Oxymitter 5000 - Emerson Rosemount Analytical... · Instruction Manual IB-106-350C Rev. 1.0 April...

Instruction ManualIB-106-350C Rev. 1.0April 2001

http://www.processanalytic.com

Oxymitter 5000Hazardous Area Oxygen Transmitterwith Foundation Fieldbus CommunicationsCertified to: CENELEC EEx d IIB T2/T6

CSA NRTL/C Class I, Division 1, Groups C, D T2/T6

Emerson Process Management

Rosemount Analytical Inc.Process Analytic Division1201 N. Main St.Orrville, OH 44667-0901T (330) 682-9010F (330) 684-4434e-mail: [email protected]


ESSENTIAL INSTRUCTIONSREAD THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national andinternational standards. Because these instruments are sophisticated technical products, youMUST properly install, use, and maintain them to ensure they continue to operate within theirnormal specifications. The following instructions MUST be adhered to and integrated into yoursafety program when installing, using, and maintaining Rosemount Analytical products. Failure tofollow the proper instructions may cause any one of the following situations to occur: Loss of life;personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any 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 applicable local and national codes. Connect all products to theproper electrical 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 partsspecified by Rosemount. Unauthorized parts and procedures can affect the product�s per-formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY.Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, exceptwhen maintenance is being performed by qualified persons, to prevent electrical shockand personal injury.

The information contained in this document is subject to change without notice.

If a Model 275 Universal HART® Communicator is used with this unit, the software withinthe Model 275 may require modification. If a software modification is required, pleasecontact your local Fisher-Rosemount Service Group or National Response Center at 1-800-433-6076 or 1-888-433-6829.

HIGHLIGHTS OF CHANGES

Effective April, 2001 Rev. 1.0

Page Summary

Throughout Removed Warning �Consult Safety Data Sheet 1A99078��.

Front Cover Moved �Essential Instructions� page xxiii/xxiv forward to Front Cover.Changed National Response Center phone number to 1-800-433-6076 or 1-888-433-6829.

Page 1-8 Changed Hazardous Area Certifications data. Changed Reference Airrequirement. Deleted Electronic Noise requirement.

Page 2-9 Added Note to Figure 2-7.

Page 5-2 Table 5-1; changed Heater Fault 6 Self-Clearing column data to �NO�and Heater Fault 8 Self-Clearing column data to �YES�.

Page 5-6 Added factory assistance phone number to paragraph 5-4d1.

Back Cover Added new Warranty statement.

Instruction ManualIB-106-350C Rev. 1.0

April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management i

Oxymitter 5000

TABLE OF CONTENTS

PREFACE........................................................................................................................P-1Definitions ........................................................................................................................ P-1Safety Instructions .......................................................................................................... P-3Material Safety Data Sheets......................................................................................... P-5

1-0 DESCRIPTION AND SPECIFICATIONS...................................................................... 1-11-1 Component Checklist Of Typical System (Package Contents) .................................. 1-11-2 System Overview............................................................................................................ 1-11-3 IMPS 4000 (Optional) .................................................................................................... 1-71-4 SPS 4000 (Optional)...................................................................................................... 1-71-5 Specifications................................................................................................................... 1-8

2-0 INSTALLATION .............................................................................................................. 2-12-1 Mechanical Installation ................................................................................................... 2-12-2 Electrical Installation....................................................................................................... 2-82-3 Pneumatic Installation .................................................................................................... 2-9

3-0 STARTUP AND OPERATION ...................................................................................... 3-13-1 General ............................................................................................................................ 3-13-2 Logic I/O ......................................................................................................................... 3-43-3 Recommended Configuration......................................................................................... 3-53-4 Power Up ........................................................................................................................ 3-63-5 Start Up Oxymitter 5000 Calibration............................................................................ 3-73-6 IMPS 4000 Connections................................................................................................ 3-73-7 SPS 4000 Connections ................................................................................................. 3-73-8 Operation From Local Keypad...................................................................................... 3-7

4-0 MAINTENANCE AND SERVICE .................................................................................. 4-14-1 Overview.......................................................................................................................... 4-14-2 Calibration........................................................................................................................ 4-14-3 LED Status Indicators.................................................................................................... 4-64-4 Hazardous Area Oxymitter 5000 Removal/Replacement ........................................... 4-74-5 Electronics Replacement................................................................................................ 4-94-6 Entire Probe Replacement (Excluding Electronics) .................................................. 4-124-7 Heater Strut Replacement ........................................................................................... 4-134-8 Cell Replacement ......................................................................................................... 4-144-9 Ceramic Diffusion Element Replacement................................................................... 4-164-10 Assembly Replacement................................................................................................ 4-17

5-0 TROUBLESHOOTING.................................................................................................... 5-15-1 General ............................................................................................................................ 5-15-2 Alarm Indications ............................................................................................................ 5-15-3 Alarm Contacts ............................................................................................................... 5-15-4 Identifying And Correcting Alarm Indications .............................................................. 5-2

6-0 OPTIONAL ACCESSORIES.......................................................................................... 6-1

7-0 RETURN OF MATERIAL .............................................................................................. 7-1


ii Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

8-0 REPLACEMENT PARTS ............................................................................................... 8-1

9-0 APPENDICES ................................................................................................................. 9-1Appendix A. Fieldbus Parameter Description.............................................................. A-1Appendix B. Analog Input (AI) Function Block .......................................................... B-1Appendix C. PID Function Block .................................................................................C-1

10-0 INDEX............................................................................................................................ 10-1


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Rosemount Analytical Inc. A Division of Emerson Process Management iii

Oxymitter 5000

LIST OF ILLUSTRATIONS

Figure 1-1. Typical System Package ....................................................................................... 1-2Figure 1-2. Hazardous Area Oxymitter 5000 Autocalibration System Options........................ 1-4Figure 1-3. Hazardous Area Oxymitter 5000 FOUNDATION Fieldbus Connections............... 1-5Figure 1-4. Typical System Installation .................................................................................... 1-6Figure 2-1. Hazardous Area Oxymitter 5000 Installation ......................................................... 2-2Figure 2-2. Hazardous Area Oxymitter 5000 with Abrasive Shield.......................................... 2-3Figure 2-3. Hazardous Area Oxymitter 5000 Adaptor Plate Installation .................................. 2-4Figure 2-4. Hazardous Area Oxymitter 5000 Mounting Flange Installation ............................. 2-5Figure 2-5. Orienting the Optional Vee Deflector ..................................................................... 2-6Figure 2-6. Installation with Drip Loop and Insulation Removal............................................... 2-7Figure 2-7. Terminal Block ....................................................................................................... 2-9Figure 2-8. Air Set, Plant Air Connection ............................................................................... 2-10Figure 2-9. Hazardous Area Oxymitter 5000 Gas Connections............................................. 2-10Figure 3-1. Integral Electronics ................................................................................................ 3-1Figure 3-2. Hazardous Area Oxymitter 5000 Defaults ............................................................. 3-3Figure 3-3. Startup and Normal Operation............................................................................... 3-6Figure 3-4. Calibration Keys..................................................................................................... 3-7Figure 3-5. Normal Operation................................................................................................... 3-8Figure 4-1. Hazardous Area Oxymitter 5000 Exploded View .................................................. 4-2Figure 4-2. Membrane Keypad................................................................................................. 4-3Figure 4-3. Inside Right Cover ................................................................................................. 4-5Figure 4-4. Terminal Block ....................................................................................................... 4-8Figure 4-5. Electronic Assembly............................................................................................... 4-9Figure 4-6. J8 Connector........................................................................................................ 4-10Figure 4-7. Fuse Location ...................................................................................................... 4-12Figure 4-8. Heater Strut Assembly......................................................................................... 4-14Figure 4-9. Cell Replacement Kit ........................................................................................... 4-14Figure 4-10. Ceramic Diffusion Element Replacement............................................................ 4-16Figure 4-11. Contact and Thermocouple Assembly Replacement .......................................... 4-18Figure 5-1. Fault 1, Open Thermocouple ................................................................................. 5-3Figure 5-2. Fault 2, Shorted Thermocouple ............................................................................. 5-4Figure 5-3. Fault 3, Reversed Thermocouple .......................................................................... 5-5Figure 5-4. Fault 4, A/D Comm Error ....................................................................................... 5-6Figure 5-5. Fault 5, Open Heater ............................................................................................. 5-7Figure 5-6. Fault 6, High High Heater Temp............................................................................ 5-8Figure 5-7. Fault 7, High Case Temp....................................................................................... 5-9Figure 5-8. Fault 8, Low Heater Temp ................................................................................... 5-10Figure 5-9. Fault 9, High Heater Temp .................................................................................. 5-11Figure 5-10. Fault 10, High Cell mV......................................................................................... 5-12Figure 5-11. Fault 11, Bad Cell ................................................................................................ 5-13Figure 5-12. Fault 12, EEPROM Corrupt ................................................................................. 5-14Figure 5-13. Fault 13, Invalid Slope ......................................................................................... 5-15Figure 5-14. Fault 14, Invalid Constant .................................................................................... 5-16Figure 5-15. Fault 15, Last Calibration Failed .......................................................................... 5-17Figure 8-1. Cell Replacement Kit ............................................................................................. 8-2Figure 8-2. Probe Disassembly Kit........................................................................................... 8-3


iv Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

LIST OF TABLES

Table 1-1. Product Matrix........................................................................................................ 1-9Table 1-2. Calibration Components ...................................................................................... 1-10Table 1-3. Intelligent Multiprobe Test Gas Sequencer ......................................................... 1-10Table 3-1. Logic I/O Configuration .......................................................................................... 3-4Table 3-2. Logic I/O Parameters............................................................................................. 3-5Table 4-1. Diagnostic/Unit Alarms .......................................................................................... 4-7Table 5-1. Diagnostic/Unit Alarm Fault Definitions ................................................................. 5-2Table 8-1. Replacement Parts for Probe ................................................................................ 8-1Table 8-2. Replacement Parts for Electronics ........................................................................ 8-4


April 2001

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

Oxymitter 5000

PREFACE

The purpose of this manual is to provide information concerning the components, func-tions, installation and maintenance of the Oxymitter 5000 Hazardous Area Oxygen Trans-mitter with Foundation Fieldbus Communications.

Some sections may describe equipment not used in your configuration. The user shouldbecome thoroughly familiar with the operation of this module before operating it. Readthis instruction manual completely.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout thispublication.

Highlights an operation or maintenanceprocedure, practice, condition, state-ment, etc. If not strictly observed, couldresult in injury, death, or long-termhealth hazards of personnel.

Highlights an operation or maintenanceprocedure, practice, condition, state-ment, etc. If not strictly observed, couldresult in damage to or destruction ofequipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure,condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERSThe number in the lower right corner of each illustration in this publication is a manual illus-tration number. It is not a part number, and is not related to the illustration in any technicalmanner.


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

Oxymitter 5000

Oxymitter 5000HAZARDOUS AREAOXYGEN TRANSMITTERWITH FOUNDATIONFIELDBUS COMMUNICATIONS

NOTICE

Read this manual before working with the product. For personal and system safety, and foroptimum product performance, make sure you thoroughly understand the contents before in-stalling, using, or maintaining this product.

The products described in this document are NOT designed for nuclear-qualifiedapplications.

Using non-nuclear-qualified products in applications that require nuclear-qualified hardwareor products may cause inaccurate readings.

For information on Fisher-Rosemount nuclear-qualified products, contact your local Fisher-Rosemount Sales Representative.

Rosemount is a registered trademark of Rosemount Inc.Delta V, the Delta V logotype, PlantWeb, and the PlantWeb logotype are trademarks of Fisher-Rosemount.FOUNDATION is a trademark of the Fieldbus Foundation.

Rosemount satisfies all obligations coming from legislation to harmonize the product require-ments in the European Union.


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Oxymitter 5000

IMPORTANT

SAFETY INSTRUCTIONSFOR THE WIRING AND INSTALLATION

OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They shouldbe strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or NationalStandards.

1. Adequate earth connections should be made to all earthing points, internal and external,where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cableanchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only bemade through a circuit breaker which will disconnect all circuits carrying conductors during afault 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 providedand clearly marked as such. Circuit breakers or switches must comply with a recognizedstandard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazard-ous voltages are likely to be present beneath. These covers should only beremoved when power is removed from the equipment � and then only bytrained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is adanger from hot surfaces beneath. These covers should only be removed bytrained service personnel when power is removed from the equipment. Cer-tain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer tothe Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the follow-ing standards: EN61010-1, IEC417, and ISO3864.



Oxymitter 5000


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Oxymitter 5000

CERAMIC FIBER PRODUCTSMATERIAL SAFETY DATA SHEET

JULY 1, 1996

SECTION I. IDENTIFICATION

PRODUCT NAME

Ceramic Fiber Heaters, Molded Insulation Modules and Ceramic Fiber Radiant Heater Panels.

CHEMICAL FAMILY

Vitreous Aluminosilicate Fibers with Silicon Dioxide.

CHEMICAL NAME

N.A.

CHEMICAL FORMULA

N.A.

MANUFACTURER�S NAME AND ADDRESS

Watlow Columbia 573-474-94022101 Pennsylvania Drive 573-814-1300, ext. 5170Columbia, MO 65202

HEALTH HAZARD SUMMARYWARNING

• Possible 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 1800ºF) can cause severe respiratory disease.



Oxymitter 5000

SECTION II. PHYSICAL DATA

APPEARANCE AND ODOR

Cream to white colored fiber shapes. With or without optional white to gray granular surface coating and/oroptional black surface coating.

SPECIFIC WEIGHT: 12-25 lb./cubic foot BOILING POINT: N.A.

VOLATILES (% BY WT.): N.A. WATER SOLUBILITY: N.A.

SECTION III. HAZARDOUS INGREDIENTS

MATERIAL, QUANTITY, AND THRESHOLD/EXPOSURE LIMIT VALUES

Aluminosilicate (vitreous) 99+ % 1 fiber/cc TWACAS. No. 142844-00-06 10 fibers/cc CLZirconium Silicate 0-10% 5 mg/cubic meter (TLV)Black Surface Coating** 0 - 1% 5 mg/cubic meter (TLV)Armorphous Silica/Silicon Dioxide 0-10% 20 mppcf (6 mg/cubic meter)

PEL (OSHA 1978) 3 gm cubic meter(Respirable dust): 10 mg/cubic meter,Intended TLV (ACGIH 1984-85)

**Composition is a trade secret.

SECTION IV. FIRE AND EXPLOSION DATA

FLASH POINT: None FLAMMABILITY LIMITS: N.A.

EXTINGUISHING MEDIA

Use extinguishing agent suitable for type of surrounding fire.

UNUSUAL FIRE AND EXPLOSION HAZARDS / SPECIAL FIRE FIGHTING PROCEDURES

N.A.


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Oxymitter 5000

SECTION V. HEALTH HAZARD DATA

THRESHOLD LIMIT VALUE

(See Section III)

EFFECTS OF OVER EXPOSURE

EYE

Avoid contact with eyes. Slightly to moderately irritating. Abrasive action may cause damage to outer surfaceof eye.

INHALATION

May cause respiratory tract irritation. Repeated or prolonged breathing of particles of respirable size maycause inflammation of the lung leading to chest pain, difficult breathing, coughing and possible fibrotic changein the lung (Pneumoconiosis). Pre-existing medical conditions may be aggravated by exposure: specifically,bronchial hyper-reactivity and chronic bronchial or lung disease.

INGESTION

May cause gastrointestinal disturbances. Symptoms may include irritation and nausea, vomiting and diarrhea.

SKIN

Slightly to moderate irritating. May cause irritation and inflammation due to mechanical reaction to sharp,broken ends of fibers.

EXPOSURE TO USED CERAMIC FIBER PRODUCT

Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) may undergo partialconversion to cristobalite, a form of crystalline silica which can cause severe respiratory disease (Pneumoco-niosis). The amount of cristobalite present will depend on the temperature and length of time in service. (SeeSection IX for permissible exposure levels).

SPECIAL TOXIC EFFECTS

The existing toxicology and epidemiology data bases for RCF�s are still preliminary. Information will be up-dated as studies are completed and reviewed. The following is a review of the results to date:

EPIDEMIOLOGY

At this time there are no known published reports demonstrating negative health outcomes of workers exposedto refractory ceramic fiber (RCF). Epidemiologic investigations of RCF production workers are ongoing.

1) There is no evidence of any fibrotic lung disease (interstitial fibrosis) whatsoever on x-ray.2) There is no evidence of any lung disease among those employees exposed to RCF that had never smoked.3) A statistical �trend� was observed in the exposed population between the duration of exposure to RCF and a

decrease in some measures of pulmonary function. These observations are clinically insignificant. In other words,if these observations were made on an individual employee, the results would be interpreted as being within thenormal range.

4) Pleural plaques (thickening along the chest wall) have been observed in a small number of employees who had along duration of employment. There are several occupational and non-occupational causes for pleural plaque. Itshould be noted that plaques are not �pre-cancer� nor are they associated with any measurable effect on lungfunction.



Oxymitter 5000

TOXICOLOGY

A number of studies on the health effects of inhalation exposure of rats and hamsters are available. Rats wereexposed to RCF in a series of life-time nose-only inhalation studies. The animals were exposed to 30, 16, 9,and 3 mg/m3, which corresponds with approximately 200, 150, 75, and 25 fibers/cc.

Animals exposed to 30 and 16 mg/m3 were observed to have developed a pleural and parenchymal fibroses;animals exposed to 9 mg/m3 had developed a mild parenchymal fibrosis; animals exposed to the lowest dosewere found to have the response typically observed any time a material is inhaled into the deep lung. While astatistically significant increase in lung tumors was observed following exposure to the highest dose, there wasno excess lung cancers at the other doses. Two rats exposed to 30 mg/m3 and one rat exposed to 9 mg/m3 de-veloped masotheliomas.

The International Agency for Research on Cancer (IARC) reviewed the carcinogenicity data on man-made vit-reous fibers (including ceramic fiber, glasswool, rockwool, and slagwool) in 1987. IARC classified ceramicfiber, fibrous glasswool and mineral wool (rockwool and slagwool) as possible human carcinogens (Group2B).

EMERGENCY FIRST AID PROCEDURES

EYE CONTACT

Flush eyes immediately with large amounts of water for approximately 15 minutes. Eye lids should be heldaway from the eyeball to insure thorough rinsing. Do not rub eyes. Get medical attention if irritation persists.

INHALATION

Remove person from source of exposure and move to fresh air. Some people may be sensitive to fiber inducedirritation of the respiratory tract. If symptoms such as shortness of breath, coughing, wheezing or chest paindevelop, seek medical attention. If person experiences continued breathing difficulties, administer oxygen un-til medical assistance can be rendered.

INGESTION

Do not induce vomiting. Get medical attention if irritation persists.

SKIN CONTACT

Do not rub or scratch exposed skin. Wash area of contact thoroughly with soap and water. Using a skin creamor lotion after washing may be helpful. Get medical attention if irritation persists.

SECTION VI. REACTIVITY DATA

STABILITY/CONDITIONS TO AVOID

Stable under normal conditions of use.

HAZARDOUS POLYMERIZATION/CONDITIONS TO AVOID

N.A.

INCOMPATIBILITY/MATERIALS TO AVOID

Incompatible with hydrofluoric acid and concentrated alkali.

HAZARDOUS DECOMPOSITION PRODUCTS

N.A.


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Oxymitter 5000

SECTION VII. SPILL OR LEAK PROCEDURES

STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED

Where possible, use vacuum suction with HEPA filters to clean up spilled material. Use dust suppressantwhere sweeping if necessary. Avoid clean up procedure which may result in water pollution. (Observe Spe-cial Protection Information Section VIII.)

WASTE DISPOSAL METHODS

The transportation, treatment, and disposal of this waste material must be conducted in compliance with all ap-plicable Federal, State, and Local regulations.

SECTION VIII. SPECIAL PROTECTION INFORMATION

RESPIRATORY PROTECTION

Use NIOSH or MSHA approved equipment when airborne exposure limits may be exceeded. NIOSH/MSHAapproved breathing equipment may be required for non-routine and emergency use. (See Section IX for suit-able equipment).

Pending the results of long term health effects studies, engineering control of airborne fibers to the lowest lev-els attainable is advised.

VENTILATION

Ventilation should be used whenever possible to control or reduce airborne concentrations of fiber and dust.Carbon monoxide, carbon dioxide, oxides of nitrogen, reactive hydrocarbons and a small amount of formalde-hyde may accompany binder burn-off during first heat. Use adequate ventilation or other precautions to elimi-nate vapors resulting from binder burn-off. Exposure to burn-off fumes may cause respiratory tract irritation,bronchial hyper-reactivity and asthmatic response.

