страница 6: ...S 4000 Components 1 5 Figure 1 4 SPS 4000 Calibration Setup 1 7 Figure 2 1 Installation 2 2 Figure 2 2 Electrical Connections 2 4 Figure 4 1 SPS 4000 Exploded View 4 2 Figure 4 2 Board Connections 4 4 Figure 5 1 SPS 4000 Troubleshooting Flowchart Sheet 1 of 2 5 3 LIST OF TABLES Table 1 1 Product Matrix 1 2 Table 1 2 Calibration Components 1 2 Table 5 1 SPS 4000 Fault Finding 5 2 Table 7 1 SPS 4000...

Страница 7: ...ound throughout this publication Highlights an operation or maintenance procedure practice condition state ment etc If not strictly observed could result in injury death or long term health hazards of personnel Highlights an operation or maintenance procedure practice condition state ment etc If not strictly observed could result in damage to or destruction of equipment or loss of effectiveness NO...

Страница 8: ... of this equipment connection to the mains supply should only be made 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 ...

Страница 9: ...Also use the product matrix in Table 1 1 to compare your order number against your unit The first part of the matrix defines the model The last part defines the various options and features of the sequencer Ensure the features and options specified by your order number are on or included with the unit 1 2 OVERVIEW The SPS 4000 provides the capability of per forming automatic timed or on demand cal...

Страница 10: ...Classifications Class I Div I Group B C D PENDING 3 SPS 4000 B 20 1 1 10 Example Notes 1 Reference air is recommended with 9 ft 2 74 m and 12 ft 3 66 m long probes Reference air is also recommended when ambient air may not contain the normal 20 95 O2 such as when the probe is mounted into a positive pressure duct with leaks or where there is a process unit nearby with leaks 2 Customer to pipe from...

Страница 11: ...GRALLY MOUNTED SPS 4000 SINGLE PROBE AUTOCALIBRATION SEQUENCER REFER TO IB 106 340 1 PROBE INTEGRAL OR REMOTE 26010003 Figure 1 2 Autocalibration System Installation Options In addition to the SPS 4000 multiprobe se quencers are also available as shown in Figure 1 2 Rosemount has offered multiprobe auto calibration sequencer systems for many years These autocalibration systems are most cost effect...

Страница 12: ...C Electrical classification NEMA 4X IP56 Explosion proof option both pending CENELEC EExd IIB H2 Class 1 Div 1 Group B C D Electrical feedthroughs 1 2 in NPT Input power 90 to 250VAC 50 60Hz Power consumption 5VA maximum External electrical noise EN 50 082 2 includes 4KV electrostatic discharge Handshake signal to from Oxymitter 4000 self powered 5V 5mA maximum Cal initiate contact input from cont...

Страница 13: ...ids activate and deactivate to allow the calibration gases to flow between the sequencer and Oxymitter 4000 c Pressure Switch The pressure switch detects if the pressure of a calibration gas is low which can be caused by an empty gas bottle a discon nected gas line etc Calibration is prohib ited when calibration gas pressure is low d Power Supply Board This board converts the incoming line volt ag...

Страница 14: ...paragraphs describe how an Oxymitter 4000 is autocali brated when used with the SPS 4000 a In addition to the calibration methods avail able via the Oxymitter 4000 keypad HART communicator AMS software or a remote contact the SPS 4000 works in conjunction with the Oxymitter 4000 s CAL RECOM MENDED feature to perform an autocalibra tion This feature automatically per forms an impedance check every ...

Страница 15: ...0 BOTTOM VIEW CALIBRATION GAS FITTING REFERENCE AIR SEE NOTE 2 CHECK VALVE SEE NOTE 1 A CHECK VALVE IS REQUIRED AT THE OXYMITTER 4000 BETWEEN THE CALI BRATION GAS FITTING AND THE GAS LINE TO PREVENT THE MIGRATION OF PROCESS GASES DOWN THE CALIBRATION GAS LINE CLEAN DRY INSTRUMENT AIR IS RECOMMENDED FOR REFERENCE AIR NO REFERENCE AIR IS REQUIRED IF AMBIENT AIR CONDITIONS CONTAIN 20 95 OXYGEN NOTE 1...