SKIN PROTECTION

Wear gloves, hats and full body clothing to prevent skin contact. Use separate lockers for work clothes to pre-vent fiber transfer to street clothes. Wash work clothes separately from other clothing and rinse washing ma-chine thoroughly after use.

EYE PROTECTION

Wear safety glasses or chemical worker�s goggles to prevent eye contact. Do not wear contact lenses whenworking with this substance. Have eye baths readily available where eye contact can occur.



Oxymitter 5000

SECTION IX. SPECIAL PRECAUTIONS

PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING

General cleanliness should be followed.

The Toxicology data indicate that ceramic fiber should be handled with caution. The handling practices de-scribed in this MSDS must be strictly followed. In particular, when handling refractory ceramic fiber in anyapplication, special caution should be taken to avoid unnecessary cutting and tearing of the material to mini-mize generation of airborne dust.

It is recommended that full body clothing be worn to reduce the potential for skin irritation. Washable or dis-posable clothing may be used. Do not take unwashed work clothing home. Work clothes should be washedseparately from other clothing. Rinse washing machine thoroughly after use. If clothing is to be laundered bysomeone else, inform launderer of proper procedure. Work clothes and street clothes should be kept separateto prevent contamination.

Product which has been in service at elevated temperatures (greater than 1800ºF/982ºC) may undergo partialconversion to cristobalite, a form of crystalline silica. This reaction occurs at the furnace lining hot face. Asa consequence, this material becomes more friable; special caution must be taken to minimize generation ofairborne dust. The amount of cristobalite present will depend on the temperature and length in service.

IARC has recently reviewed the animal, human, and other relevant experimental data on silica in order to criti-cally evaluate and classify the cancer causing potential. Based on its review, IARC classified crystalline silicaas a group 2A carcinogen (probable human carcinogen).

The OSHA permissible exposure limit (PEL for cristobalite is 0.05 mg/m3 (respirable dust). The ACGIHthreshold limit value (TLV) for cristobalite is 0.05 mg/m3 (respirable dust) (ACGIH 1991-92). Use NIOSH orMSHA approved equipment when airborne exposure limits may be exceeded. The minimum respiratory pro-tection recommended for given airborne fiber or cristobalite concentrations are:

CONCENTRATION

0-1 fiber/cc or 0-0.05 mg/m3 cristobalite Optional disposable dust respirator (e.g. 3M(the OSHA PEL) 9970 or equivalent).

Up to 5 fibers/cc or up to 10 times the Half face, air-purifying respirator equippedOSHA PEL for cristobalite with high efficiency particulate air (HEPA)

filter cartridges (e.g. 3M 6000 series with2040 filter or equivalent).

Up to 25 fibers/cc or 50 times the OSHA Full face, air-purifying respirator with highPEL for cristobalite (2.5 mg/m3) efficiency particulate air (HEPA) filter cart-

ridges (e.g. 3M 7800S with 7255 filters orequivalent) or powered air-purifying respirator(PARR) equipped with HEPA filter cartridges(e.g. 3M W3265S with W3267 filters orequivalent).

Greater than 25 fibers/cc or 50 times the Full face, positive pressure supplied air respira-OSHA PEL for cristobalite (2.5 mg/m3) tor (e.g. 3M 7800S with W9435 hose & W3196

low pressure regulator kit connected to cleanair supply or equivalent).


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Oxymitter 5000

If airborne fiber or cristobalite concentrations are not known, as minimum protection, use NIOSH/MSHA ap-proved half face, air-purifying respirator with HEPA filter cartridges.

Insulation surface should be lightly sprayed with water before removal to suppress airborne dust. As waterevaporates during removal, additional water should be sprayed on surfaces as needed. Only enough watershould be sprayed to suppress dust so that water does not run onto the floor of the work area. To aid the wet-ting process, a surfactant can be used.

After RCF removal is completed, dust-suppressing cleaning methods, such as wet sweeping or vacuuming,should be used to clean the work area. If dry vacuuming is used, the vacuum must be equipped with HEPAfilter. Air blowing or dry sweeping should not be used. Dust-suppressing components can be used to clean uplight dust.

Product packaging may contain product residue. Do not reuse except to reship or return Ceramic Fiber prod-ucts to the factory.



Oxymitter 5000

GENERAL PRECAUTIONS FOR HANDLING ANDSTORING HIGH PRESSURE GAS CYLINDERS

Edited from selected paragraphs of the CompressedGas Association�s �Handbook of Compressed Gases�published in 1981Compressed Gas Association1235 Jefferson Davis HighwayArlington, Virginia 22202Used by Permission

1. Never drop cylinders or permit them to strike each other violently.

2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to preventrusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extremetemperatures are prevalent.

3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in acylinder stand, and is ready to be used.

4. Avoid dragging, rolling, or sliding cylinders, even for short distance; they should be moved by using a suitable hand-truck.

5. Never tamper with safety devices in valves or cylinders.

6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is attached to a pres-surized system.

7. No part of cylinder should be subjected to a temperature higher than 125°F (52°C). A flame should never be permitted tocome in contact with any part of a compressed gas cylinder.

8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions mustbe taken to prevent striking an arc against the cylinder.


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

Oxymitter 5000

SECTION 1DESCRIPTION AND SPECIFICATIONS

1-1 COMPONENT CHECKLIST OF TYPICALSYSTEM (PACKAGE CONTENTS)

A typical Rosemount Hazardous Area Oxymitter5000 Oxygen Transmitter should contain theitems shown in Figure 1-1. Record the partnumber, serial number, and order number foreach component of your system in the table lo-cated on the first page of this manual.

The Hazardous Area Oxymitter 5000 isoffered in both hazardous and generalpurpose configurations. The hazard-ous area version has the �EX� andCSA symbols on the apparatus ap-proval label. The general purpose ver-sion does not have an approval label.If you received the general purposeversion, ensure you do not install it ina potentially explosive atmosphere.

Use the product matrix in Table 1-1 at the endof this section to compare your order numberagainst your unit. The first part of the matrix de-fines the model. The last part defines the vari-ous options and features of the Hazardous AreaOxymitter 5000. Ensure the features and op-tions specified by your order number are on orincluded with the unit.

1-2 SYSTEM OVERVIEW

a. Scope

This Instruction Bulletin is designed to sup-ply details needed to install, start up, oper-ate, and maintain the Hazardous AreaOxymitter 5000. Integral signal conditioningelectronics outputs a digital FOUNDATIONfieldbus signal representing an O2 value andprovides a membrane keypad for setup,calibration, and diagnostics. This same in-formation, plus additional details, can be

accessed via fieldbus digitalcommunications.

b. FOUNDATION Fieldbus Technology

FOUNDATION fieldbus is an all digital, serial,two-way communication system that intercon-nects field equipment such as sensors, actua-tors, and controllers. Fieldbus is a Local AreaNetwork (LAN) for instruments used in both pro-cess and manufacturing automation with built-incapacity to distribute the control applicationacross the network. The fieldbus environment isthe base level group of digital networks in thehierarchy of planet networks.

The fieldbus retains the desirable features of the4-20 mA analog system, including a standard-ized physical interface to the wire, bus powereddevices on a single wire, and intrinsic safety op-tions, and enables additional capabilities, suchas:

• Increased capabilities due to full digitalcommunications

• Reduced wiring and wire terminations dueto multiple devices on one set of wires

• Increased selection of suppliers due tointeroperability

• Reduced loading on control room equip-ment with the distribution of some controland input/ output functions to field devices

• Speed options for process control andmanufacturing applications

c. System Description

The Hazardous Area Oxymitter 5000 is de-signed to measure the net concentration ofoxygen in an industrial process; i.e., theoxygen remaining after all fuels have beenoxidized. The probe is permanently posi-tioned within an exhaust duct or stack andperforms its task without the use of a sam-pling system.


1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

21

5

4

3

33100001

6

1. Instruction Bulletin 2. IMPS 4000 Intelligent Multiprobe Test Gas Sequencer (Optional) 3. Hazardous Area Oxymitter 5000 with Integral Electronics 4. SPS 4000 Single Probe Autocalibration Sequencer (Optional) � (Shown with reference air option) (Safe area only) 5. Adaptor Plate with Mounting Hardware and Gasket 6. Reference Air Set (used if SPS 4000 without reference air option or IMPS 4000 not supplied)

Figure 1-1. Typical System Package


April 2001


Oxymitter 5000

The equipment measures oxygen percent-age by reading the voltage developedacross a heated electrochemical cell, whichconsists of a small yttria-stabilized, zirconiadisc. Both sides of the disc are coated withporous metal electrodes. When operated atthe proper temperature, the millivolt outputvoltage of the cell is given by the followingNernst equation:

EMF = KT log10(P1/P2) + CWhere:

1. P2 is the partial pressure of the oxygenin the measured gas on one side of thecell.

2. P1 is the partial pressure of the oxygenin the reference air on the opposite sideof the cell.

3. T is the absolute temperature.4. C is the cell constant.5. K is an arithmetic constant.

NOTE

For best results, use clean, dry, in-strument air (20.95% oxygen) as thereference air.

When the cell is at operating temperatureand there are unequal oxygen concentra-tions across the cell, oxygen ions will travelfrom the high oxygen partial pressure sideto the low oxygen partial pressure side ofthe cell. The resulting logarithmic outputvoltage is approximately 50 mV per decade.The output is proportional to the inverselogarithm of the oxygen concentration.Therefore, the output signal increases asthe oxygen concentration of the sample gasdecreases. This characteristic enables theHazardous Area Oxymitter 5000 to provideexceptional sensitivity at low oxygenconcentrations.

The Hazardous Area Oxymitter 5000 meas-ures net oxygen concentration in the pres-ence of all the products of combustion,including water vapor. Therefore, it may beconsidered an analysis on a �wet� basis. Incomparison with older methods, such as theportable apparatus, which provides ananalysis on a �dry� gas basis, the �wet�analysis will, in general, indicate a lowerpercentage of oxygen. The difference willbe proportional to the water content of thesampled gas stream.

d. System Configuration

Hazardous Area Oxymitter 5000 units areavailable in three length options, giving theuser the flexibility to use an in situ penetra-tion appropriate to the size of the stack orduct. The options on length are 457 mm (18in.), 0.91 m (3 ft), 1.83 m (6 ft).

The integral electronics control probe tem-perature and provide an output that repre-sents the measured oxygen concentration.The power supply can accept voltages of90-250 VAC and 50/60 Hz; therefore, nosetup procedures are required. The oxygensensing cell is maintained at a constanttemperature by modulating the duty cycle ofthe probe heater portion of the integralelectronics. The integral electronics acceptsmillivolt signals generated by the sensingcell and produces the outputs to be used byremotely connected devices. The output is aFOUNDATION fieldbus digital communica-tion signal.

Two calibration gas sequencers are avail-able to the Hazardous Area Oxymitter 5000,but they must be installed in a non-hazardous, explosive-free environment: theIMPS 4000 and the SPS 4000 (Figure 1-2).

Systems with multiprobe applications mayemploy an optional IMPS 4000 IntelligentMultiprobe Test Gas Sequencer. The IMPS4000 provides automatic calibration gas se-quencing for up to four Hazardous AreaOxymitter 5000 units and accommodatesautocalibrations based on the CALIBRA-TION RECOMMENDED signal from theHazardous Area Oxymitter 5000, a timedinterval set up via fieldbus or the IMPS4000, or when a calibration request isinitiated.

For systems with one or two HazardousArea Oxymitter 5000 units per combustionprocess, an optional remote mounted SPS4000 Single Probe Autocalibration Se-quencer can be used with each HazardousArea Oxymitter 5000 to provide automaticcalibration gas sequencing. The sequencerperforms autocalibrations based on theCALIBRATION RECOMMENDED signalfrom the Hazardous Area Oxymitter 5000, atimed interval set up in fieldbus, or when-ever a calibration request is initiated.



Oxymitter 5000

HAZARDOUS AREA

OXYMITTER 5000

IMPS 4000

(1 TO 4 PROBES)(MUST BE INSTALLED

IN A SAFE AREAOR BE X- OR Z-PURGED

BY THE CUSTOMER)

REMOTE MOUNTED

SPS 4000

(1 PROBE)(MUST BE INSTALLED

IN A SAFE AREA)

33100002

Figure 1-2. Hazardous Area Oxymitter 5000Autocalibration System Options

e. System Features

1. The CALIBRATION RECOMMENDEDfeature detects when the sensing cell islikely out of limits. This may eliminatethe need to calibrate on a �time sincelast cal� basis.

2. The cell output voltage and sensitivityincrease as the oxygen concentrationdecreases.

3. Membrane keypad and FOUNDATIONfieldbus communication are standard.

4. Field replaceable cell, heater, thermo-couple, and diffusion element.

5. The Hazardous Area Oxymitter 5000 isconstructed of rugged 316 L stainlesssteel for all wetted parts.

6. Integral electronics eliminates tradi-tional wiring between probe andelectronics.

7. The integral electronics are adaptablefor line voltages from 90-250 VAC;therefore, no configuration isnecessary.

8. The Hazardous Area Oxymitter 5000membrane keypad is available in fivelanguages:

EnglishFrenchGermanItalianSpanish

9. An operator can calibrate and diagnos-tically troubleshoot the Hazardous AreaOxymitter 5000 in one of three ways:

Accessing the probe keypad requiresopening the electronics housing.Opening the electronic housing willcause the loss of ALL hazardous per-mits. Opening the electronics housingin hazardous areas may cause an ex-plosion resulting in loss of property,severe personal injury, or death. Itmay be required to get a hot workpermit from your company safety offi-cer before opening the electronichousing.

(a) Membrane Keypad. The mem-brane keypad, housed within theright side of the electronics hous-ing, provides fault indication byway of flashing LEDs. Calibrationcan be performed from the mem-brane keypad.

(b) FOUNDATION fieldbus Interface.The Hazardous Area Oxymitter5000�s output carries a signalcontaining the oxygen level en-coded in digital format. This digitaloutput can also be used to com-municate with the Oxymitter andaccess all of the Oxymitter�s statusinformation.


April 2001


Oxymitter 5000

(c) Optional IMPS 4000. The Pro-grammable Logic Controller (PLC)in the IMPS 4000 provides fault in-dications using flashing LEDs andLCD display messages. Refer tothe IMPS 4000 Intelligent Multi-probe Test Gas Sequencer In-struction Bulletin for moreinformation.

f. Handling the Hazardous Area Oxymitter5000

It is important that printed circuitboards and integrated circuits arehandled only when adequate antistaticprecautions have been taken to pre-vent possible equipment damage.

The Hazardous Area Oxymitter 5000 isdesigned for industrial applications.Treat each component of the systemwith care to avoid physical damage.Some probe components are madefrom ceramics, which are susceptibleto shock when mishandled.

g. System Considerations

Prior to installing your Hazardous AreaOxymitter 5000, make sure you have all thecomponents necessary to make the systeminstallation. Ensure all the components areproperly integrated to make the systemfunctional.

After verifying that you have all the compo-nents, select mounting locations and deter-mine how each component will be placed interms of available line voltage, ambienttemperatures, environmental considera-tions, convenience, and serviceability. Fig-ure 1-3 shows a typical system wiring. Atypical system installation is illustrated inFigure 1-4.

A source of instrument air is optional at theHazardous Area Oxymitter 5000 for refer-ence air use. Since the unit is equipped withan in-place calibration feature, provisionscan be made to permanently connect cali-bration gas tanks to the Hazardous AreaOxymitter 5000.

LINE VOLTAGE

2 CALIBRATION GAS LINESBY CUSTOMER

[300 FT (90 M) MAX]

HAZARDOUS AREAOXYMITTER 5000

WITH INTEGRAL ELECTRONICS

FIELDBUS COMPUTERTERMINAL

FIELDBUS DIGITALSIGNAL

33100003

Figure 1-3. Hazardous Area Oxymitter 5000 FOUNDATION Fieldbus Connections



Oxymitter 5000

THE IMPS 4000 OR SPS 4000 MUSTBE INSTALLED IN A NON-HAZARDOUS,EXPLOSIVE-FREE ENVIRONMENT.

FIELDBUSDIGITALSIGNAL

HAZARDOUS AREAOXYMITTER

5000

IMPS 4000* OPTION

IMPS 4000

REFERENCEAIR

LOGIC I/O

CALIBRATIONGAS

ADAPTERPLATE

STACK

DUCT

GASES

CALIBRATIONGAS

1

CALIBRATIONGAS

2

INST. AIRSUPPLY

LINEVOLTAGE


5000

REMOTE MOUNTED

SPS 4000* OPTION

REFERENCEAIR

LOGIC I/O

CALIBRATIONGAS *NOTE:

(WITH REFERENCE AIROPTION)

CALIBRATIONGAS 1

INSTRUMENT AIR SUPPLY

CALIBRATION GAS 2

LINE VOLTAGE

RELAY OUTPUTS ANDREMOTE CONTACT INPUT

ADAPTERPLATE

STACK

DUCT

GASES

LINEVOLTAGE



DUCT

STACK

GASES

CALIBRATIONGAS

ADAPTERPLATE

LINEVOLTAGE

LOGIC I/O

INSTRUMENTAIR SUPPLY(REFERENCE AIR)

PRESSUREREGULATOR

FLOWMETER

STANDARD


5000

33100004

Figure 1-4. Typical System Installation


April 2001


Oxymitter 5000

If the calibration gas bottles will be perma-nently connected, a check valve is requirednext to the calibration fittings on the integralelectronics. This check valve is to preventbreathing of the calibration gas line andsubsequent flue gas condensation and cor-rosion. The check valve is in addition to thestop valve in the calibration gas kit or thesolenoid valves in the IMPS 4000 or SPS4000.

NOTE

The integral electronics is rated NEMA4X (IP66) and is capable of operationat temperatures up to 65°C (149°F).

Retain the packaging in which theHazardous Area Oxymitter 5000 ar-rived from the factory in case anycomponents are to be shipped to an

other site. This packaging has beendesigned to protect the product.

1-3 IMPS 4000 (OPTIONAL)

If using an IMPS 4000 with a Hazardous AreaOxymitter 5000, the sequencer must be in-stalled in a non-hazardous, explosive-free envi-ronment. For further IMPS 4000 information,refer to the IMPS 4000 Intelligent MultiprobeTest Gas Sequencer Instruction Bulletin.

1-4 SPS 4000 (OPTIONAL)

If using an SPS 4000 with a Hazardous AreaOxymitter 5000, the sequencer must be in-stalled in a non-hazardous, explosive-free envi-ronment. For further SPS 4000 information,refer to SPS 4000 Single Probe AutocalibrationSequencer Instruction Bulletin.



Oxymitter 5000

1-5 SPECIFICATIONS

Hazardous Area Oxymitter 5000

Hazardous Area Certifications CENELEC EEx d IIB T2/T6CSA NRTL/C Class I, Division 1, Groups C,D T2

O2 Range:Standard............................................. 0 to 10% O2

0 to 25% O2

0 to 40% O2 (via FOUNDATION fieldbus)Accuracy .................................................... ±0.75% of reading or 0.05% O2, whichever is greaterSystem Response to Calibration Gas........ Initial response in less than 3 seconds

T90 in less than 8 secondsTemperature Limits:

Process .............................................. 0° to 704°C (32° to 1300°F) up to 1300°C (2400°F)with optional accessories

Electronics.......................................... -40° to 85°C (-40° to 185°F)Operating temperature of electronics inside of instrumenthousing, as measured via FOUNDATION fieldbus, or Rose-mount Asset Management Solutions software.

Probe Lengths............................................ 457 mm (18 in.)0.91 m (3 ft)1.83 m (6 ft)

Mounting and Mounting Position ............... Vertical or horizontalSpool pieces are available, P/N 3D39761G02, to offsettransmitter housing from hot ductwork.

Materials:Probe.................................................. Wetted or welded parts - 316L stainless steel

Non-wetted parts - 304 stainless steel, low-copperaluminum

Electronics Enclosure ........................ Low-copper aluminumCalibration.................................................. Manual, semi-automatic, or automaticCalibration Gas Mixtures Recommended.. 0.4% O2, Balance N2

8% O2, Balance N2

Calibration Gas Flow ................................. 2.5 l/m (5 scfh)Reference Air ............................................. 0.25 l/hr (0.5 scfh), clean, dry, instrument-quality air

(20.95% O2), regulated to 34 kPa (5 psi)Electronics ................................................. NEMA 4X, IP66 with fitting and pipe on reference exhaust

port to clear dry atmosphereLine Voltage............................................... 90-250 VAC, 50/60 Hz. No configuration necessary.

3/4 in.-14 NPT conduit port.Signals:

Digital Output ..................................... FOUNDATION fieldbus compatibleLogic I/O............................................. Two-terminal logic contact configurable as either an alarm

output or as a bi-directional calibration handshake signal toIMPS 4000 or SPS 4000.Self-powered (+5 V), in series with 340 ohmsConduit ports � 3/4 in.-14 NPT (one threaded hole for bothanalog output and logic I/O)

Power Requirements:Probe Heater...................................... 175 W nominalElectronics.......................................... 10 W nominalMaximum ........................................... 500 W

Fisher-Rosemount has satisfied all obligations coming from the European legislation to harmonizethe product requirements in Europe.


April 2001


Oxymitter 5000

Table 1-1. Product Matrix

OXT5C Hazardous Area Oxymitter 5000 Explosion Proof In Situ Oxygen Transmitter

Explosion Proof Oxygen Transmitter - Instruction Book

Code Sensing Probe Type with Flame Arrestor1 Ceramic Diffusion Element Probe (ANSI 3 in. 150 lb)2 Snubber Diffusion Element (ANSI 3 in. 150 lb)3 Ceramic Diffusion Element Probe (DIN 2527) - 1/4 in. Tube Fittings4 Snubber Diffusion Element (DIN 2527) - 1/4 in. Tube Fittings5 Ceramic Diffusion Element Probe (JIS)6 Snubber Diffusion Element (JIS)

Code Probe Assembly0 18 in. (457 mm) Probe1 18 in. (457 mm) Probe with 3 ft Bypass2 18 in. (457 mm) Probe with Abrasive Shield(1)

3 3 ft (0.91 m) Probe4 3 ft (0.91 m) Probe with Abrasive Shield(1)

5 6 ft (1.83 m) Probe6 6 ft (1.83 m) Probe with Abrasive Shield(1)

Code Mounting Adaptor - Stack Side0 No Adaptor Plate (“0” must be chosen under “Mounting Adaptor – Probe side” below)1 New Installation - Square weld plate with studs2 Model 218 Mounting Plate (with Model 218 Shield Removed)3 Competitor’s Mount(2)

Code Mounting Adaptor - Probe Side0 No Adaptor Plate1 Probe Only (ANSI)2 New Bypass or New Abrasive Shield (ANSI)4 Probe Only (DIN)5 New Bypass or New Abrasive Shield (DIN)7 Probe Only (JIS)8 New Bypass or New Abrasive Shield (JIS)

Code Electronics Housing - NEMA 4X, IP6611 Standard Filtered Termination12 Transient Protected Filtered Termination

Code Operator Interface(3)

1 Membrane Keypad - fieldbus

Code Language

1 English

2 German

3 French

4 Spanish

5 Italian

OXT5C 3 3 1 1 10 1 1 Continued Example



Oxymitter 5000

Table 1-1. Product Matrix (Continued)

Continued Code Termination Filtering

00 No Option - Specified as part of Electronic Housing

Code Calibration Accessories

00 No Hardware

01 Cal/Ref Flowmeters and Ref Pressure Regulator

02 IMPS 4000 (Safe Area Only) Refer to IMPS matrix

03 SPS 4000 Remote Mounted (Safe Area Only) Refer to SPS matrix

Code Hazardous Area Approval

10 CENELEC EEx d IIB + H2 T2/T6 (Electronics)

20 CSA - Class I, Div. 1, Groups B, C and D T2/T6 (Electronics)

Continued 00 01 10 Example

NOTES:(1)Recommended usages: High velocity particulates in flue stream, installation within 3.5 m (10 ft) of soot blowers or heavy salt cake buildup.

Applications: Pulverized coal, recovery boilers, lime kiln. Regardless of application, abrasive shields with support brackets are recommendedfor 2.74 m (9 ft) and 3.66 m (12 ft) probe installations, particularly horizontal installations.

(2)Where possible, specify SPS number; otherwise, provide details of the existing mounting plate as follows:

Plate with studs Bolt circle diameter, number, and arrangement of studs, stud thread, stud height above mounting plate.

Plate without studs Bolt circle diameter, number, and arrangement of holes, thread, depth of stud mounting plate with accessories.

(3)Start-up, calibration, and operation can be implemented using the standard membrane keyboard. Remove access and additional functional-ity available via Fieldbus Communications (DeltaV).

Table 1-2. Calibration Components

PARTNUMBER DESCRIPTION

1A99119G01 Two disposable calibration gas bot-tles � 0.4% and 8% O2, balancenitrogen � 550 liters each, includesbottle rack*

1A99119G02 Two pressure regulators for calibra-tion gas bottles

* Calibration gas bottles cannot be shipped viaairfreight.

When the bottles are used with �CALIBRATIONRECOMMENDED� features, the bottles shouldprovide 2 to 3 years of calibrations in normalservice.

Table 1-3. Intelligent Multiprobe Test GasSequencer

PARTNUMBER DESCRIPTION

NUMBER OFHAZARDOUS

AREAOXYMITTER5000 UNITS

3D39695G01 IMPS 1

3D39695G02 IMPS 2

3D39695G03 IMPS 3

3D39695G04 IMPS 4

3D39695G05 IMPS w/115 V Heater 1









April 2001

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

Oxymitter 5000

SECTION 2INSTALLATION

The Hazardous Area Oxymitter 5000and probe abrasive shield are heavy.Use proper lifting and carrying proce-dures to avoid personal injury.

Install all protective equipment coversand safety ground leads after installa-tion. Failure to install covers andground leads could result in seriousinjury or death.

2-1 MECHANICAL INSTALLATION

a. Selecting Location

1. The location of the Hazardous AreaOxymitter 5000 in the stack or flue ismost important for maximum accuracyin the oxygen analyzing process. TheHazardous Area Oxymitter 5000 mustbe positioned so the gas it measures isrepresentative of the process. Best re-sults are normally obtained if the Haz-ardous Area Oxymitter 5000 ispositioned near the center of the duct(40 to 60% insertion). Longer ductsmay require several Hazardous AreaOxymitter 5000 units since the O2 canvary due to stratification. A point toonear the wall of the duct, or the insideradius of a bend, may not provide arepresentative sample because of thevery low flow conditions. The sensingpoint should be selected so the proc-ess gas temperature falls within arange of 0° to 704°C (32° to 1300°F).Figure 2-1 through Figure 2-4 providemechanical installation references. Theambient temperature of the integralelectronics housing must not exceed65°C (149°F).

2. Check the flue or stack for holes andair leakage. The presence of this con-dition will substantially affect the accu-racy of the oxygen reading. Therefore,either make the necessary repairs orinstall the Hazardous Area Oxymitter5000 upstream of any leakage.

3. Ensure the area is clear of internal andexternal obstructions that will interferewith installation and maintenance ac-cess to the membrane keypad. Allowadequate clearance for removal of theHazardous Area Oxymitter 5000(Figure 2-1 or Figure 2-2).

Do not allow the temperature of theHazardous Area Oxymitter 5000 inte-gral electronics to exceed 65°C (149°F)or damage to the unit may result.

b. Installation

1. Ensure all components are available toinstall the Hazardous Area Oxymitter5000. If equipped with the optional ce-ramic diffusor element, ensure it is notdamaged.

2. The Hazardous Area Oxymitter 5000may be installed intact as it is received.

NOTE

An abrasive shield is recommendedfor high velocity particulates in theflue stream (such as those in coal-fired boilers, kilns, and recoveryboilers).

3. Weld or bolt adaptor plate (Figure 2-4)onto the duct.


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

Oxymitter 5000

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33100005

Figure 2-1. Hazardous Area Oxymitter 5000 Installation


April 2001


Oxymitter 5000

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E IN

MIL

LIM

ET

ER

SW

ITH

INC

HE

S IN

PA

RE

NT

HE

SE

S.

Figure 2-2. Hazardous Area Oxymitter 5000 with Abrasive Shield



Oxymitter 5000

22

.5o

BC

8T

HR

EA

DE

DH

OL

ES

EQ

UA

LLY

SP

AC

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ON

DD

IAB

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.

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E5

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TIN

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EN

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ITT

ER

50

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HA

BR

AS

IVE

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DIM

EN

SIO

NS

MM

(in

.)

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EN

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MM

(in

.)A

NS

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ID

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INJIS

"A"

"A"

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ST

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.

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DIA

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19

7(7

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29

(9.0

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0.6

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12

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19

1(7

.50

)

15

2.4

(6.0

0)

0.6

25

-11

21

6(8

.50

)2

35

(9.2

5)

M1

6x

21

00

(3.9

4)

19

0(7

.48

)

17

0.0

(6.6

9)

M1

6x

2

23

5(9

.25

)

12

5(4

.92

)

20

0(7

.89

)

M2

0x

2.5

MO

UN

TIN

GP

LA

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FO

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HA

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RD

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SA

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AO

XY

MIT

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R5

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0

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HA

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AS

IVE

SH

IEL

D

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GP

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MIT

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OS

SH

AT

CH

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EA

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AY

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OV

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AD

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ION

AL

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ING

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33100007

C

MO

UN

TIN

GP

LA

TE

OU

TL

INE

Figure 2-3. Hazardous Area Oxymitter 5000 Adaptor Plate Installation


April 2001


Oxymitter 5000

NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPTADAPTOR PLATE NOT FURNISHED BY ROSEMOUNT.

INSTALLATION FOR MASONRYWALL STACK CONSTRUCTION

INSTALLATION FOR METALWALL STACK OR DUCT

CONSTRUCTION

13 (0.50)

95 (3.75)

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

MTG HOLESSHOWN ROTATED45 OUT OFTRUE POSITION

o

WELD OR BOLT MOUNTINGPLATE TO METAL WALLOF STACK OR DUCT.JOINT MUST BE AIRTIGHT.

13 (0.50)

114 (4.50)O.D. REF

PIPE 4.00 IN. SCHED 40PIPE SLEEVE (NOTBY ROSEMOUNT)LENGTH BY CUSTOMER

MASONRYSTACK WALL

OUTSIDE WALLSURFACE

JOINT MUSTBE AIRTIGHT

MTG HOLESSHOWN ROTATED

45 OUT OFTRUE POSITION

o

FIELD WELDPIPE TO

MOUNTING PLATE

BOLT MOUNTINGPLATE TO OUTSIDE

WALL SURFACE

NOTE: DIMENSIONS IN MILLIMETERS WITHINCHES IN PARENTHESES.

82.5 (3.25)

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

WELD OR BOLT MOUNTINGPLATE TO METAL WALLOF STACK OR DUCT.JOINT MUST BE AIRTIGHT.

FIELD WELDPIPE TOMOUNTING PLATE

102 (4.0)O.D. REF

PIPE 3.5 IN. SCHED 40PIPE SLEEVE (NOTBY ROSEMOUNT)LENGTH BY CUSTOMER

MASONRYSTACK WALLOUTSIDE WALL

SURFACE

JOINT MUSTBE AIRTIGHT

BOLT MOUNTINGPLATE TO OUTSIDE

WALL SURFACE

PROBE MOUNTING

ABRASIVE SHIELD MOUNTING

27540004

Figure 2-4. Hazardous Area Oxymitter 5000 Mounting Flange Installation



Oxymitter 5000

4. If using the optional ceramic diffusorelement, the vee deflector must be cor-rectly oriented. Before inserting theHazardous Area Oxymitter 5000, checkthe direction of flow of the gas in theduct. Orient the vee deflector so theapex points upstream toward the flow(Figure 2-5). This may be done byloosening the setscrews and rotatingthe vee deflector to the desired posi-tion. Retighten the setscrews.

5. In vertical installations, ensure thesystem cable drops vertically from theHazardous Area Oxymitter 5000 andthe conduit is routed below the level ofthe electronics housing. This drip loopminimizes the possibility that moisturewill damage the electronics (Figure2-6).

6. If the system has an abrasive shield,check the dust seal gaskets. The jointsin the two gaskets must be staggered180°. Also, make sure the gaskets arein the hub grooves as the HazardousArea Oxymitter 5000 slides into the 15°forcing cone in the abrasive shield.

NOTE

If process temperatures will exceed200°C (392°F), use anti-seize com-pound on stud threads to ease futureremoval of Hazardous Area Oxymitter5000.

7. Insert probe through the opening in themounting plate and bolt the unit to theplate.

NOTE

To maintain CE compliance, ensure agood connection exists between themounting plate studs or earthingscrews on electronics housing andearth.

8. Ensure the Hazardous Area Oxymitter5000 is properly earthed by way ofboth internal and external points.

Uninsulated stacks or ducts maycause ambient temperatures aroundthe electronics to exceed 65°C (149°F),which may cause overheating damageto the electronics.

9. If insulation is being removed to accessthe duct work for Hazardous AreaOxymitter 5000 mounting, make surethe insulation is replaced afterward.See Figure 2-6.

10. Ensure the insulation does not obscurethe messages on either housing cover.

VEEDEFLECTOR

VEEDEFLECTOR

CERAMICDIFFUSIONELEMENT

SETSCREWFILTER

GAS FLOWDIRECTION

APEX

27540009

Figure 2-5. Orienting the Optional Vee Deflector


April 2001


Oxymitter 5000

PS U

E

ITP

IC

RH

WE

NT

HGC

KE

NI -

E

E RW

AVISOLP

-X

OMT

A GNI

N-

R

I

T

LA

I

VE-E

EH

GA

SC

AL.

DRIPLOOP

FIELD BUSDIGITALSIGNALLINE

VOLTAGE

REPLACE INSULATIONAFTER INSTALLINGHAZARDOUS AREAOXYMITTER 5000

INSULATION

MOUNTINGPLATE STACK OR DUCT

METAL WALL33100010

Figure 2-6. Installation with Drip Loop and Insulation Removal



Oxymitter 5000

2-2 ELECTRICAL INSTALLATION

All wiring must conform to local and nationalcodes.

Disconnect and lock out power beforeconnecting the unit to the powersupply.

Install all protective equipment coversand safety ground leads after installa-tion. Failure to install covers andground leads could result in seriousinjury or death.

To meet the Safety Requirements ofIEC 1010 (EC requirement), and ensuresafe operation of this equipment, con-nection to the main electrical powersupply must be made through a circuitbreaker (min 10 A) which will discon-nect all current-carrying conductorsduring a fault situation. This circuitbreaker should also include a me-chanically operated isolating switch. Ifnot, then another external means ofdisconnecting the supply from theequipment should be located close by.Circuit breakers or switches mustcomply with a recognized standardsuch as IEC 947.

The probe and probe abrasive shieldare heavy. Use proper lifting and car-rying procedures to avoid personnelinjury.

a. Remove screw (22, Figure 4-1), cover lock(23), and captive washer (24). Remove ter-minal block cover (21).

b. Connect Line Voltage

Connect the line, or L1, wire to the L1 ter-minal and the neutral, or L2 wire, to the N

terminal (Figure 2-7). The Hazardous AreaOxymitter 5000 automatically will configureitself for 90-250 VAC line voltage and 50/60Hz. The power supply requires no setup.

c. Connect fieldbus Digital Signal andLogic I/O/ Calibration Handshake Leads(Figure 2-7).

1. Fieldbus Digital Signal. The fieldbusdigital signal carries the O2 value. Thisdigital signal can also be used to com-municate with the Oxymitter.

If using an IMPS 4000 or SPS 4000, in-stall it in a non-hazardous, explosive-free environment.

2. Logic I/O/Calibration Handshake. Theoutput can either be an alarm or pro-vide the handshaking to interface withan IMPS 4000. For more information,refer to paragraph 5-3 and the IMPS4000 Intelligent Multiprobe Test GasSequencer Instruction Bulletin.

3. If autocalibration is not utilized, acommon bi-directional logic contact isprovided for any of the diagnosticalarms listed in Table 5-1. The assign-ment of alarms which can actuate thiscontact can be modified to one ofseven additional groupings listed inTable 3-1.

The logic contact is self-powered, +5VDC, 340 ohm series resistance. Aninterposing relay will be required if thiscontact is to be utilized to annunciate ahigher voltage device, such as a lightor horn, and may also be required forcertain DCS input cards. A Potter &Brumfield R10S-E1Y1-J1.0K 3.2 MADC or an equal interposing relay will bemounted where the contact wires ter-minate in the control/relay room.

d. Install terminal block cover (21, Figure 4-1)and secure with captive washer (24), coverlock (23), and screw (22).


April 2001


Oxymitter 5000

AC L1

AC N

+

+

-

-FIELDBUS

GROUNDLUGS

LOGIC I/O/CALIBRATION HANDSHAKE

LINE VOLTAGE(85 TO 264 VAC)

AC TERMINALCOVER

TERMINALBLOCK AC LINE

VOLTAGE PORT

SIGNALPORTLEFT SIDE OF

HAZARDOUS AREAOXYMITTER 5000


33570002

NOTE: SUITABLE GLANDS AND SEALSREQUIRED FOR PROPERELECTRICAL ISOLATION

Figure 2-7. Terminal Block

2-3 PNEUMATIC INSTALLATION

a. Reference Air Package

After the Hazardous Area Oxymitter 5000 isinstalled, connect the reference air set tothe Hazardous Area Oxymitter 5000. Thereference air set should be installed in ac-cordance with Figure 2-8.

Instrument Air (Reference Air): 68.95 kPag(10 psig) minimum, 1551.38 kPag (225psig) maximum at 0.25 l/hr (0.5 scfh) maxi-mum; less than 40 parts-per-million totalhydrocarbons. Regulator outlet pressureshould be set at 35 kPa (5 psi).


If using an IMPS 4000, refer to the IMPS4000 Intelligent Multiprobe Test Gas Se-quencer Instruction Bulletin for the properreference air connections.

If using an SPS 4000, refer to the SPS 4000Single Probe Autocalibration Sequencer In-struction Bulletin for the proper reference airconnections.



Oxymitter 5000

TO ELECTRONICS

REF AIR SET263C152G01

1 FLOWMETER 0.2-2.0 SCFH 771B635H02

2 2" PRESSURE GAGE 0-15 PSIG 275431-006

3 COMBINATION FILTER-REG. 0-30 PSIG 4505C21G01

NOTE: DIMENSIONS ARE IN INCHES WITHMILLIMETERS IN PARENTHESES.

12

3

4.81 (122.17)

FLOW SETPOINT KNOB

0.125-27 NPT FEMALEOUTLET CONNECTION

1.19(30.22)

10.0(254)REF

DRAIN VALVE

3.12 (79.25) MAX

8.50(215.90)

MAX

2.0(50.80)

2 MOUNTING HOLES3.19 (81.03) LG

THROUGH BODY FOR0.312 (7.92) DIA BOLTS

1.50(38.10)

2.250 (57.15)

SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON HAZARDOUS AREA OXYMITTER 5000 PROBE HEAD.

OUTLET

0.25-18 NPT FEMALEINLET CONNECTION

INSTRUMENT AIR SUPPLY10-225 PSIG MAX PRESSURE

28550036

0.250 OR 6 MM O.D. TUBING(SUPPLIED BY CUSTOMER)

FITTING (SUPPLIED BY WECO)TUBE COMPRESSION0.250 OR 6 MM O.D.

500 VA

SERIAL NO.TAG NO.

OXYMITTER 4000

WATTS:VOLTS:FUSE:LINEOUTPUT:

Rosemount Analytical Inc.Orrville, OH 44667-0901

85-264 VAC 48-62 Hz

TM

800-433-6076

4-20 mA

R

5 Amps

TMHARTSMART FAMILY

Figure 2-8. Air Set, Plant Air Connection

Do not use 100% nitrogen as a low gas(zero gas). It is suggested that gas forthe low (zero) be between 0.4% and2.0% O2. Do not use gases with hydro-carbon concentrations of more than 40parts per million. Failure to use propergases will result in erroneousreadings.

Figure 2-9. Hazardous Area Oxymitter 5000 GasConnections

b. Calibration Gas

Two calibration gas concentrations are usedwith the Hazardous Area Oxymitter 5000,Low Gas - 0.4% O2 and High Gas - 8% O2.See Figure 2-9 for the Hazardous AreaOxymitter 5000 connections.


If using an IMPS 4000, refer to the IMPS4000 Intelligent Multiprobe Test Gas Se-quencer Instruction Bulletin for the properreference air connections.