Страница 16: ...Instruction Manual IB 106 340AC Rev 1 3 January 2003 1 8 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management SPS 4000 ...

Страница 17: ...following procedure to connect the cali bration gases and reference air a Reference Air Figure 2 1 1 For units with the optional reference air components connect the instrument air supply to the IN port of the pressure regulator 2 The pressure regulator is factory set at 20 psi 138 kPa If necessary readjust by turning the knob on the top of the regulator until the desired pressure is obtained 3 Ne...

Страница 18: ...OMINAL CLEARANCE TO REMOVE COVER 1 4 IN TUBE FITTING FOR INSTRUMENT AIR IN OPTIONAL 1 2 IN CONDUIT FITTING FOR LINE VOLTAGE 1 2 IN NPT CONDUIT PORT SEE NOTE 2 14 81 376 17 NOMINAL CALIBRATION GAS FLOWMETER CALIBRATION GAS OUT TO OXYMITTER 4000 REFERENCE AIR FLOWMETER OPTIONAL REFERENCE AIR OUT TO OXYMITTER 4000 13 50 342 90 4 25 107 95 NOTES 1 2 DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTH...

Страница 19: ...h one of the 1 2 in NPT conduit ports on the manifold Figure 2 1 and out through the bottom of the manifold Connect the 5V 5 mA maximum logic I O leads from the Oxymitter 4000 to the terminal strip as indicated in Figure 2 2 d To set up the SPS 4000 to initiate a calibra tion from a remote location route the 5 VDC calibration initiate contact input through one of the 1 2 in NPT conduit ports on th...

Страница 20: ...IN CAL NEUTRAL GROUND 5 V 5mA MAXIMUM LOGIC I O HANDSHAKE CONNECTION TO OXYMITTER 4000 5 30 VDC TO RELAY OUTPUT CONNECTIONS 5 VDC SELF POWERED TO REMOTE CONTACT INPUT CONNECTION 90 250 VAC 50 60 HZ LINE VOLTAGE INPUT FACTORY WIRING TO INTERFACE BOARD NOT USED FACTORY WIRING TO POWER SUPPLY BOARD 26010007 BLACK WHITE RED YELLOW BROWN BLUE ORANGE GREEN Figure 2 2 Electrical Connections ...

Страница 21: ...able gas bottles available from Rosemount two ad ditional sources of calibrated gas mixtures are LIQUID CARBONIC GAS CORP SPECIALTY GAS LABORATORIES 700 South Alameda Street Los Angeles California 90058 213 585 2154 767 Industrial Road San Carlos California 94070 415 592 7303 9950 Chemical Road Pasadena Texas 77507 713 474 4141 12054 S W Doty Avenue Chicago Illinois 60628 312 568 8840 603 Bergen S...

Страница 22: ...when the CAL RECOMMENDED LED activates To enable handshake mode the Oxymitter 4000 logic I O must be set for mode 8 Handshake mode is configured at the fac tory or can be accessed through HART AMS Refer to the logic I O information in the HART AMS section of the Oxymitter 4000 Oxygen Transmitter Instruction Bulle tin for more information b Timed Interval An automatic calibration can also be pro gr...

Страница 23: ...p and turning 1 4 turn clockwise f Install manifold cover 28 and secure with manifold cover lock 21 and screw 22 4 3 BOARD REPLACEMENT Perform the following procedure to replace power supply board 23 Figure 4 1 or interface board 31 Disconnect and lock out power before working on any electrical components a Turn off power to the system b Remove screw 22 securing manifold cover lock 21 and remove t...