If using an SPS 4000, refer to the SPS 4000Single Probe Autocalibration Sequencer In-struction Bulletin for the proper reference airconnections.


April 2001


Oxymitter 5000

NOTE!Upon completing installation, make sure that the Hazardous Area Oxymitter 5000 is turned onand operating prior to firing up the combustion process. Damage can result from having acold Hazardous Area Oxymitter 5000 exposed to the process gases.

During outages, and if possible, leave all Hazardous Area Oxymitter 5000 units running toprevent condensation and premature aging from thermal cycling.

If the ducts will be washed down during outage, MAKE SURE to power down the HazardousArea Oxymitter 5000 units and remove them from the wash area.



Oxymitter 5000


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-1

Oxymitter 5000

SECTION 3STARTUP AND OPERATION

Install all protective equipment coversand safety ground leads beforeequipment startup. Failure to installcovers and ground leads could resultin serious injury or death.

NOTE

Refer to Appendices A, B, and C forfieldbus information concerning theHazardous Area Oxymitter 5000.

3-1 GENERAL

a. Verify Mechanical Installation

Ensure the Hazardous Area Oxymitter 5000is installed correctly (Section 2,INSTALLATION).

b. Verify Terminal Block Wiring

1. Remove screw (22, Figure 4-1), coverlock (23), and captive washer (24) thatsecure the terminal block cover. Re-move the cover to expose the terminalblock (Figure 3-1).

2. Check the terminal block wiring. Besure the power, fieldbus signal, andlogic outputs are properly connectedand secure.

3. Install the housing cover on the termi-nal block and secure with captivewasher (24, Figure 4-1), cover lock(23), and screw (22).

AC

L1

AC

N

++ --F

IELD

BU

S

500 VA

SERIAL NO.TAG NO.

HAZARDOUS AREA OXYMITTER 5000

WATTS:VOLTS:FUSE:LINEOUTPUT:


85-264 VAC 48-62 Hz

TM

800-433-6076

4-20 mA

R

5 Amps

TMHARTSMART FAMILY

DIAGNOSTICALARMS

TESTPOINTS

HEATER T/CHEATER02 CELL

CALIBRATION

CALIBRATION RECOMMENDED

02 CELL mV +02 CELL mv -HEATER T/C +HEATER T/C -

INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% 02

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON


LOGIC I/O

GROUND LUGS

TERMINALBLOCK

HAZARDOUS AREAOXYMITTER 5000ELECTRONICSHOUSING

33100014

Figure 3-1. Integral Electronics


3-2 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

c. Verify Hazardous Area Oxymitter 5000Configuration

Located on the microprocessor board, thetop board, is a switch that controls thesimulate enable status of the HazardousArea Oxymitter 5000 (Figure 3-2). To allowthe Oxymitter to be placed in simulationmode, place position two of SW2 in the ONposition. Once the Oxymitter has been setto the simulate mode, switch position two ofSW2 to the OFF position to remove theOxymitter from simulate mode. Note thatSW2 does not actually place the Oxymitterin simulate mode, it only allows the Oxy-mitter to be placed into simulate modethrough the fieldbus interface.

Positions 1, 3, and 4 of SW 2 are not used,and should remain in the OFF position.

Typically, the probe�s sensing cell,which is in direct contact with the pro-cess gases, is heated to approximately736°C (1357°F), and the external tem-perature of the probe body may ex-ceed 450°C (842°F). If operatingconditions also contain high oxygenlevels and combustible gases, theHazardous Area Oxymitter 5000 mayself-ignite.

d. O2 Range

The O2 range of the Oxymitter is set throughthe fieldbus interface using the AI

block. Refer to Appendix A for more infor-mation on using the AI block.

e. Once the cell is up to operating tempera-ture, the O2 percentage can be read:

1. Access TP5 and TP6 next to the mem-brane keypad. Attach a multimeteracross TP5 and TP6. The calibrationand process gases can now be moni-tored. Pressing the INC or DEC oncewill cause the output to switch from theprocess gas to the calibration gas.Pressing INC or DEC a second timewill increase or decrease the calibra-tion gas parameter. If the keys havebeen inactive for one minute, the out-put reverts to the process gas. When acalibration has been initiated, the valueat TP5 and TP6 is the % O2 seen bythe cell. Oxygen levels, as seen on themultimeter, are:

8.0% O2 = 8.0 VDC0.4% O2 = 0.4 VDC

NOTE

The maximum reading available at TP5and TP6 is 30 VDC. While the Oxymit-ter will measure oxygen concentra-tions up to 40%, the test point outputwill reach a maximum of 30 VDC at a30% oxygen concentration.

2. FOUNDATION fieldbus.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS

HEATER T/CHEATERO2 CELL

CALIBRATION


O2 CELL mV +O2 CELL mV -HEATER T/C +HEATER T/C -

INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3R

ED

YE

LG

RN

OR

GTP4

TP5

TP6

ON

NOT USED

OFF

NOT USED

NOT USED

NOT USED

NOT USED

ON

NOT USED

DEFAULTPOSITION

(EX-FACTORY)

SIMULATEENABLE

1234

28550011

Figure 3-2. Hazardous Area Oxymitter 5000 Defaults



Oxymitter 5000

3-2 LOGIC I/O

This two-terminal logic contact can be config-ured either as a solid-state relay-activated alarmor as a bi-directional calibration handshake sig-nal to an IMPS 4000 or SPS 4000. The configu-ration of this signal depends on the setting ofthe IO_PIN_MODE parameter via fieldbus. Thedifferent modes available are described in Table3-1. The IO_PIN_MODE and IO_PIN_STATEparameters are described in Table 3-2.

a. Alarm

When configured as an alarm, this signalalerts you to an out-of-spec condition. Theoutput is 5 V in series with a 340 ohm re-sistor. For optimum performance, Rose-mount recommends connecting the outputto a Potter & Bromfield 3.2 mA DC relay(P/N R10S-E1Y1-J1.0K).

Of the ten modes in Table 3-1, modes 0through 7 are the alarm modes. The factorydefault is mode 5 for Hazardous Area Oxy-mitter 5000 units without an IMPS 4000 orSPS 4000. In this mode, the output will sig-nal when a unit alarm or a CALIBRATIONRECOMMENDED indication occurs.

b. Calibration Handshake Signal

If using an optional IMPS 4000 or SPS4000, the logic I/O must be configured forcalibration handshaking. Of the ten modesin Table 3-1, only modes 8 and 9 are con-figured for calibration handshaking. For anHazardous Area Oxymitter 5000 with anIMPS 4000 or an SPS 4000, the factory setsthe default to mode 8. In this mode, thelogic I/O will be used to communicate be-tween the Hazardous Area Oxymitter 5000and sequencer and to signal the sequencerwhen a CALIBRATION RECOMMENDA-TION indication occurs.

Table 3-1. Logic I/O Configuration

Mode Configuration

0 The unit is not configured for any alarm condition.

1 The unit is configured for a Unit Alarm.

2 The unit is configured for Low O2.

3 The unit is configured for both a Unit Alarm and Low O2.

4 The unit is configured for a High AC Impedance/CALIBRATION RECOMMENDED.

5* The unit is configured for both a Unit Alarm and a High AC Impedance/CALIBRATIONRECOMMENDED.

6 The unit is configured for both a Low O2 and High AC Impedance/CALIBRATIONRECOMMENDED.

7 The unit is configured for a Unit Alarm, a Low O2, and a High AC Impedance/CALIBRATIONRECOMMENDED.

8** The unit is configured for a calibration handshake with IMPS 4000 or SPS 4000. CALIBRA-TION RECOMMENDED will initiate the calibration cycle.

9 The unit is configured for a calibration handshake. CALIBRATION RECOMMENDED will notinitiate the calibration cycle with the IMPS 4000 or SPS 4000.

*The default condition for an Hazardous Area Oxymitter 5000 without an IMPS 4000 or SPS 4000.**The default condition for an Hazardous Area Oxymitter 5000 with an IMPS 4000 or SPS 4000.


April 2001


Oxymitter 5000

Table 3-2. Logic I/O Parameters

Parameter Definition RangeParameter

Number

IO_PIN_MODE This parameter represents the operating mode ofthe discrete IO pin of the transmitter.

1-10 40

IO_PIN_STATE This parameter represents the current state of thetransmitter�s discrete IO pin. 0=FALSE, 1=TRUE.

0-1 41

3-3 RECOMMENDED CONFIGURATION

a. Fieldbus Signal Upon Critical Alarm

When a critical alarm occurs which causesthe O2 reading to become unstable or unre-liable, the Oxymitter will flag the O2 reading.All further O2 readings will be flagged as OutOf Service until the problem has been cor-rected.

If the O2 measurement is being utilized aspart of an automatic control loop, the loopshould be placed in manual upon this failureevent, or other appropriate action should betaken.

b. Calibration

Rosemount recommends utilizing an auto-calibration system, actuated by the �calibra-tion recommended� diagnostic. New O2 cellsmay operate for more than a year, but oldercells may require recalibration every fewweeks as they near the end of their life. Thisstrategy ensures that the O2 reading is al-ways accurate, and eliminates many un-necessary calibrations based on calendardays or weeks since previous calibration.When utilizing the SPS 4000 or the IMPS

4000, consider wiring some or all associ-ated alarm contacts.

1. CALIBRATION INITIATE. Contactfrom the control room to an SPS 4000or IMPS 4000 (one per probe) providesthe ability to manually initiate a calibra-tion at any time from the control room.Note that calibrations can also be initi-ated via fieldbus or from the keypad onthe Hazardous Area Oxymitter 5000.

2. IN CALIBRATION. One contact perprobe provides notification to the con-trol room that the �calibration recom-mended� diagnostic has initiated anautomatic calibration through the SPS4000 or IMPS 4000. If the O2 signal isbeing utilized in an automatic controlloop, this contact should be utilized toplace the control loop into manual dur-ing calibration.

3. CALIBRATION FAILED. One contactper probe from and SPS 4000 or IMPS4000 to the control room for notificationthat the calibration procedure failed.Grouped with this alarm is an outputfrom a pressure switch that indicateswhen the calibration gas bottles areempty.



Oxymitter 5000

3-4 POWER UP

a. Startup Display

When power is applied to the probe, the cellheater turns on. It takes approximately onehalf hour for the cell to heat to operatingtemperature. This condition is indicated bythe top four LEDs (DIAGNOSTIC ALARMS)on the membrane keypad (Figure 3-3).Starting with the CALIBRATION LED, theLEDs light in ascending order until all fourLEDs are on. At this point, all four turn offand the cycle starts again. This ramp cyclecontinues until the cell is up to operatingtemperature.

b. Operating Display

The ramp cycle turns into a cycle where thediagnostic LEDs light in sequence from thetop to the bottom, one at a time. After thebottom LED turns on, the sequence starts

again at the top with the HEATER T/C LED(Figure 3-3).

c. Error

If there is an error condition at startup, oneof the diagnostics LEDs will be blinking.Refer to Section 5, TROUBLESHOOTING,to determine the cause of the error. Clearthe error, cycle power, and the operatingdisplay should return.

d. Keypad

The five membrane keys on the membranekeypad are only used during calibration toadjust the high and low gas and to initiatethe calibration sequence (Figure 3-4).

e. Reference Air

Ensure reference air, if used, is set to 56.61/hr (2 scfh).

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION


O2 CELL mV +O2 CELL mv -HEATER T/C +HEATER T/C -

INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

HEATER T/C

HEATER

O CELL2

CALIBRATION

LIGHTING SEQUENCE DURING NORMAL OPERATION

1 2 3 4 1 2 3 4

HEATER T/C

HEATER

O CELL2

CALIBRATION

LIGHTING SEQUENCE DURING WARM-UP

1 2 3 4 1 2 3 4

28550012

Figure 3-3. Startup and Normal Operation


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION


02 CELL mV +02 CELL mv -HEATER T/C +HEATER T/C -

INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% 02

MEMBRANEKEYS

MEMBRANEKEYS

MEMBRANEKEY

33100017

Figure 3-4. Calibration Keys

3-5 START UP OXYMITTER 5000CALIBRATION

Refer to Section 4, MAINTENANCE ANDSERVICE, for calibration instructions.

3-6 IMPS 4000 CONNECTIONS

Ensure the IMPS 4000 is installed in a safe(non-hazardous, explosive-free) area and verifythe wiring and pneumatic connections per theIMPS 4000 Intelligent Multiprobe Test Gas Se-quencer Instruction Bulletin.

3-7 SPS 4000 CONNECTIONS

Ensure the SPS 4000 is installed in a safe (non-hazardous, explosive-free) area and verify thewiring and pneumatic connections per the SPS4000 Single Probe Autocalibration SequencerInstruction Bulletin.

3-8 OPERATION FROM LOCAL KEYPAD

a. Overview

Ensure the Hazardous Area Oxymitter 5000is at normal operation. The diagnostic LEDswill display the operating cycle. All otherLEDs should be off (Figure 3-5).

1. DIAGNOSTIC ALARM LEDS. If thereis an error in the system, one of theseLEDs will flash various blink codes(Section 5, TROUBLESHOOTING). Inthe case of multiple errors, only onewill be displayed based on a prioritysystem. Correct the problem and cyclepower. The operating display will returnor the next error will be displayed. Thealarms are:

HEATER T/CHEATERO2 CELLCALIBRATION

2. CALIBRATION RECOMMENDEDLED. Turns on when the system de-termines a calibration is recommended.

3. TEST POINTS. Test points 1 through6 will allow you to monitor with a mul-timeter: the heater thermocouple, O2

cell millivolt, and the process O2.

(a) TP1 and TP2 monitor the oxygencell millivolt output which equatesto the percentage of oxygenpresent.

(b) TP3 and TP4 monitor the heaterthermocouple.

(c) TP5 and TP6 monitor the processgas or the calibration gas parame-ter. The maximum reading avail-able from these test points is 30VDC. This corresponds to 30%oxygen concentrations.



Oxymitter 5000

4. CAL LED. The CAL LED is on steadyor flashing during calibration. Furtherinformation is available in Section 4,MAINTENANCE AND SERVICE.

5. Keys.

(a) INC and DEC. The INC and DECkeys are used to set the values ofthe calibration gases. Attach amultimeter across TP5 and TP6.The calibration and process gasescan now be monitored. Pressingthe INC or DEC once will cause theoutput to switch from the processgas to the calibration gas. PressingINC or DEC a second time will in-crease or decrease the calibrationgas parameter. If the keys havebeen inactive for one minute, theoutput reverts to the process gas.

When a calibration has been initi-ated, the value at TP5 and TP6 isthe % O2 seen by the cell. Oxygenlevels, as seen on the multimeter,are:

8.0% O2 = 8.0 volts DC0.4% O2 = 0.4 volts DC

(b) CAL. The CAL key can:

1 Initiate a calibration.

2 Sequence through calibration.

3 Abort the calibration.

b. Model 751 Remote Powered Loop LCDDisplay (Optional)

Refer to Remote Powered Loop LCD man-ual for calibration and operation.

HEATER T/C

HEATER

O CELL2

CALIBRATION

LIGHTING SEQUENCE DURING NORMAL OPERATION

1 2 3 4 1 2 3 4

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

CAL LED

28550013

Figure 3-5. Normal Operation


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-1

Oxymitter 5000

SECTION 4MAINTENANCE AND SERVICE

When working on this equipment onthe laboratory bench, be aware thatthe Hazardous Area Oxymitter 5000,probe tube, and flame arrester hub canbe hot [up to 300°C (572°F)] in the re-gion of the probe heater.

Install all protective equipment coversand safety ground leads after equip-ment repair or service. Failure to in-stall covers and ground leads couldresult in serious injury or death.

4-1 OVERVIEW

This section identifies the calibration methodsavailable and provides the procedures to main-tain and service the Hazardous Area Oxymitter5000.

4-2 CALIBRATION

a. During a calibration, two calibration gaseswith known O2 concentrations are applied tothe Hazardous Area Oxymitter 5000. Slopeand constant values calculated from the twocalibration gases determine if the Hazard-ous Area Oxymitter 5000 is correctly meas-uring the net concentration of O2 in theindustrial process.

Before calibrating the Hazardous AreaOxymitter 5000, verify that the calibrationgas parameters are correct by setting the

gas concentrations used when calibratingthe unit (paragraph 3-8a.5) and by settingthe calibration gas flowmeter.

The calibration gas flowmeter regulates thecalibration gas flow and must be set to 5scfh. However, only adjust the flowmeter to5 scfh after placing a new diffusion elementon the end of the Hazardous Area Oxymitter5000. Adjusting the flowmeter at any othertime can pressurize the cell and bias thecalibration.

In applications with a heavy dust loading,the O2 probe diffusion element may becomeplugged over time, causing a slower speedof response. The best way to detect aplugged diffusion element is to note the timeit takes the Hazardous Area Oxymitter 5000to return to the normal process reading afterthe last calibration gas is removed and thecalibration gas line is blocked off. A pluggedelement also can be indicated by a slightlylower reading on the flowmeter.

Change the diffusion element when thecalibration gas flowmeter reads slightlylower during calibration or when the re-sponse time to the process flue gases be-comes very slow. Each time the diffusionelement is changed, reset the calibrationgas flowmeter to 5 scfh and calibrate theHazardous Area Oxymitter 5000. To changethe diffusion element, refer to paragraph4-8.

b. Three types of calibration methods areavailable: automatic, semi-automatic, andmanual.


4-2 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

33100018

42

40

41

27

39

22

22

24 Integral ElectricalBarrier/Feedthrough

24

23

23

15

16

17

18

1920

21

1. Right Housing Cover2. Electronic Assembly3. Screw4. Membrane Keypad5. Microprocessor Board6. Fieldbus Output Board7. Fieldbus Isolator Board8. Fuse Cap9. Fuse10. Power Supply Board

29. Corrugated Seal30. Cell and Flange Assembly

. Retainer Screw32. Flame Arrester with

Snubber Diffuser

11. Snap Connector12. Washer13. Screw14. Captive Screw15. Electronic Housing16. Screw17. Lock Washer18. Cable Clamp19. Terminal Block20. Captive Screw21. Left Housing Cover22. Screw23. Cover Lock24. Captive Washer25. Washer26. Screw27. Probe Tube Assembly28. Gasket

31

33. Tube Nut(Inside Finned Housing)

34. Capillary Breather Tube35. Gas Port36. Cap37. Tube Nut38. O-ring39. Strut Pressure Clamp40. Heater Strut Assembly41. Tube Clamp42. Silicon Tube

Note: Not all parts shown.

35

35

35

34

34

34

33

33

33

37

36

36

29

28

3031

32

38

2625

Note: The Electronic Assembly, item 2,consists of items 3 through 14.

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION

CALIBRATION RECOMMENDED02 CELL mV +

02 CELL mv -

HEATER T/C +

HEATER T/C -

INCINC

DECDEC

HIGHGAS LOWGAS CAL

TEST GAS +PROCESS -% 02

1 14

34

5

6

72

11

8 9

10

1213

Figure 4-1. Hazardous Area Oxymitter 5000 Exploded View


April 2001


Oxymitter 5000

Do not install an IMPS 4000 or SPS4000 within the hazardous area. In-stalling the unit in a potentially explo-sive environment could cause seriousinjury or death and equipment dam-age. Ensure the sequencer is installedin a safe area.

NOTE

A calibration can be aborted any timeduring the process by pressing theCAL key (Figure 4-2) on the HazardousArea Oxymitter 5000 keypad threetimes in a three second interval or viaFOUNDATION fieldbus or an IMPS4000. An aborted calibration will retainthe values of the previous goodcalibration.

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

22220067

Figure 4-2. Membrane Keypad

1. Automatic Calibration. Automatic cali-brations require no operator action.

However, the calibration gases mustbe permanently piped to the Hazard-ous Area Oxymitter 5000, an SPS4000 or IMPS 4000 must be installedto sequence the gases, and the Haz-ardous Area Oxymitter 5000�s logic I/Omust be set to mode 8 via fieldbus us-ing the IO_PIN_MODE parameter sothe sequencer and Hazardous AreaOxymitter 5000 can communicate.

Depending on your system setup, anautomatic calibration can be initiatedby the following methods:

(a) The Hazardous Area Oxymitter5000�s CALIBRATION RECOM-MENDED alarm signals that a cali-bration is required.

(b) Enter a time to next calibration us-ing the TIME_TO_NEXT_CAL pa-rameter via fieldbus. Calibrationswill then occur regularly at thisinterval.

(c) If using an IMPS 4000, enter atime interval via the IMPS 4000keypad that will initiate an auto-matic calibration at a scheduledtime interval (in hours). To set theCalIntvX parameter of theCHANGE PRESETS displaymode, refer to the IMPS 4000 In-telligent Multiprobe Test Gas Se-quencer Instruction Bulletin formore information.

Once an automatic calibration is initi-ated, by any of the methods previouslydescribed, the Hazardous Area Oxy-mitter 5000�s CALIBRATION REC-OMMENDED alarm signals an IMPS4000 or SPS 4000 to initiate a calibra-tion. The sequencer sends an �in cal�signal to the control room so that anyautomatic control loops can be placedin manual. Then, the sequencer beginsto sequence the calibration gases.



Oxymitter 5000

2. Semi-Automatic Calibration. Semi-automatic calibrations only require op-erator initiation. However, the calibra-tion gases must be permanently pipedto the Hazardous Area Oxymitter 5000,an SPS 4000 or IMPS 4000 must beinstalled to sequence the gases, andthe Hazardous Area Oxymitter 5000�slogic I/O must be set to mode 8 or 9 viafieldbus so the sequencer and Hazard-ous Area Oxymitter 5000 cancommunicate.

Depending on your system setup, asemi-automatic calibration can be initi-ated by the following methods:

(a) Hazardous Area Oxymitter 5000.Press the CAL key on the Hazard-ous Area Oxymitter 5000 keypad.

(b) IMPS 4000. Use the IMPS 4000keypad to change the InitCalX pa-rameter of the CHANGE PRE-SETS display mode from 0000 to0001. Refer to the IMPS 4000 In-telligent Multiprobe Test Gas Se-quencer Instruction Bulletin formore information.

(c) FOUNDATION fieldbus. Use field-bus to perform the O2 CAL method.

(d) Remote Contact. Initiate a calibra-tion from a remote location via theremote contact input connectionprovided by an IMPS 4000 or SPS4000. Refer to the documentationavailable for the control system inuse for more information.

Once a semi-automatic calibration isinitiated, by any of the methods previ-ously described, the Hazardous AreaOxymitter 5000�s CALIBRATIONRECOMMENDED alarm signals anIMPS 4000 or SPS 4000 to initiate acalibration. The sequencer sends an�in cal� signal to the control room sothat any automatic control loops can beplaced in manual. Then, the sequencerbegins to sequence the calibrationgases.

3. Manual Calibration. Manual calibra-tions must be performed at the Haz-ardous Area Oxymitter 5000 site andrequire operator intervention through-out the process.

Manual calibration instructions can alsobe found, in condensed form, on theinside of the right electronics housingcover (Figure 4-3).

Use the following procedure to performa manual calibration:

(a) Place control loop in manual.

(b) Verify the calibration gas parame-ters are correct per paragraph4-2a.

(c) If performing a manual calibrationwith CALIBRATION RECOM-MENDED LED off and the CALLED off, start at step 1.

(d) If performing a manual calibrationwith CALIBRATION RECOM-MENDED LED on and the CALLED on, start at step 2.

1 Push the CAL key. The CALI-BRATION RECOMMENDEDLED will come on and theCAL LED will be on solid. If amultimeter is attached acrossTP5 and TP6, the reading willdisplay the percentage ofoxygen seen by the cell.

2 Push the CAL key. The CALI-BRATION RECOMMENDEDLED will turn off and the CALLED will flash continuously.The flashing LED indicatesthat the Hazardous AreaOxymitter 5000 is ready toaccept the first calibrationgas.

3 Apply the first calibration gas.(Electronics will abort the cali-bration if step 4 is not donewithin 30 minutes).


April 2001


Oxymitter 5000

SW2 DIP SWITCH

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

LED

HEATER

O2 CELL

CALIBRATION

HEATER T/C

STATUS

OPEN

SHORTED

REVERSED

HIGH HIGH

TEMP

HIGH CASE

TEMP

LOW TEMP

HIGH TEMP

OPEN

BAD

EPROM

CORRUPT

INVALID SLOPE

INVALID

CONSTANT

FLASHES

1

2

3

4

1

2

OPEN

3

4

5

1

3

4

1

2

PUSH CALCAL LED ON

APPLY TG1

PUSH CAL

CAL LED ON SOLID

REMOVE TG1 & APPLY TG2

PUSH CALCAL LED ON SOLID

WAIT FOR FLASH

REMOVE TG2

PUSH CAL

1

2

3

4

5

6

7

ALARMS

MANUAL

CALIBRATION

CAL LED ON FOR

PURGE TIME

WAIT FOR FLASH

CAL LED OFF

PUSH CALCAL LED FLASH

2 FLASH-VALID CAL

3 FLASH-INVALID CAL

8

PLACE CONTROL LOOP

IN MANUAL

IF CAL LED ON

GO TO STEP 2

*

*

3LAST CAL

FAILED

A/D COMM

ERROR

OFF ON

33100019

Figure 4-3. Inside Right Cover

4 Push the CAL key; the CALLED will be on solid. A timer isactivated to allow the calibra-tion gas adequate time to flow(default time of five minutes).When the timer times out, theHazardous Area Oxymitter5000 has taken the readingsusing the first calibration gasand the CAL LED will flashcontinuously. The flashing in-dicates the Hazardous AreaOxymitter 5000 is ready totake readings using the sec-ond calibration gas.

5 Remove the first calibrationgas and apply the secondcalibration gas. (Electronicswill abort the calibration if step6 is not done within 30minutes).

6 Push the CAL key; the CALLED will be on solid. The timeris activated for the second

calibration gas flow. When thetimer times out, the CAL LEDwill flash a 2 pattern flash or a3 pattern flash (2 pattern flashequals a valid calibration, 3pattern flash equals an invalidcalibration).

If the slope or the constant isout of specification, a diag-nostic alarm LED will beflashing. The diagnostic alarmwill remain active until thepurge cycle is over. If thethree pattern flash occurswithout a diagnostic alarm, thecalibration gases could be thesame or the calibration gaswas not turned on.

The CAL LED flashing indi-cates the calibration is done.(See Section 5, TROUBLE-SHOOTING, for an explana-tion of the 2 pattern and 3pattern flashes).



Oxymitter 5000

7 Remove the second calibra-tion gas and cap off the cali-bration gas port.

8 Push the CAL key; the CALLED will be on solid as theunit purges. (Default purgetime is three minutes). Whenthe purge is complete, theCAL LED will turn off.

If the calibration was valid, the DI-AGNOSTIC ALARMS LEDs will in-dicate normal operation. If the newcalibration values, slope or con-stant, is not within the parameters,the DIAGNOSTIC ALARMS LEDwill indicate an alarm. (See Section5, TROUBLESHOOTING, for alarmcodes). If the calibration was inva-lid, the Hazardous Area Oxymitter5000 will return to normal opera-tion, as it was before a calibrationwas initiated, and the parameterswill not be updated.

(e) Place control loop in automatic.

c. FOUNDATION fieldbus O2 CALMETHOD

To perform a calibration using FOUNDA-TION fieldbus, use the following procedure.

1. From the computer running the fieldbuscontrol program, run the O2 CalMethod.

Failure to remove the Hazardous AreaOxymitter 5000 from automatic controlloops prior to performing this proce-dure may result in a dangerous oper-ating condition.

2. In the first O2 CAL screen, a �Loopshould be removed from automaticcontrol� warning appears. Remove theHazardous Area Oxymitter 5000 fromany automatic control loops to avoid apotentially dangerous operating condi-tion and press OK.

3. From this point, follow the on-screenprompts to complete the calibrationprocedure. When a step is complete,select Proceed to Next Step and pressthe Next button.

4. During the wait periods, such as duringa purge, the Time Remaining displaymay be updated by selecting Updateand pressing the Next button.

4-3 LED STATUS INDICATORS

a. Diagnostic/Unit Alarms

Table 4-1 lists the types and status ofalarms that will be encountered. (SeeSection 5, TROUBLESHOOTING, for a de-tailed description of each fault).


April 2001


Oxymitter 5000

b. When the electronics determines a calibra-tion is recommended, the CALIBRATIONRECOMMENDED LED is on solid.

c. The CAL LED turns on when a calibration isrecommended and is on during the calibra-tion process. During calibration, the CALLED can be flashing, which would indicateoperator action is requested, or on solid,which indicates calculations and measure-ments are in progress.

It is recommended that the HazardousArea Oxymitter 5000 be removed fromthe stack for all service activities. Theunit should be allowed to cool and betaken to a clean work area. Failure tocomply may cause severe burns.

Disconnect and lock out power beforeworking on any electrical components.There is voltage up to 115 VAC.

4-4 HAZARDOUS AREA OXYMITTER 5000REMOVAL/REPLACEMENT

a. Remove

1. Turn off power to the system.

2. Shut off the calibration gases at thecylinders and the instrument air.

3. Disconnect the calibration gas and in-strument air lines from the HazardousArea Oxymitter 5000.

4. While facing the Hazardous AreaOxymitter 5000 and looking at theRosemount label, remove screw (22,Figure 4-1), cover lock (23) and captivewasher (24) securing left housingcover (21). Remove the cover to ex-pose the terminal block Figure 4-4.

Table 4-1. Diagnostic/Unit Alarms

LED FLASHES STATUS FAULT

1 OPEN 1HEATER T/C 2 SHORTED 2

3 REVERSED 34 A/D COMM

ERROR4

1 OPEN 52 HIGH HIGH

TEMP6

HEATER 3 HIGH CASETEMP

7

4 LOW TEMP 85 HIGH TEMP 9

1 HIGH mV 10O2 CELL 3 BAD 11

4 EEPROMCORRUPT

12

CALIBRATION 1 INVALIDSLOPE

13

2 INVALIDCONSTANT

14

3 LASTCALIBRATION

FAILED

15

5. Loosen the screw on the AC terminalcover and slide the cover back to ac-cess the neutral and line terminals.Loosen the AC line and neutral termi-nal screws and remove the leads.Loosen the ground lug screws and re-move the leads. Slide the line powerleads out of the AC line voltage port.

6. Loosen the logic I/O and the fieldbussignal terminal screws. Remove theleads from the terminals and slide thewires out of the signal port.

7. Remove insulation to access themounting bolts. Unbolt the HazardousArea Oxymitter 5000 from the stackand take it to a clean work area.

8. Allow the unit to cool to a comfortableworking temperature.



Oxymitter 5000

b. Replace

1. Bolt the Hazardous Area Oxymitter5000 to the stack and install insulation.

2. Insert the logic I/O and fieldbus signalleads in the signal port and connect tothe logic I/O and fieldbus digital signalscrew terminals (Figure 4-4).

3. Insert the power leads in the AC linevoltage port and connect to the AC linescrew terminals. Connect the line, orL1, wire to the L1 terminal, and theneutral, or L2, wire to the N terminal.Slide the AC terminal cover over theterminal connection and tighten thecover screw.

4. Install left housing cover (21, Figure4-1) and ensure it is tight. Secure thecover using captive washer (24), coverlock (23), and screw (22).

5. Connect the calibration gas and in-strument air lines to the HazardousArea Oxymitter 5000.

6. Turn on the calibration gases at thecylinders and turn on instrument air.

7. Restore power to the system per para-graph 3-4 of Section 3, STARTUP andOPERATION. When the probe is atoperating temperature, calibrate theprobe per paragraph 4-2.

500 VA

R

SERIAL NO.TAG NO.

OXYMITTER 5000

VOLTS: WATTS:OUTPUT: LINE FUSE:


85-264 VAC 48-62 Hz

TM

800-433-6076

4-20 mA

R

5 Amps

TMHARTSMART FAMILY

AC

L1

AC

N

++ --F

IELD

BU

S

GROUNDLUGS

LOGIC I/O


LINE VOLTAGE(90 TO 250 VAC)

AC TERMINALCOVER

TERMINALBLOCK

AC LINEVOLTAGE PORT

SIGNALPORT

LEFT SIDE OFHAZARDOUS AREAOXYMITTER 5000

MOUNTINGSCREW

MOUNTINGSCREW

MOUNTINGSCREW

33100021

Figure 4-4. Terminal Block


April 2001


Oxymitter 5000

4-5 ELECTRONICS REPLACEMENT

Each of the following procedures details how toremove and replace a specific electronic com-ponent of the Hazardous Area Oxymitter 5000.

NOTE

Recalibration is required wheneverelectronic cards or sensing cell is re-placed.

a. Entire Electronics Replacement (withHousing)

1. Follow the instructions in paragraph4-4.a to remove the Hazardous AreaOxymitter 5000 from the stack or duct.

Do not force the probe housing wheninstalling or removing from the inte-gral electrical barrier/feedthrough(Figure 4-1). Damage to the aluminumprobe housing can occur.

2. Remove four screws (26, Figure 4-1)and washers (25) from the probe tubeassembly. The probe and the elec-tronic housing can now be separated.

NOTE

The integral electrical barrier/feedthrough is thread-locked into theelectrical housing and cannot be re-moved.

3. Make sure o-ring (38) is in good condi-tion. Install new electronic housing ando-ring onto the probe tube assembly.

Figure 4-5. Electronic Assembly



Oxymitter 5000

4. Make sure that the conduit port of theelectronic housing is on the same sideas the CAL and REF gas ports. Re-place four washers (25) and screws(26) and tighten.

5. Follow the instructions in paragraph4-4b to install the Hazardous AreaOxymitter 5000 into the stack or duct.

Opening the electronic housing willcause the loss of ALL hazardous per-mits. Opening the electronics housingin hazardous areas may cause an ex-plosion resulting in loss of property,severe personal injury, or death. Itmay be required to get a hot workpermit from your company safety offi-cer before opening the electronichousing.

b. Electronic Assembly Replacement(Figure 4-5)

1. Remove screw (22, Figure 4-1), coverlock (23), and captive washer (24) se-curing right housing cover (1). Removethe right housing cover to expose theelectronic assembly. See Figure 4-5.

2. Depress and remove the J1 (cell andT/C) connector from the J1 socket.Loosen the three captive mountingscrews on the microprocessor board(top board).

3. The J8 connector (heater leads) can beaccessed by moving the J1 connectorleads out of the slot on the microproc-essor board and sliding the electronicassembly partially out of the housing.See Figure 4-6.

3D39619G

REV

1

+

250VACTIME LAG

5A

+

+

+

+

+

+

+

+

1

J8

POWERSUPPLYBOARD

22220061

Figure 4-6. J8 Connector

4. Squeeze the J8 connector on the sidesand carefully remove. The electronicassembly can now be completely re-moved from the housing.

5. The J8 connector (heater leads) can beaccessed by moving the J1 connectorleads out of the slot on the microproc-essor board and sliding the electronicassembly partially out of the housing.See Figure 4-6.


7. Reconnect the J8 connector to thepower supply board. Make sure theconnector is secure.

8. Holding the J1 connector leads, slidethe electronic assembly the rest of theway into the housing. Align the elec-tronic assembly so that it fits flush onthe pins. To ensure that it is flush, gen-tly try to rotate the electronics. If theelectronics rotates, repeat thealignment.


April 2001


Oxymitter 5000

9. Reconnect the J1 connector to the mi-croprocessor board (Figure 4-5). En-sure the connector is secure andtighten the three captive screws on themicroprocessor board (top board).

10. Replace right housing cover (1, Figure4-1) and ensure it is tight. Secure thecover using captive washer (24), coverlock (23), and screw (22).


c. Terminal Block Replacement.(Figure 4-4).

1. Loosen the mounting screws on theterminal block and carefully lift theblock out of the housing.

2. Carefully align the new terminal blockon the pins so that it sits flat in thehousing. The round end of the terminalblock should be on the opposite side ofthe housing conduit ports and shouldnot be able to rotate.

3. Tighten the three mounting screws andensure the terminal block is secure inthe housing.


d. Fuse Replacement. (Figure 4-5).

1. Remove screw (22, Figure 4-1), coverlock (23), and captive washer (24) se-curing right housing cover (1). Removethe right housing cover to expose theelectronic assembly. See Figure 4-5.

2. Depress and remove the J1 (cell andT/C) connector from the J1 socket.Loosen the three captive mountingscrews on the microprocessor board(top board).

3. The J8 connector (heater leads) can beaccessed by moving the J1 connectorleads out of the slot on the microproc-essor board and sliding the electronicassembly partially out of the housing(Figure 4-6).


5. Completely remove the three mountingscrews on the microprocessor board.



Oxymitter 5000

3D39619G

REV

1

+

250VACTIME LAG

5A

+

+

+

+

+

+

+

+

1

FUSE

POWERSUPPLYBOARD

22220058

Figure 4-7. Fuse Location

6. Turn the electronic assembly over sothat you are looking at the bottom ofthe power supply printed circuit board.Gently depress the two white posts oneat a time. Carefully separate the powersupply board from the microprocessorboard.

7. Remove the fuse and replace it with anew one (Figure 4-7).

8. Align the white posts with the postholes on the power supply board andthe pin connector on the power supplyboard with the connector port on theback of the microprocessor board.Gently push the boards together untilthe white posts snap in place. Ensurethe assembly is secure by gently tryingto separate the boards.

9. Reconnect connector J8 to the powersupply board. Make sure the connectoris secure.

10. Holding the J1 connector leads, slidethe electronic assembly the rest of theway into the housing. Align the elec-tronic assembly so that it fits flush on

the pins. To ensure that it is flush, gen-tly try to rotate the electronics. If theelectronics rotates, repeat thealignment.

11. Reconnect the J1 connector to the mi-croprocessor board. Ensure the con-nector is secure and tighten the threecaptive screws on the microprocessorboard (top board).

12. Replace right housing cover (1, Figure4-1) and ensure it is tight. Secure thecover using captive washer (24), coverlock (23), and screw (22).


4-6 ENTIRE PROBE REPLACEMENT(EXCLUDING ELECTRONICS)

Do not attempt to replace the probe until allother possibilities for poor performance havebeen considered. If probe replacement isneeded, see Table 8-1 for part numbers.

a. Follow the instructions in paragraph 4-4a toremove the Hazardous Area Oxymitter 5000from the stack or duct.

b. Separate the probe and the electronicshousing per paragraph 4-5a, step 2.

c. Reinstall electronics on the new probe perparagraph 4-5a, steps 3 and 4.

d. Follow the instructions in paragraph 4-4b toinstall the Hazardous Area Oxymitter 5000into the stack or duct.


April 2001


Oxymitter 5000


4-7 HEATER STRUT REPLACEMENT

This paragraph covers heater strut replacement.Do not attempt to replace the heater strut untilall other possibilities for poor performance havebeen considered. If heater strut replacement isneeded, order a replacement heater strut.(Table 8-1).

Use heat resistant gloves and clothingwhen removing probe. Do not attemptto work on the probe until it hascooled to room temperature. Theprobe can be as hot as 427°C (800°F).This can cause severe burns.


b. Remove entire electronics per paragraph4-5a, steps 2 through 6.

c. Carefully remove the CAL and REF gas sili-con tubes by pulling them off the CAL andREF gas ports. Pull the silicon tubes off theCAL and REF gas lines.

d. Carefully remove the CAL and REF gas sili-con tubes by pulling them off the CAL andREF gas ports.

e. Once the probe and electronic housing areseparated, spring tension releases and theheater strut moves up. Remove strut pres-sure clamp (39, Figure 4-1).

f. Remove tube nuts (33) and capillarybreather tubes (34) from the CAL, REF, andVENT ports.

g. Grasp the wire loop and carefully slide thestrut out of the probe tube. See Figure 4-8.

h. When replacing the strut, align the slot onthe heater plate with the calibration gas linein the probe tube. Slide the strut into theprobe tube. It will turn to align the hole onthe back plate of the strut with the calibra-tion gas line. When the hole and the cali-bration gas line are aligned correctly, thestrut will slide in the rest of the way.

i. Push down on the back plate of the strut tomake sure you have spring tension andthen install strut pressure clamp (39, Figure4-1) on the back plate.

j. Install tube nuts (33) and capillary breathertubes (34) to the CAL, REF, and VENTports.

k. Replace the CAL and REF gas silicontubes.

l. Install the entire electronics per paragraph4-5a, steps 3 through 4.

m. Follow the instructions in paragraph 4-4b toinstall the Hazardous Area Oxymitter 5000into the stack or duct.



Oxymitter 5000

27540007

WIRELOOP

CERAMIC SUPPORT ROD

CELL FLANGE

HEATER

CERAMICDIFFUSERASSEMBLY

V-DEFLECTOR

Figure 4-8. Heater Strut Assembly


4-8 CELL REPLACEMENT

This paragraph covers oxygen sensing cell re-placement. Do not attempt to replace the celluntil all other possibilities for poor performancehave been considered. If cell replacement isneeded, order the cell replacement kit(Table 8-1).