Страница 24: ...26010009 50 49 48 47 1 2 3 6 4 5 7 12 13 12 11 12 23 24 14 15 16 17 18 19 20 NOTE A STANDARD SPS 4000 IS EQUIPPED WITH TEFLON TUBING AND BRASS FITTINGS OPTIONAL STAINLESS STEEL TUBING AND FITTINGS ARE ALSO AVAILABLE REFER TO SECTION VI FOR ORDERING INFORMATION 27 25 26 28 29 30 31 32 33 34 35 36 9 10 8 10 38 39 41 40 42 43 44 45 46 37 Figure 4 1 SPS 4000 Exploded View ...

Страница 25: ...g Optional 49 Straight Fitting Optional 50 Flowmeter Bracket 51 Bracket 52 Screw j Carefully separate boards 23 and 31 k Connect replacement board to board 23 or 31 l Install screws 37 washers 34 and stop nuts 33 to secure interface board 31 and power supply board 23 to spacers 35 m Install all applicable leads in the appropriate locations on the power supply board or in terface board as shown in ...

Страница 26: ...L FAIL LINE IN IN CAL NEUTRAL GROUND N STATUS INDICATOR OUTPUT 26010012 REMOTE CONTACT INPUT LINE VOLTAGE INPUT TO CALIBRATION GAS 2 SOLENOID TO CALIBRATION GAS 1 SOLENOID TO PRESSURE SWITCH POWER SUPPLY BOARD INTERFACE BOARD GROUND VAC INPUT TO OXYMITTER 4000 L1 LOGIC I O HANDSHAKE TO OXYMITTER 4000 WHITE RED BLUE ORANGE GREEN YELLOW YELLOW BROWN Figure 4 2 Board Connections ...

Страница 27: ... mounting holes on the manifold and securing with screws 32 Ensure o rings 36 are in stalled between the spacers and the mani fold surface k Install manifold cover 28 and secure with manifold cover lock 21 and screw 22 l Turn on the calibration gases at the cylinders 4 5 PRESSURE SWITCH REPLACEMENT Use the following procedure to replace pressure switch 27 Figure 4 1 a Turn off power to the system ...

Страница 28: ... the cell and bias the calibration In applications with a heavy dust loading the O2 probe diffusion element may become plugged over time causing a slower speed of response The best way to detect a plugged diffusion element is to note the time it takes the Oxymitter 4000 to return to the normal process reading after the last cali bration gas is removed and the calibration gas line is blocked off A ...

Страница 29: ...is not nec essary to remove fittings 39 and 49 from the street fittings For calibration gas flowmeter 46 remove elbow fittings 44 and 47 i Apply pipe thread sealant to the threads of top fitting 48 or 47 and bottom fitting 43 or 44 and install fittings into new flowmeter 45 or 46 j Position flowmeter 45 or 46 into flowmeter bracket 50 and secure with bracket 51 and screw 52 k For reference air flo...

Страница 30: ...Instruction Manual IB 106 340AC Rev 1 3 January 2003 4 8 Maintenance and Service Rosemount Analytical Inc A Division of Emerson Process Management SPS 4000 ...

Страница 31: ...prob lem occurred Refer to Table 5 1 or Figure 5 1 to troubleshoot the SPS 4000 2 If the LAST CAL FAILED alarm is indi cated on the keypad or in the HART AMS STATUS sub menu the failure is due to either a bad Oxymitter 4000 cell or a calibration gas flow problem a Verify your calibration setup per paragraph 2 3 in Section 2 IN STAL LATION Section 3 OP ERATION and paragraph 4 8 in Section 4 MAINTEN...

Страница 32: ...bration gas flow meter knob counter clockwise to allow calibration gas to flow Calibration gas line between manifold and calibration gas flowmeter Clogged calibration gas line Replace clogged calibration gas line Fuse on power supply board Blown fuse Replace fuse per paragraph 4 2 Interface board option Interface board not sending signals Replace interface board per paragraph 4 3 Check valve Clogg...