The cell replacement kit (Figure 4-9) contains acell and flange assembly, corrugated seal,setscrews, socket head cap screws, and anti-seize compound. The items are carefully pack-aged to preserve precise surface finishes. Donot remove items from the packaging until they

are ready to be used. Spanner wrenches andhex wrenches needed for this procedure arepart of an available special tools kit (Table 8-1).

SOCKET HEADCAP SCREWS

CALIBRATION GASPASSAGE

26310016

PROBE TUBE(NOT INCLUDED

IN KIT)

CORRUGATEDSEAL

CELL ANDFLANGE

ASSEMBLY

Figure 4-9. Cell Replacement Kit


April 2001


Oxymitter 5000

Use heat-resistant gloves and clothingwhen removing the probe. Do not at-tempt to work on these componentsuntil they have cooled to room tem-perature. Probe components can beas hot as 427°C (800°F). This cancause severe burns.

Disconnect and lock out power beforeworking on any electrical components.There is voltage of up to 115 VAC.

Do not remove the cell unless certainit needs to be replaced. Removal maydamage the cell and platinum pad. Gothrough the complete troubleshootingprocedure to make sure the cell needsto be replaced before removing it.


The flame arrester and flame arresterhub are among the critical compo-nents of this type of protection.

b. If the probe uses the standard diffusionelement, use a spanner wrench to removethe diffusion element.

NOTE

To determine if the diffusion elementneeds to be replaced, refer to para-graph 4-2.

c. Remove the locking set screw from theflame arrester. Use spanner wrenches fromthe probe disassembly kit (Table 8-1) to turnthe flame arrester hub free from the probeflange. If equipped with the flame arresterwith ceramic diffuser, remove and discardthe setscrews and remove the vee deflector(Figure 4-10). Inspect the ceramic diffuser.If damaged, replace using paragraph 4-9.

d. Loosen the four socket head cap screwsfrom the cell and flange assembly and re-move the assembly and the corrugatedseal. The cell flange has a notch that maybe used to gently pry the flange away fromthe probe. Note that the contact pad insideof the probe will sometimes fuse to the oxy-gen sensing cell. If the cell is fused to thecontact pad, push the cell assembly backinto the probe (against spring pressure) andquickly twist the cell assembly. The cell andcontact pad should separate. If the contactpad stays fused to the cell, a new con-tact/thermocouple assembly must be in-stalled. Disconnect the cell and thethermocouple wires at the probe electronicsand withdraw the cell with the wires stillattached.

e. Remove entire electronics per paragraph4-5a, steps 2 through 6.

f. If the contact assembly is damaged, replacethe strut or the contact pad. Instructions forreplacing the contact pad are in the cell re-placement kit.

g. Remove and discard the corrugated seal.Clean the mating faces of the probe tubeand retainer. Remove burrs and raised sur-faces with a block of wood and crocus cloth.Clean the threads on the retainer and hub.

h. Rub a small amount of anti-seize compoundon both sides of the new corrugated seal.

i. Assemble the cell and flange assembly, cor-rugated seal, and probe tube. Make surethe calibration tube lines up with the calibra-tion gas passage in each component. Applya small amount of anti-seize compound tothe screw threads and use the screws tosecure assembly. Torque to 4 N·m(35 in-lbs).

j. Apply anti-seize compound to the probethreads, flame arrester hub, and setscrews.Reinstall the flame arrester on the probe.Using pin spanner wrenches, torque to 14N·m (10 ft-lbs). Secure the flame arresterwith the locking setscrew Torque to 2.8 N·m(25 in-lbs). If applicable, reinstall the veedeflector, orienting apex toward gas flow.Secure with the setscrews and anti-seizecompound. Torque to 2.8 N·m (25 in-lbs).



Oxymitter 5000

27540008

PORTCEMENT

THREADEDPROBE FLANGE

SPANNERWRENCH

M5-0.8 x 5 mmLOCKING SET SCREW(USE 2.5 mm HEX KEY)

CERAMICDIFFUSIONELEMENT

M6-1 x 6 mmSETSCREW(USE 3 mmHEX KEY)

CEMENTFILLET

VEEDEFLECTOR

FLAMEARRESTER

HUB

Figure 4-10. Ceramic Diffusion ElementReplacement

k. On systems equipped with an abrasiveshield, install the dust seal gaskets, withjoints 180° apart.

l. If previously removed, install the entireelectronics per paragraph 4-5a, steps 3through 4.

m. Follow the instructions in paragraph 4-4b toinstall the Hazardous Area Oxymitter 5000into the stack or duct. If there is an abrasiveshield in the stack, make sure the dust sealgaskets are in place as they enter the 15°reducing cone.

4-9 CERAMIC DIFFUSION ELEMENTREPLACEMENT

NOTE

This refers to ceramic diffuser elementonly.

a. General

The diffusion element protects the cell fromparticles in process gases. It does not nor-mally need to be replaced because the veedeflector protects it from particulate erosion.

In severe environments, the filter may bebroken or subject to excessive erosion. Ex-amine the ceramic diffusion element when-ever removing the probe for any purpose.Replace if damaged.

Damage to the ceramic diffusion elementmay become apparent during calibration.Compare probe response with previous re-sponse. A broken diffusion element willcause a slower response to calibration gas.

Hex wrenches needed to remove setscrewsand socket head screws in the followingprocedure are available as part of a ProbeDisassembly Kit, Table 8-1.

b. Replacement Procedure

1. Follow the instructions in paragraph4-4a to remove the Hazardous AreaHazardous Area Oxymitter 5000 fromthe stack or duct.

2. Loosen setscrews, Figure 4-10, usinghex wrench from Probe DisassemblyKit, Table 8-1, and remove vee deflec-tor. Inspect setscrews. If damaged, re-place with stainless setscrews coatedwith anti-seize compound.

3. On systems equipped with abrasiveshield, remove dual dust seal gaskets.

4. Use spanner wrenches from ProbeDisassembly Kit, Table 8-1, to turn hubfree from retainer.

5. Put hub in vise. Break out old ceramicdiffusion element with chisel along ce-ment line. Use a 9.5 mm (3/8 in.) pinpunch and clean fillet from the cementport.

6. Break out remaining ceramic diffusionelement by tapping lightly around hubwith hammer. Clean grooves withpointed tool if necessary.

7. Replace ceramic diffusion element us-ing the ceramic diffusion element re-placement kit in Table 8-1. Thisconsists of a diffusion element, ce-ment, setscrews, anti-seize compound,and instructions.

8. Test fit replacement ceramic diffusionelement to be sure seat is clean.


April 2001


Oxymitter 5000

Do not get cement on ceramic diffu-sion element except where it touchesthe hub. Any cement on ceramic diffu-sion element blocks airflow throughelement. Wiping wet cement off of ce-ramic only forces cement into pores.Also, do not get any cement onto theflame arrester element.

9. Thoroughly mix cement and insert tipof squeeze bottle into cement port. Tiltbottle and squeeze while simultane-ously turning ceramic diffusion elementinto seat. Do not get any cement onupper part of ceramic diffusion ele-ment. Ensure complete penetration ofcement around 3 grooves in hub. Ce-ment should extrude from oppositehole. Wipe excess material back intoholes and wipe top fillet of cement toform a uniform fillet. (A cotton swab isuseful for this.) Clean any excess ce-ment from hub with water.

10. Allow filter to dry at room temperatureovernight or 1 to 2 hours at 93°C(200°F).

11. Wipe a heavy layer of anti-seize com-pound onto the threads and matingsurfaces of the flame arrester, diffusionhub, and probe tube.

12. Assemble flame arrester and diffusionhub with two pin spanner wrenches.Torque to 14 N·m (10 ft-lbs). Securewith hub retaining setscrew.

13. On systems equipped with abrasiveshield, install dust seal gaskets withjoints 180° apart.

14. Reinstall vee deflector, orienting apextoward gas flow. Apply anti-seize com-pound to setscrews and tighten withhex wrench.

15. Reinstall probe on stack flange.

4-10 ASSEMBLY REPLACEMENT

See Figure 4-11.

a. Remove the cell per paragraph 4-8, steps athrough e.

b. Remove the heater strut assembly perparagraph 4-7, steps c through g.

c. Use a pencil to mark locations of the springclips on the ceramic rod of the contact andthermocouple assembly.

d. Squeeze the tabs on the spring clips andpull the contact and thermocouple assemblyout of the heater strut assembly. Retain thespring clips and spring; replace if damaged.



Oxymitter 5000

e. While very carefully handling the new con-tact and thermocouple assembly, lay the oldassembly next to the new one. Transfer thepencil marks to the new rod. Throw awaythe old contact and thermocouple assembly.

f. Carefully guide the new contact and ther-mocouple assembly through the spring,spring clips (held open by squeezing thetabs), tube supports, and heater support ofthe heater strut assembly until the springclip reaches the pencil mark.

g. Install the cell per the instructions in para-graph 4-8, steps f through k.

h. Slide the heater strut assembly into theprobe per the instructions in paragraph 4-7,steps h through l.

i. On systems equipped with an abrasiveshield, install the dust seal gaskets, withjoints 180° apart.

j. Follow the instructions in paragraph 4-4b toinstall the Hazardous Area Oxymitter 5000into the stack or duct. If there is an abrasiveshield in the stack, make sure the dust sealgaskets are in place as they enter the 15°reducing cone.

26310022

STRUT

TUBESUPPORTS

CONTACT ANDTHERMOCOUPLE

ASSEMBLY

SPRINGCLIP

SPRING

Figure 4-11. Contact and Thermocouple AssemblyReplacement


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-1

Oxymitter 5000

SECTION 5TROUBLESHOOTING

Install all protective equipment coversand safety ground leads after trouble-shooting. Failure to install covers andground leads could result in seriousinjury or death.

5-1 GENERAL

The troubleshooting section describes how toidentify and isolate faults that may develop inthe Hazardous Area Oxymitter 5000. Whentroubleshooting the Hazardous Area Oxymitter5000, reference the following information.

a. Grounding

It is essential that adequate grounding pre-cautions are taken when installing the sys-tem. Thoroughly check both the probe andelectronics to ensure the grounding qualityhas not degraded during fault finding. Thesystem provides facilities for 100% effectivegrounding and the total elimination ofground loops.

b. Electrical Noise

The Hazardous Area Oxymitter 5000 hasbeen designed to operate in the type of en-vironment normally found in a boiler room orcontrol room. Noise suppression circuits areemployed on all field terminations and maininputs. When fault finding, evaluate theelectrical noise being generated in the im-mediate circuitry of a faulty system. Also,ensure all cable shields are connected toearth.

c. Loose Integrated Circuits

The Hazardous Area Oxymitter 5000 uses amicroprocessor and supporting integratedcircuits (IC). If the electronics are handledroughly during installation or located wheresubjected to severe vibration, the ICs couldwork loose. Before troubleshooting thesystem, ensure all ICs are fully seated.

d. Electrostatic Discharge

Electrostatic discharge can damage the ICsused in the electronics. Before removing orhandling the processor board or the ICs,ensure you are at ground potential.

5-2 ALARM INDICATIONS

The majority of the fault conditions for the Haz-ardous Area Oxymitter 5000 will be indicated byone of the four LEDs referred to as diagnostic,or unit, alarms on the operator�s keypad. AnLED will flash a code that will correspond to anerror message. Only one LED will blink at atime. An alarm code guide is provided inside thescrew cover for the electronics. All alarm indica-tions will be available via fieldbus. When the er-ror is corrected and/or power is cycled, thediagnostic alarms will clear or the next error onthe priority list will appear.

5-3 ALARM CONTACTS

a. If autocalibration is not utilized, a commonbi-directional logic contact is provided forany of the diagnostic alarms listed in Table5-1. The assignment of alarms which canactuate this contact can be modified to oneof seven additional groupings listed in Table8-1.

The logic contact is self-powered, +5 VDC,340 ohm series resistance. An interposingrelay will be required if this contact is to beutilized to annunciate a higher voltage de-vice, such as a light or horn, and may alsobe required for certain DCS input cards. APotter & Brumfield R10S-E1Y1-J1.0K 3.2MA DC or an equal interposing relay will bemounted where the contact wires terminatein the control/relay room.

b. If autocalibration systems are utilized, thebi-directional logic contact is utilized as a�handshake� signal between the autocali-bration system (SPS 4000 or IMPS 4000)and is unavailable for alarming purposes.


5-2 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

The following additional contacts are pro-vided through the autocalibration systems:

1. SPS 4000 and IMPS 4000, 1-4 probes.

(a) One contact closure per probefrom the control room to the SPS4000 or IMPS 4000 for �calibrationinitiate�.

(b) One contact output per probe fromSPS 4000 or IMPS 4000 to thecontrol room for �in calibration� no-tification.

(c) Once contact output per probefrom the SPS 4000 or IMPS 4000to the control room for �calibrationfailed� notification. (Includes outputfrom pressure switch indicating �calgas bottles empty�.)

2. Additional IMPS Alarm Contacts.

(a) One contact per IMPS 4000 for�low calibration gas flowing�.

(b) One contact per IMPS 4000 for�high calibration gas flowing�.

5-4 IDENTIFYING AND CORRECTING ALARMINDICATIONS

Faults in the Hazardous Area Oxymitter 5000are indicated using the four diagnostic, or unit,alarms. The pattern of repeating blinks will de-fine the problem. A condensed table of the er-rors and the corresponding blink codes can befound on the inside right cover of the electronicshousing. Table 5-1 also identifies the blink codeand fault status of each LED as well as the out-put of the fieldbus digital signal line and a faultnumber that corresponds to the troubleshootinginstructions provided in this section.

Table 5-1. Diagnostic/Unit Alarm Fault Definitions

LED FLASHES STATUS PV STATUS FAULT SELF-CLEARING

HEATER T/C 1 OPEN BAD 1 NO2 SHORTED BAD 2 NO3 REVERSED BAD 3 NO4 A/D COMM ERROR BAD 4 NO

HEATER 1 OPEN BAD 5 NO2 HIGH HIGH TEMP BAD 6 NO3 HIGH CASE TEMP BAD 7 YES4 LOW TEMP BAD 8 YES5 HIGH TEMP BAD 9 YES

O2 CELL 1 HIGH mV BAD 10 YES3 BAD UNCERTAIN 11 YES4 EEPROM CORRUPT BAD 12 NO

CALIBRATION 1 INVALID SLOPE UNCERTAIN 13 YES2 INVALID CONSTANT UNCERTAIN 14 YES3 LAST CALIBRATION

FAILEDUNCERTAIN 15 YES

** CALIBRATIONRECOMMENDED

GOOD YES

*Critical alarm conditions will render the O2 measurement as unusable, and any of these events will cause thePV values to be tagged Out of Service. Alarms which are not �self-clearing� will require recycling of power tothe electronics.

**The CALIBRATION RECOMMENDED alarm flashes the Calibration Recommended alarm LED on the op-erator�s keypad.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550014

Figure 5-1. Fault 1, Open Thermocouple

a. Fault 1, Open Thermocouple

The HEATER T/C LED flashes once,pauses for three seconds, and repeats (Fig-ure 5-1).

1. Check connector J1. Ensure the con-nector is properly seated.

2. Using a multimeter, measure TP3+ toTP4-. If the reading is 1.2 VDC ±0.1VDC, the thermocouple is open.

3. Remove power. Disconnect J1. Meas-ure continuity across the red and yel-low thermocouple leads.

4. The measurement should read ap-proximately 1 ohm.

5. If the thermocouple is open, see para-graph 4-7, Heater Strut Replacement.



Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550015

Figure 5-2. Fault 2, Shorted Thermocouple

b. Fault 2, Shorted Thermocouple

The HEATER T/C LED flashes twice,pauses for three seconds, and repeats (Fig-ure 5-2).

1. Using a multimeter, measure acrossTP3+ and TP4-.

2. If the reading is 0 ±0.5 mV, then ashorted thermocouple is likely.

3. Remove power and disconnect J1.

4. Measure from TP3+ to TP4-. Thereading should be approximately 20Kohms.

5. If so, the short is not on the PC board.See paragraph 4-7, Heater Strut Re-placement.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550016

Figure 5-3. Fault 3, Reversed Thermocouple

c. Fault 3, Reversed Thermocouple

The HEATER T/C LED flashes three times,pauses for three seconds, and repeats (Fig-ure 5-3).

1. Using a multimeter, measure TP3+ toTP4-.

2. If the reading is negative, the thermo-couple wiring is reversed.

3. Check red and yellow wires in the J1connector for the proper placement.

4. If the wiring is correct, the fault is in thePC board. See paragraph 4-5b, Elec-tronic Assembly Replacement.



Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION


O2 CELL mV +O2 CELL m -HEATER T/C +HEATER T/C -

V

INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

29770006

Figure 5-4. Fault 4, A/D Comm Error

d. Fault 4, A/D Comm Error

The HEATER T/C LED flashes four times,pauses for three seconds, and repeats (Fig-ure 5-4).

1. Call the factory for assistance at 1-800-433-6076.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550017

Figure 5-5. Fault 5, Open Heater

e. Fault 5, Open Heater

The HEATER LED flashes once, pauses forthree seconds, and repeats (Figure 5-5).

1. Remove power. Remove the electronicassembly per paragraph 4-5b, Elec-tronic Assembly Replacement.

2. Using a multimeter, measure acrossthe heater connector J8.

3. The measurement should be approxi-mately 72 ohms. If the heater is open,see paragraph 4-7, Heater StrutReplacement.



Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550018

Figure 5-6. Fault 6, High High Heater Temp

f. Fault 6, High High Heater Temp

The HEATER LED flashes twice, pauses forthree seconds, and repeats (Figure 5-6).

1. The high high heater temp alarm willactivate when the thermocouple pro-duces a voltage of 37.1 mV(900°C/1652°F).

2. The triac and the temperature controlmay be at fault.

3. Remove power. Allow Hazardous AreaOxymitter 5000 to cool for five minutes.Restore power.

4. If the condition repeats, replace theelectronic assembly per paragraph4-5b, Electronic AssemblyReplacement.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550019

Figure 5-7. Fault 7, High Case Temp

g. Fault 7, High Case Temp

The HEATER LED flashes three times,pauses for three seconds, and repeats (Fig-ure 5-7).

1. If the case temperature exceeds 85°C(185°F), the temperature control willshut off and a fieldbus alarm will besent.

2. This signifies that the environmentwhere the Hazardous Area Oxymitter5000 is installed exceeds the ambienttemperature requirements or that heatdue to convection is causing case tem-perature to rise above the limit.

3. Placing a spool piece between thestack flange and the Hazardous AreaOxymitter 5000 flange may eliminatethis problem.

4. If a spool piece does not solve theproblem, relocation is the only solution.



Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550020

Figure 5-8. Fault 8, Low Heater Temp

h. Fault 8, Low Heater Temp

The HEATER LED flashes four times,pauses for three seconds, and repeats (Fig-ure 5-8).

1. The low heater temperature alarm isactive when the thermocouple readinghas dropped below 28.6 mV.

2. If the thermocouple reading continuesto ramp downward for one minute anddoes not return to the temperature setpoint of approximately 29.3 mV, thenan Open Heater fault will be displayed.

3. Power down the electronics. Removethe electronic assembly per paragraph4-5b, Electronic Assembly Replace-ment. Using a multimeter, measureacross the heater connector, J8.

4. If the heater is good, the reading will beapproximately 70 ohms. If the heater isopen, see paragraph 4-7, Heater StrutReplacement.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550021

Figure 5-9. Fault 9, High Heater Temp

i. Fault 9, High Heater Temp

The HEATER LED flashes five times,pauses for three seconds, and repeats (Fig-ure 5-9).

1. If the thermocouple produces a voltagein excess of approximately 30.7 mV,the high heater temp alarm activates.

2. An alarm is sent via fieldbus.

3. This alarm is self-clearing. When tem-perature control is restored and thethermocouple voltage returns to thenormal range, the alarm clears.

4. If the temperature continues to rise, thenext alarm will be the high high heatertemp alarm.



Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550022

Figure 5-10. Fault 10, High Cell mV

j. Fault 10, High Cell mV

The O2 CELL flashes once, pauses for threeseconds, and repeats (Figure 5-10).

1. Using a multimeter, measure acrossTP1+ to TP2-.

2. If you measure 204 mV to 1 volt DC,the cell reading is due to high combus-tibles. This is a self-clearing alarm,once the combustible conditions goaway.

3. If you measure 1.2 VDC, the cell wires,either orange or green, have becomedetached from the input.

4. One possible cause is connector J1.The orange or green wire has comeloose from the crimped connection.

5. The platinum pad could also be at fault.The pad could have broken free fromthe back of the cell.

6. Replace heater strut per paragraph4-7, Heater Strut Replacement. If nec-essary, replace the cell flange assem-bly per paragraph 4-8, CellReplacement.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550023

Figure 5-11. Fault 11, Bad Cell

k. Fault 11, Bad Cell

The O2 CELL flashes three times, pausesfor three seconds, and repeats (Figure5-11).

1. The bad cell alarm activates when thecell exceeds the maximum resistancevalue.

2. The cell should be replaced. Seeparagraph 4-8, Cell Replacement, forcell replacement instructions.



Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550024

Figure 5-12. Fault 12, EEPROM Corrupt

l. Fault 12, EEPROM Corrupt

The O2 CELL LED flashes four times,pauses for three seconds, and repeats (Fig-ure 5-12).

1. This alarm can occur if the EEPROM ischanged for a later version. At powerup, the EEPROM is not updated.

2. To correct this problem, power downand then restore power. The alarmshould clear.

3. If the alarm occurs while the unit isrunning, there is a hardware problemon the microprocessor board.

4. If cycling the power does not clear thealarm, see paragraph 4-5b, ElectronicAssembly Replacement.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550025

Figure 5-13. Fault 13, Invalid Slope

m. Fault 13, Invalid Slope

The CALIBRATION LED flashes once,pauses for three seconds, and repeats (Fig-ure 5-13).

1. During a calibration, the electronicscalculates a slope value. If the value ofthe slope is less than 35 mV/deg ormore than 52 mV/deg, the slope alarmwill be active until the end of the purgecycle.

2. See paragraph 6-2, Calibration. Verifythe calibration by carefully repeating it.Ensure the calibration gases match thecalibration gas parameters. If you at-tach a multimeter to TP1+ and TP2-,sample gas measurements are:

8% O2 ≈ 23 mV0.4% O2 ≈ 85 mV

3. Power down the Hazardous AreaOxymitter 5000 and remove it from thestack.

4. Replace the cell per paragraph 4-8,Cell Replacement.



Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550026

Figure 5-14. Fault 14, Invalid Constant

n. Fault 14, Invalid Constant

The CALIBRATION LED flashes twice,pauses for three seconds, and repeats (Fig-ure 5-14).

1. After a calibration has been performed,the electronics calculates a cell con-stant value.

2. If the cell constant value is outside ofthe range, -4 mV to 10 mV, the alarmwill activate. See paragraph 4-2, Cali-bration, and verify the last calibrationwas performed correctly.

3. Power down the Hazardous AreaOxymitter 5000 and remove it from thestack.

4. Replace the cell per paragraph 4-8,Cell Replacement.


April 2001


Oxymitter 5000

DIAGNOSTICALARMS

TESTPOINTS


CALIBRATION



INC INC

DEC DEC

HIGHGAS

LOWGAS

CAL

TEST GAS +PROCESS -

% O2

SW2

TP1J1

TP2

TP3

RE

DY

EL

GR

NO

RGTP4

TP5

TP6

ON

28550027

Figure 5-15. Fault 15, Last Calibration Failed

o. Fault 15, Last Calibration Failed

The CALIBRATION LED flashes threetimes, pauses for three seconds, and re-peats (Figure 5-15).

1. The last calibration failed alarm acti-vates when the slope and constantvalues calculated are out of range andthe unit reverts to using the previouscalibration values.

2. The cell should be replaced. See para-graph 4-8, Cell Replacement, for cellreplacement instructions.



Oxymitter 5000


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Optional Accessories 6-1

Oxymitter 5000

SECTION 6OPTIONAL ACCESSORIES

BY-PASS PACKAGES

The specially designed Rosemount Analytical By-PassPackage for oxygen analyzers has proven to withstandthe high temperatures in process heaters while pro-viding the same advantages offered by the in situ sen-sor. Inconel or Kanthal steel tubes provide effectiveresistance to corrosion, and the package uses nomoving parts, air pumps, or other components com-mon to other sampling systems.

For more information, call Rosemount Analytical at1-800-433-6076.

PS U

E

ITP

IC

RH

WE

NT

HG

C

E

NI

E

E RW

AVIS

OLP-

XOM

TA GNI

N-

R

I

T

L A

I

VE-E

EH

GA

SC

AL

.

26170024

IMPS 4000 INTELLIGENT MULTIPROBETEST GAS SEQUENCER

The IMPS 4000 Intelligent Multiprobe Test Gas Se-quencer is housed within an IP56 (NEMA 4X) enclo-sure and has the intelligence to provide calibration gassequencing of up to four Hazardous Area Oxymitter5000 units to accommodate automatic and semi-automatic calibration routines.

This sequencer works in conjunction with the Hazard-ous Area Oxymitter 5000 CALIBRATION RECOM-MENDED feature, eliminating out-of-calibrationoccurrences and the need to send a technician to theinstallation site. In addition, the SPS 4000 provides aremote contact input to initiate a calibration from a re-mote location and relay outputs to alert when a cali-bration is in progress, an Hazardous Area Oxymitter5000 is out of calibration, calibration gases are on, andcalibration gas pressure is low.


33100020


6-2 Optional Accessories Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

SPS 4000 SINGLE PROBEAUTOCALIBRATION SEQUENCER

Rosemount Analytical specifically designed the SPS4000 Single Probe Autocalibration Sequencer to pro-vide the capability to perform automatic or on-demandHazardous Area Oxymitter 5000 calibrations. The SPS4000 must be installed in a remote location in a non-hazardous area.

The SPS 4000 works in conjunction with the Hazard-ous Area Oxymitter 5000�s CALIBRATION RECOM-MENDED feature, eliminating out-of-calibrationoccurrences and the need to send a technician to theinstallation site. In addition, the SPS 4000 provides aremote contact input to initiate a calibration from a re-mote location and relay outputs to indicate when acalibration is in progress or the Hazardous Area Oxy-mitter 5000 is out of calibration.


REMOTE MOUNTEDSPS 4000(IN A SAFE AREA)

26310009

HAZARDOUS AREA

OXYMITTER 4000

O2 CALIBRATION GAS SEQUENCER

Rosemount Analytical�s O2 Calibration Gas and Serv-ice Kits have been carefully designed to provide amore convenient and fully portable means of testing,calibrating, and servicing Rosemount Analytical�s oxy-gen analyzers. These lightweight, disposable gas cyl-inders eliminate the need to rent gas bottles.


26170021


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 7-1

Oxymitter 5000

SECTION 7RETURN OF MATERIAL

7-1 EQUIPMENT RETURN PROCEDURE

If factory repair of defective equipment is re-quired, proceed as follows:

a. Secure a return authorization number froma Rosemount Analytical Sales Office or rep-resentative before returning the equipment.Equipment must be returned with completeidentification in accordance with Rosemountinstructions or it will not be accepted.

In no event will Rosemount be responsiblefor equipment returned without properauthorization and identification.

b. Carefully pack defective unit in a sturdy boxwith sufficient shock absorbing material toensure that no additional damage will occurduring shipping.

c. In a cover letter, describe completely:

1. The symptoms from which it was de-termined that the equipment is faulty.

2. The environment in which the equip-ment has been operating (housing,weather, vibration, dust, etc.).

3. Site from which equipment wasremoved.

4. Whether warranty or nonwarrantyservice is requested.

5. Complete shipping instructions for re-turn of equipment.

6. Reference the return authorizationnumber.

d. Enclose a cover letter and purchase orderand ship the defective equipment accordingto instructions provided in Rosemount Re-turn Authorization, prepaid, to:

Rosemount Analytical Inc.RMR Department1201 N. Main StreetOrrville, Ohio 44667

If warranty service is requested, the defec-tive unit will be carefully inspected andtested at the factory. If failure was due toconditions listed in the standard Rosemountwarranty, the defective unit will be repairedor replaced at Rosemount's option, and anoperating unit will be returned to the cus-tomer in accordance with shipping instruc-tions furnished in the cover letter.

For equipment no longer under warranty,the equipment will be repaired at the factoryand returned as directed by the purchaseorder and shipping instructions.


7-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 8-1

Oxymitter 5000

SECTION 8REPLACEMENT PARTS

Table 8-1. Replacement Parts for Probe

FIGURE andINDEX No. PART NUMBER DESCRIPTION

No Dust Seal Dust Seal

4-1, 27 3D39746G01 3D39745G01 18 in. ANSI Flame Arrestor with Ceramic Diffuser Probe4-1, 27 3D39746G02 3D39745G02 3 ft ANSI Flame Arrestor with Ceramic Diffuser Probe4-1, 27 3D39746G03 3D39745G03 6 ft ANSI Flame Arrestor with Ceramic Diffuser Probe4-1, 27 3D39746G04 3D39745G04 18 in. JIS Flame Arrestor with Ceramic Diffuser Probe4-1, 27 3D39746G05 3D39745G05 3 ft JIS Flame Arrestor with Ceramic Diffuser Probe4-1, 27 3D39746G06 3D39745G06 6 ft JIS Flame Arrestor with Ceramic Diffuser Probe4-1, 27 3D39746G07 3D39745G07 18 in. DIN Flame Arrestor with Ceramic Diffuser Probe4-1, 27 3D39746G08 3D39745G08 3 ft DIN Flame Arrestor with Ceramic Diffuser Probe4-1, 27 3D39746G09 3D39745G09 6 ft DIN Flame Arrestor with Ceramic Diffuser Probe

4-1, 27 3D39746G10 3D39745G10 18 in. ANSI Flame Arrestor with Snubber Diffuser Probe4-1, 27 3D39746G11 3D39745G11 3 ft ANSI Flame Arrestor with Snubber Diffuser Probe4-1, 27 3D39746G12 3D39745G12 6 ft ANSI Flame Arrestor with Snubber Diffuser Probe4-1, 27 3D39746G13 3D39745G13 18 in. JIS Flame Arrestor with Snubber Diffuser Probe4-1, 27 3D39746G14 3D39745G14 3 ft JIS Flame Arrestor with Snubber Diffuser Probe4-1, 27 3D39746G15 3D39745G15 6 ft JIS Flame Arrestor with Snubber Diffuser Probe4-1, 27 3D39746G16 3D39745G16 18 in. DIN Flame Arrestor with Snubber Diffuser Probe4-1, 27 3D39746G17 3D39745G17 3 ft DIN Flame Arrestor with Snubber Diffuser Probe4-1, 27 3D39746G18 3D39745G18 6 ft DIN Flame Arrestor with Snubber Diffuser Probe


8-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

Table 8-1. Replacement Parts for Probe (Continued)


4-1, 40 3D39744G01 18 in. Heater Strut Assy.4-1, 40 3D39744G02 3 ft Heater Strut Assy.4-1, 40 3D39744G03 6 ft Heater Strut Assy.

8-1 4847B61G26 ANSI 18 in. Cell Replacement Kit*8-1 4847B61G27 ANSI 3 ft Cell Replacement Kit*8-1 4847B61G28 ANSI 6 ft Cell Replacement Kit*8-1 4847B61G29 JIS 18 in. Cell Replacement Kit*8-1 4847B61G30 JIS 3 ft Cell Replacement Kit*8-1 4847B61G31 JIS 6 ft Cell Replacement Kit*8-1 4847B61G20 DIN 18 in. Cell Replacement Kit*8-1 4847B61G21 DIN 3 ft Cell Replacement Kit*8-1 4847B61G25 DIN 6 ft Cell Replacement Kit*

2-2 3D39003G16 ANSI 18 in. Abrasive Shield Assy.2-2 3D39003G17 ANSI 3 ft Abrasive Shield Assy.2-2 3D39003G18 ANSI 6 ft Abrasive Shield Assy.2-2 3D39003G19 JIS 18 in. Abrasive Shield Assy.2-2 3D39003G20 JIS 3 ft Abrasive Shield Assy.2-2 3D39003G21 JIS 6 ft Abrasive Shield Assy.2-2 3D39003G22 DIN 18 in. Abrasive Shield Assy.2-2 3D39003G23 DIN 3 ft Abrasive Shield Assy.2-2 3D39003G24 DIN 6 ft Abrasive Shield Assy.

*Includes pad and wire.

PROBE TUBE(NOT INCLUDED

IN KIT)

M6-1 x 6 mmSOCKET HEADCAP SCREWSCORRUGATED

SEAL

ANSIGASKET

WIRE ANDPAD ASSEMBLY

ANTI-SEIZECOMPOUND

22 GA.WIRE

SET SCREWS

TEFLONTUBING

CLOSED ENDCONNECTOR

CELL ANDFLANGE

ASSEMBLY

CALIBRATION GASPASSAGE

27540010

Figure 8-1. Cell Replacement Kit


April 2001


Oxymitter 5000

Table 8-1. Replacement Parts for Probe (Continued)


4507C26G07 Bypass Gas Pickup Tube (3 ft)4507C26G08 Bypass Gas Pickup Tube (6 ft)4507C26G09 Bypass Gas Pickup Tube (9 ft)

2-1 1U05677G01 Flame Arrester with Ceramic Diffuser2-2 1U05677G02 Flame Arrester with Ceramic Diffuser and Dust Seal2-2 1U05677G03 Flame Arrester with Ceramic Diffuser and Spare Dust Seal2-1 1U05677G04 Flame Arrester with Snubber Diffuser2-2 1U05677G05 Flame Arrester with Snubber Diffuser and Dust Seal2-2 1U05677G06 Flame Arrester with Snubber Diffuser and Spare Dust Seal4-10 1L03650H01 Flame Arrester Diffusion Hub Setscrew (M5-0.8 x 5 mm)2-8 263C152G01 Reference Air Gas Set

771B635H01 Calibration Gas Flowmeter8-2 3535B42G03 Probe Disassembly Kit4-1, 39 5R10130H01 Strut Pressure Clamp4-10 6292A74G02 Ceramic Diffusion Element Replacement Kit

HEX KEYS

TUBE INSERTIONTUBE

PHILIPSSCREWDRIVER

SPANNERWRENCH

ANTI-SEIZECOMPOUND

26310008

Figure 8-2. Probe Disassembly Kit



Oxymitter 5000

Table 8-2. Replacement Parts for Electronics


XXXXXXXX Electronics English-Standard4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G02 Electronic Assembly and keypad English4-1, 19 3D39767G01 Termination Block-Standard4-1, 1 5R10145G01 Cover

XXXXXXXX Electronics German-Standard4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G03 Electronic Assembly and keypad German4-1, 19 3D39767G01 Termination Block-Standard4-1, 1 5R10145G01 Cover

XXXXXXXX Electronics French-Standard4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G04 Electronic Assembly and keypad French4-1, 19 3D39767G01 Termination Block-Standard4-1, 1 5R10145G01 Cover

XXXXXXXX Electronics Spanish-Standard4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G05 Electronic Assembly and keypad Spanish4-1, 19 3D39767G01 Termination Block-Standard4-1, 1 5R10145G01 Cover

XXXXXXXX Electronics Italian-Standard4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G06 Electronic Assembly and keypad Italian4-1, 19 3D39767G01 Termination Block-Standard4-1, 1 5R10145G01 Cover

XXXXXXXX Electronics English-Transient Protected4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G02 Electronic Assembly and keypad English4-1, 19 3D39767G02 Termination Block-Transient Protected4-1, 1 5R10145G01 Cover

XXXXXXXX Electronics German-Transient Protected4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G03 Electronic Assembly and keypad German4-1, 19 3D39767G02 Termination Block-Transient Protected4-1, 1 5R10145G01 Cover

XXXXXXXX Electronics French-Transient Protected4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G04 Electronic Assembly and keypad French4-1, 19 3D39767G02 Termination Block-Transient Protected4-1, 1 5R10145G01 Cover


April 2001


Oxymitter 5000

Table 8-2. Replacement Parts for Electronics (Continued)


XXXXXXXX Electronics Spanish-Transient Protected4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G05 Electronic Assembly and keypad Spanish4-1, 19 3D39767G02 Termination Block-Transient Protected4-1, 1 5R10145G01 Cover

XXXXXXXX Electronics Italian-Transient Protected4-1, 15, 21 4850B86G01 Housing and Cover4-1, 2 3D39778G06 Electronic Assembly and keypad Italian4-1, 19 3D39767G02 Termination Block-Transient Protected4-1, 1 5R10145G01 Cover

4-1, 2 3D39778G01 Electronic Assembly4-1, 4 4849B72H01 Membrane Keypad English4-1, 4 4849B72H02 Membrane Keypad German4-1, 4 4849B72H03 Membrane Keypad French4-1, 4 4849B72H04 Membrane Keypad Spanish4-1, 4 4849B72H05 Membrane Keypad Italian

4-1, 19 3D39767G01 Termination Block Standard4-1, 19 3D39767G02 Termination Block Transient Protected



Oxymitter 5000


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 9-1

Oxymitter 5000

SECTION 9APPENDICES

APPENDIX A. FIELDBUS PARAMETER DESCRIPTION

APPENDIX B. ANALOG INPUT (AI) FUNCTION BLOCK

APPENDIX C. PID FUNCTION BLOCK


9-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

IB-106-350A-1

APPENDIX A. FIELDBUS PARAMETER DESCRIPTION

Parameter Mnemonic Valid RangeInitialValue Units Description

ParameterNumber

ALARM_POINT_LOW 0.0-40.0 %O2 This is the point at which the Low O2 alarm willbecome active.

37

ALERT_KEY See Function Block Specification, part 1. FF-890,page 50.

4

AUTOCAL_ENABLED 0: Not enabled1: Enabled

Enumerated This parameter enables automatic calibrations. 46

AUTOCAL_INTERVAL 0-9999 Hours This is the time between automatic calibrations, inhours.

47

BLOCK_ALM See Function Block Specification, part 2. FF-891,page 41.

8

BLOCK_ERR See Function Block Specification, part 2. FF-891,page 41.

6

BUILD_DATE 0 N/A This is the date that the Oxymitter software was built. 62BUILD_NUMBER 0-65535 0 N/A This is the build number of the Oxymitter software. 60CAL_CONSTANT ± 20.0 mV This parameter represents the constant (offset) value

used in the calculation of converting the sensorvoltage to an O2 value. The value of this parametermay be manually entered or calculated during asensor calibration.

27

CAL_GAS_TIME 60-1200 Sec This is the length of time test gases are applied tothe O2 probe before each measurement of thecalibration cycle.

22

CAL_LAST_CONSTANT

± 20.0 mV The constant from the last successful calibration. 29

CAL_LAST_SLOPE 34.5-57.5 mV/Decade The slope from the last successful calibration. 28CAL_POINT_HI 0.0-40.0 %O2 This is the actual value of the gas being applied

during the high test gas phase of a calibration.17

CAL_POINT_LO 0.0-40.0 %O2 This is the actual value of the gas being appliedduring the low test gas phase of a calibration.

18

CAL_PURGE_TIME 60-1200 Sec This is the length of time after a calibration iscomplete before the O2 value status returns tonormal.

23

CAL_SENSOR_IMPEDANCE

0-10000 Ohms This is the sensor impedance value measured at thetime of the last calibration.

25

CAL_SLOPE 34.5-57.5 mV/Decade This parameter represents the slope value used inthe calculation of converting the sensor voltage to anO2 value. The value of this parameter may bemanually entered or calculated during a sensorcalibration.

26

CAL_STATE See Table 1 Enumerated This parameter represents the present state thecalibration cycle is in. Refer to Table 1 for thedefinition of states.

19

CAL_STATE_STEP 0: No effect1: Go to nextstep2: AbortCalibration

0 Enumerated This parameter is used to step the transmitterthrough a sensor calibration. Setting this parameterto 1 requests the transmitter to move to the nextcycle state of the calibration procedure. The requestis only valid when the CAL_STATE value representsa state that is waiting for an external event such asthe changing of a test gas value. The transmitter willset this parameter value back to 0 when it hascompleted processing the step request. Setting thisparameter to a value of 2 will cause the presentcalibration to be aborted.

20

CAL_STATE_TIME 0-1200 Sec This is the time in seconds remaining in the presentcalibration state.

21

CAL_TRACKS This parameter is no longer used. 24CELL_MV_VALUE ± INF mV This is the raw signal from the O2 sensor. 43

CELL_TC_MV_VALUE -1000.0 - 500.0 mV This is the raw signal from the O2 sensorthermocouple.