Страница 33: ...HART AMS REPLACED CLOGGED CAL GAS LINE BETWEEN CAL GAS CYLINDER AND MANIFOLD REPLACED CLOGGED CAL GAS LINE BETWEEN MANIFOLD AND CAL GAS FLOWMETER 35970001 PROPERLY CONNECT WIRING OR SECURE LOOSE WIRING CON NECTIONS REPLACE DAMAGED WIRING REPLACE FUSE PER PARAGRAPH 4 2 SYMPTOM NO CALIBRATION GAS FLOW NO NO NO NO YES YES YES YES YES NO CONTINUED ON SHEET 2 OF 2 IS WIRING PROPERLY CONNECTED AND SECUR...

Страница 34: ... MANIFOLD OUTPUT PORT REPLACE PRESSURE SWITCH PER PARAGRAPH 4 5 DISCONNECT SOLENOID FROM POWER SUPPLY BOARD AND USE METER TO MEASURE ACROSS TWO OUTER PINS OF BOARD CONNECTOR SEE NOTE 4 CHECK BOTH SOLENOIDS REPLACE CHECK VALVE PER PARAGRAPH 4 6 SEE NOTE 3 REPLACE CLOGGED CAL GAS LINE BETWEEN CAL GAS FLOWMETER AND CHECK VALVE DISCONNECT CAL GAS LINE AT TOP FITTING OF CAL GAS FLOWMETER REPLACE FAULTY...

Страница 35: ...ment is faulty 2 The environment in which the equip ment was operating housing weather vibration dust etc 3 Site from where the equipment was removed 4 Whether warranty or nonwarranty service is requested 5 Complete shipping instructions for the return of the equipment d Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in a Rosemount Ret...

Страница 36: ...Instruction Manual IB 106 340AC Rev 1 3 January 2003 6 2 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management SPS 4000 ...

Страница 37: ...rence Air Pressure Regulator Optional Figure 4 1 25 1A97913H03 Fuse 5A 250V 5 x 20 mm Slow Blow Figure 4 1 31 4850B56G02 Interface Board Figure 4 1 23 4850B54G01 Power Supply Board Figure 4 1 27 7305A67H01 Pressure Switch Figure 4 1 24 and 30 3D39435G01 Solenoid Figure 4 1 18 4850B75H01 Terminal Cover Gasket Figure 4 1 16 1A99147H01 Terminal Strip Table 7 2 Calibration Replacement Parts Figure and...

Страница 38: ...Instruction Manual IB 106 340AC Rev 1 3 January 2003 7 2 Replacement Parts Rosemount Analytical Inc A Division of Emerson Process Management SPS 4000 ...

Страница 39: ...Electrical Feedthroughs 1 4 1 5 Electrical Noise 1 4 Explosion proof Rating 1 4 F Flow Regulators 1 2 7 1 Flowmeter 1 6 2 1 3 2 4 3 4 6 4 7 5 2 5 3 5 4 Fuse 4 1 5 2 5 3 G Gas Connections 2 1 H Handshake Signal 1 4 2 3 3 2 HART 1 6 3 2 5 1 5 2 5 3 Humidity 1 4 I Input Power 1 4 Interface Board 1 6 2 4 4 1 4 3 4 4 5 1 5 2 5 4 L Line Voltage 2 3 Logic I O 2 3 2 4 3 2 5 2 5 3 M Manifold 1 4 1 5 2 1 Me...

Страница 40: ...Instruction Manual IB 106 340AC Rev 1 3 January 2003 8 2 Index Rosemount Analytical Inc A Division of Emerson Process Management SPS 4000 ...

Страница 41: ...e remedy ies for any failure of Rosemount to comply with the warranty provisions whether claims by the purchaser are based in contract or in tort including negligence Rosemount does not warrant equipment against normal deterioration due to environment Factors such as corrosive gases and solid particulates can be detrimental and can create the need for re pair or replacement as part of normal wear ...

Страница 42: ...rescent Singapore 128461 Republic of Singapore T 65 777 8211 F 65 777 0947 http www processanalytic com Fisher Rosemount GmbH Co Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884209 EUROPE MIDDLE EAST AFRICA Fisher Rosemount Ltd Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 LATIN AMERICA Fisher Rosemount Av das Americas 3333 sala 10...

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