44

CELL_TEMPERATURE This is the current temperature of the O2 sensor. 54CHECKSUM 0000 N/A This is the checksum of the Oxymitter software. 61

IB-106-350A-2


ParameterNumber

COLD_JUNC_MV_VALUE

± INF mV This is the raw signal from the case/thermocouplecold junction sensor.

45

COLLECTION_DIRECTORY

See Transducer Block Specification, part 1. FF-902,page 11.

12

CONFIG_CHANGED 0-255 0 N/A This indicates that a static parameter in the Oxymitterhas changed by some means other than Fieldbus.

51

TB_DETAILED_STATUS

0-16777215 0 Enumerated This is a bit-enumerated value used to communicatethe status of the Oxymitter. (This is similar in natureto the command 48 status bits in HART.)

55

HIGH_CASE_TEMP 0-10000.0 OC This is the highest temperature that has beenmeasured inside the electronics enclosure.

38

HIGH_CASE_TEMP_RESET

0: No effect1: Reset highcasetemperature

0 Enumerated This parameter is used to request the parameterCASE_TEMP_MAX be reset to the current internalcase temperature. Setting this parameter at a valueof 1 will cause the transmitter to reset theCASE_TEMP_MAX value. The transmitter will setthis parameter to 0 once it has completed thisprocess.

39

IO_PIN_MODE See table 2 Enumerated This parameter represents the operating mode of thediscrete IO pin of the transmitter. 0 = Alarm ContactMode, 1=Calibration Sequence Mode.

40

IO_PIN_STATE 0: Off1: On

Enumerated This parameter represents the current state of thetransmitters discrete IO pin. 0 = FALSE, 1 = TRUE.

41

MODE_BLK See Function Block Specification, part 1. FF-890,page 50.

5

O2_PERCENT_OF_RANGE

0.0-100.0 % This is the percent of total range value. 15

O2_RANGE 0-40 %O2 This contains the upper and lower %O2 range values,the units, and the precision.

16

OXY_BLOCK_ALARM See section 4.7in FF-903

0 Enumerated This is the FF block alarm code. See TransducerBlocks, part 2. FF-903, page 41.

53

OXY_BLOCK_ERR See table 3 0 Enumerated This is the Oxymitter's device alarm code. See Table3.

52

PRIMARY_VALUE(O2_VALUE)

0.0-25.0 %O2 This is the value that should appear on the outputchannel of the transducer block. In the Oxymitter,this is the present %O2 reading and should reflectany test gas being applied.

13

PRIMARY_VALUE_TYPE

See section 4.1in FF-903

0 Enumerated Selected from list in Transducer Block Specification,part 2. FF-903, page 39, section 4.1.

14

SECONDARY_VALUE -10000 - 10000 OC See Transducer Block Specification, part 2. FF-903,page 37. In the Oxymitter, this is the temperature ofthe electronics.

49

SECONDARY_VALUE_UNITS


50

SENSOR_CAL_DATE See Transducer Block Specification, part 2. FF-903,page 37.

36

SENSOR_CAL_LOC See Transducer Block Specification, part 2. FF-903,page 37.

35

SENSOR_CAL_METHOD

Last calibration method. Selected from list inTransducer Block Specification, part 2. FF-903,page 40, section 4.5.

34

SENSOR_CAL_WHO This is used to store the name of the individual wholast performed a calibration.

42

SENSOR_IMPEDANCE 0-10000 Ohms This is the sensor impedance value that was lastmeasured.

30

SENSOR_RANGE 0-100 %O2 See Transducer Block Specification, part 2. FF-903,page 37.

32

SENSOR_SN See Transducer Block Specification, part 2. FF-903,page 37.

33

IB-106-350A-3


ParameterNumber

SENSOR_TYPE Selected from list in Transducer Block Specification,part 2. FF-903, page 40, section 4.3.

31

ST_REV See Function Block Specification, part 1. FF-890,page 49.

1

STATS_ATTEMPTS This shows the number of communication attemptsbetween the Oxymitter and the internal fieldbusinterface card.

56

STATS_FAILURES This shows the number of communication failuresbetween the Oxymitter and the internal fieldbusinterface card.

57

STATS_TIMEOUTS This shows the number of communication failuresdue to reply timeout between the Oxymitter and theinternal fieldbus interface card.

58

STRATEGY See Function Block Specification, part 1. FF-890,page 49.

3

TAG_DESC See Function Block Specification, part 1. FF-890,page 49.

2

TIME_TO_NEXT_CAL 0.0-9999.0 Hours This is the time remaining until the next automaticcalibration.

48

TRANSDUCER_DIRECTORY


9

TRANSDUCER_TYPE Selected from list in Transducer Block Specification,part 2. FF-903, page 39, section 4.2.

10

UPDATE_EVT See Function Block Specification, part 2. FF-891,page 45.

7

VERSION N/A This is the version of the Oxymitter software. 59XD_ERROR See Transducer Block Specification, part 2. FF-903,

page 38.11

IB-106-350A-4

Table A-1. Calibration State Values

Code Value DescriptionExternal Event Required to

Go to Next Step?

0 Normal System Operation Yes

1 Calibration Required Yes

2 Apply Test Gas 1 Yes

3 Test Gas 1 Flow No

4 Test Gas 1 Read No

5 Test Gas 1 Done No

6 Apply Test Gas 2 Yes

7 Test Gas 2 Flow No

8 Test Gas 2 Read No

9 Test Gas 2 Done No

10 Abort/Fail Yes

11 Stop Gas Yes

12 Purge No

Table A-2. IO Pin Mode Values

Code Value Description

0 No Alarm

1 Unit Alarm

2 Low 02 Alarm

3 Low 02/Unit Alarm

4 Cal Recommended

5 Cal Recommended/Unit Alarm

6 Low 02/Cal Recommended

7 Low 02/Unit/Cal

8 Cal Recommended->Handshake

9 Handshake

IB-106-350A-5

Table A-3. Unit Alarm Values

AlarmNumber

Value OfDETAILED_STATUS

Value of BLOCK_ALARM(see FF-903) Description

0 0 NONE No Alarm Active

1 1 MECHANICAL_FAILURE Open Thermocouple

2 2 MECHANICAL_FAILURE Shorted Thermocouple

3 4 MECHANICAL_FAILURE Reversed Thermocouple

4 8 N/A Not a valid alarm


6 32 MECHANICAL_FAILURE Heater Open Circuit

7 64 MECHANICAL_FAILURE High High Heater Temperature

8 128 MECHANICAL_FAILURE High Case Temp

9 256 MECHANICAL_FAILURE Low Heater Temperature

10 512 MECHANICAL_FAILURE High Heater Temperature

11 1024 MECHANICAL_FAILURE Open Cell Circuit


13 4096 MECHANICAL_FAILURE High AC Impedance / Cell Bad

14 8192 DATA_INTEGRITY_ERROR Eeprom Parameters Corrupt

15 16384 N/A Calibration Recommended

16 32768 CONFIGURATION_ERROR Invalid Slope value

17 65536 CONFIGURATION_ERROR Invalid Cell Constant Value

18 131072 CONFIGURATION_ERROR Bad Calibration

Table A-4. I/O Channel Configuration

Transducer BlockChannel Value Process Variable XD_SCALE Units

1 Oxygen %

2 Case Temperature ºC

3 Sensor Temperature ºC

Refer to Appendix B for instructions on how to implement these variables.

IB-106-350A-6

Table A-5. Channel 1 Status

Alarm Condition Channel 1 Status Self-clearing?

Open Thermocouple Bad No

Shorted Thermocouple Bad No

Reversed Thermocouple Bad No

Heater Open Circuit Bad No

High High Heater Temperature Bad No

High Case Temperature Bad Yes

Low Heater Temperature Bad Yes

High Heater Temperature Bad Yes

Open Cell Circuit Bad Yes

High AC Impedance / Cell Bad Uncertain Yes

EEPROM Parameters Corrupt Bad No

Calibration Recommended Good No

Invalid Slope Value Uncertain No

Invalid Cell Constant Value Uncertain No

Bad Calibration Uncertain No

In Calibration Uncertain Yes

During Warm Up Bad Yes

The status of channel 1 is affected by the state of the unit alarm, as shown in Table A-5. Inall cases, the channel will read what it believes is the correct oxygen value. Self-clearingalarms are reset when the alarm condition goes away. All others require the Oxymitter 5000to be restarted.

Appendix

B Analog Input (AI) Function Block

The Analog Input (AI) function block processes field device measurements and makes them available to other function blocks. The output value from the AI block is in engineering units and contains a status indicating the quality of the measurement. The measuring device may have several measurements or derived values available in different channels. Use the channel number to define the variable that the AI block processes.

The AI block supports alarming, signal scaling, signal filtering, signal status calculation, mode control, and simulation. In Automatic mode, the block’s output parameter (OUT) reflects the process variable (PV) value and status. In Manual mode, OUT may be set manually. The Manual mode is reflected on the output status. A discrete output (OUT_D) is provided to indicate whether a selected alarm condition is active. Alarm detection is based on the OUT value and user specified alarm limits. Figure B-1 on page B-4 illustrates the internal components of the AI function block, and Table B-1 lists the AI block parameters and their units of measure, descriptions, and index numbers.

TABLE B-1. Definitions of Analog Input Function Block System Parameters.

OUT = The block output value and statusOUT_D = Discrete output that signals a selected

alarm condition

OUT_D

AI OUT

field

bus-

fbus

_31a

Parameter Index Number

Units Description

ACK_OPTION 23 None Used to set auto acknowledgment of alarms.

ALARM_HYS 24 Percent The amount the alarm value must return within the alarm limit before the associated active alarm condition clears.

ALARM_SEL 38 None Used to select the process alarm conditions that will cause the OUT_D parameter to be set.

ALARM_SUM 22 None The summary alarm is used for all process alarms in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the Active status in the Status parameter. As soon as the Unreported status is cleared by the alert reporting task, another block alert may be reported without clearing the Active status, if the subcode has changed.

ALERT_KEY 04 None The identification number of the plant unit. This information may be used in the host for sorting alarms, etc.

B-1

Model 4081FG Oxygen Analyzer with F

OUNDATION

fieldbus Communications

BLOCK_ALM 21 None The block alarm is used for all configuration, hardware, connection failure or system problems in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the Active status in the Status parameter. As soon as the Unreported status is cleared by the alert reporting task, another block alert may be reported without clearing the Active status, if the subcode has changed.

BLOCK_ERR 06 None This parameter reflects the error status associated with the hardware or software components associated with a block. It is a bit string, so that multiple errors may be shown.

CHANNEL 15 None The CHANNEL value is used to select the measurement value. Refer to the appropriate device manual for information about the specific channels available in each device.

You must configure the CHANNEL parameter before you can configure the XD_SCALE parameter.

FIELD_VAL 19 Percent The value and status from the transducer block or from the simulated input when simulation is enabled.

GRANT_DENY 12 None Options for controlling access of host computers and local control panels to operating, tuning, and alarm parameters of the block. Not used by device.

HI_ALM 34 None The HI alarm data, which includes a value of the alarm, a timestamp of occurrence and the state of the alarm.

HI_HI_ALM 33 None The HI HI alarm data, which includes a value of the alarm, a timestamp of occurrence and the state of the alarm.

HI_HI_LIM 26 EU of PV_SCALE The setting for the alarm limit used to detect the HI HI alarm condition.

HI_HI_PRI 25 None The priority of the HI HI alarm.

HI_LIM 28 EU of PV_SCALE The setting for the alarm limit used to detect the HI alarm condition.

HI_PRI 27 None The priority of the HI alarm.

IO_OPTS 13 None Allows the selection of input/output options used to alter the PV. Low cutoff enabled is the only selectable option.

L_TYPE 16 None Linearization type. Determines whether the field value is used directly (Direct), is converted linearly (Indirect), or is converted with the square root (Indirect Square Root).

LO_ALM 35 None The LO alarm data, which includes a value of the alarm, a timestamp of occurrence and the state of the alarm.

LO_LIM 30 EU of PV_SCALE The setting for the alarm limit used to detect the LO alarm condition.

LO_LO_ALM 36 None The LO LO alarm data, which includes a value of the alarm, a timestamp of occurrence and the state of the alarm.

LO_LO_LIM 32 EU of PV_SCALE The setting for the alarm limit used to detect the LO LO alarm condition.

LO_LO_PRI 31 None The priority of the LO LO alarm.

LO_PRI 29 None The priority of the LO alarm.

LOW_CUT 17 % If percentage value of transducer input fails below this, PV = 0.

MODE_BLK 05 None The actual, target, permitted, and normal modes of the block.

Target: The mode to “go to”

Actual: The mode the “block is currently in”

Permitted: Allowed modes that target may take on

Normal: Most common mode for target

OUT 08 EU of OUT_SCALE The block output value and status.

OUT_D 37 None Discrete output to indicate a selected alarm condition.

OUT_SCALE 11 None The high and low scale values, engineering units code, and number of digits to the right of the decimal point associated with OUT.

PV 07 EU of XD_SCALE The process variable used in block execution.


Units Description

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Simulation To support testing, you can either change the mode of the block to manual and adjust the output value, or you can enable simulation through the configuration tool and manually enter a value for the measurement value and its status. In both cases, you must first set the ENABLE jumper on the field device.

NOTEAll fieldbus instruments have a simulation jumper. As a safety measure, the jumper has to be reset every time there is a power interruption. This measure is to prevent devices that went through simulation in the staging process from being installed with simulation enabled.

With simulation enabled, the actual measurement value has no impact on the OUT value or the status.

PV_FTIME 18 Seconds The time constant of the first-order PV filter. It is the time required for a 63% change in the IN value.

SIMULATE 09 None A group of data that contains the current transducer value and status, the simulated transducer value and status, and the enable/disable bit.

STRATEGY 03 None The strategy field can be used to identify grouping of blocks. This data is not checked or processed by the block.

ST_REV 01 None The revision level of the static data associated with the function block. The revision value will be incremented each time a static parameter value in the block is changed.

TAG_DESC 02 None The user description of the intended application of the block.

UPDATE_EVT 20 None This alert is generated by any change to the static data.

VAR_INDEX 39 % of OUT Range The average absolute error between the PV and its previous mean value over that evaluation time defined by VAR_SCAN.

VAR_SCAN 40 Seconds The time over which the VAR_INDEX is evaluated.

XD_SCALE 10 None The high and low scale values, engineering units code, and number of digits to the right of the decimal point associated with the channel input value.

The XD_SCALE units code must match the units code of the measurement channel in the transducer block. If the units do not match, the block will not transition to MAN or AUTO


Units Description

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FIGURE B-1. Analog InputFunction Block Schematic.

FIGURE B-2. Analog Input Function Block Timing Diagram.

Filtering The filtering feature changes the response time of the device to smooth variations in output readings caused by rapid changes in input. You can adjust the filter time constant (in seconds) using the PV_FTIME parameter. Set the filter time constant to zero to disable the filter feature.

FIE

LDB

US

-FB

US

_02A

Analog Measurement

AccessAnalogMeas.

CHANNEL

SIMULATE

OUT_SCALEXD_SCALE

FIELD_VAL

L_TYPE

IO_OPTS

PV_FTIME MODE

STATUS_OPTS

HI_HI_LIMHI_LIM

LO_LO_LIMLO_LIM

ALARM_HYS

ALARM_TYPE

OUT_D

OUTPVConvert Cutoff Filter StatusCalc.

Alarm Detection

NOTES:OUT = block output value and status.OUT_D = discrete output that signals a selected alarm condition.

LOW_CUT

PV_FTIME

63% of Change

OUT (mode in man)

OUT (mode in auto)

PV

Time (seconds)

FIELD_VAL

FIE

LDB

US

-FB

US

_03A

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Signal Conversion You can set the signal conversion type with the Linearization Type (L_TYPE) parameter. You can view the converted signal (in percent of XD_SCALE) through the FIELD_VAL parameter.

You can choose from direct, indirect, or indirect square root signal conversion with the L_TYPE parameter.

DirectDirect signal conversion allows the signal to pass through the accessed channel input value (or the simulated value when simulation is enabled).

IndirectIndirect signal conversion converts the signal linearly to the accessed channel input value (or the simulated value when simulation is enabled) from its specified range (XD_SCALE) to the range and units of the PV and OUT parameters (OUT_SCALE).

Indirect Square RootIndirect Square Root signal conversion takes the square root of the value computed with the indirect signal conversion and scales it to the range and units of the PV and OUT parameters.

When the converted input value is below the limit specified by the LOW_CUT parameter, and the Low Cutoff I/O option (IO_OPTS) is enabled (True), a value of zero is used for the converted value (PV). This option is useful to eliminate false readings when the differential pressure measurement is close to zero, and it may also be useful with zero-based measurement devices such as flowmeters.

NOTELow Cutoff is the only I/O option supported by the AI block. You can set the I/O option in Manual or Out of Service mode only.

Block Errors Table B-2 lists conditions reported in the BLOCK_ERR parameter. Conditions in italics are inactive for the AI block and are given here only for your reference.

FIELD_VAL 100 Channel Value EU*@0%–( )×EU*@100% EU*@0%–( )

--------------------------------------------------------------------------------------=

* XD_SCALE values

PV Channel Value=

PVFIELD_VAL

100--------------------------------

EU**@100% EU**@0%–( ) EU**@0%+×=

** OUT_SCALE values

PVFIELD_VAL

100--------------------------------

EU**@100% EU**@0%–( ) EU**@0%+×=

** OUT_SCALE values

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TABLE B-2. BLOCK_ERR Conditions.

Modes The AI Function Block supports three modes of operation as defined by the MODE_BLK parameter:

• Manual (Man) The block output (OUT) may be set manually• Automatic (Auto) OUT reflects the analog input measurement

or the simulated value when simulation is enabled.• Out of Service (O/S) The block is not processed. FIELD_VAL

and PV are not updated and the OUT status is set to Bad: Out of Service. The BLOCK_ERR parameter shows Out of Service. In this mode, you can make changes to all configurable parameters. The target mode of a block may be restricted to one or more of the supported modes.

Alarm Detection A block alarm will be generated whenever the BLOCK_ERR has an error bit set. The types of block error for the AI block are defined above.

Process Alarm detection is based on the OUT value. You can configure the alarm limits of the following standard alarms:

• High (HI_LIM)• High high (HI_HI_LIM)• Low (LO_LIM)• Low low (LO_LO_LIM)

Condition Number

Condition Name and Description

0 Other

1 Block Configuration Error: the selected channel carries a measurement that is incompatible with the engineering units selected in XD_SCALE, the L_TYPE parameter is not configured, or CHANNEL = zero.

2 Link Configuration Error

3 Simulate Active: Simulation is enabled and the block is using a simulated value in its execution.

4 Local Override

5 Device Fault State Set

6 Device Needs Maintenance Soon

7 Input Failure/Process Variable has Bad Status: The hardware is bad, or a bad status is being simulated.

8 Output Failure: The output is bad based primarily upon a bad input.

9 Memory Failure

10 Lost Static Data

11 Lost NV Data

12 Readback Check Failed

13 Device Needs Maintenance Now

14 Power Up

15 Out of Service: The actual mode is out of service.

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In order to avoid alarm chattering when the variable is oscillating around the alarm limit, an alarm hysteresis in percent of the PV span can be set using the ALARM_HYS parameter. The priority of each alarm is set in the following parameters:

• HI_PRI• HI_HI_PRI• LO_PRI• LO_LO_PRI

Alarms are grouped into five levels of priority:

Status Handling Normally, the status of the PV reflects the status of the measurement value, the operating condition of the I/O card, and any active alarm condition. In Auto mode, OUT reflects the value and status quality of the PV. In Man mode, the OUT status constant limit is set to indicate that the value is a constant and the OUT status is Good.

The Uncertain - EU range violation status is always set, and the PV status is set high- or low-limited if the sensor limits for conversion are exceeded.

In the STATUS_OPTS parameter, you can select from the following options to control the status handling:

BAD if Limited – sets the OUT status quality to Bad when the value is higher or lower than the sensor limits.

Uncertain if Limited – sets the OUT status quality to Uncertain when the value is higher or lower than the sensor limits.

Uncertain if in Manual mode – The status of the Output is set to Uncertain when the mode is set to Manual

NOTES1. The instrument must be in Manual or Out of Service mode to set the status option.2. The AI block only supports the BAD if Limited option. Unsupported options are not grayed out; they appear on the screen in the same manner as supported options.

Priority Number

Priority Description

0 The priority of an alarm condition changes to ) after the condition that caused the alarm is corrected.

1 An alarm condition with a priority of 1 is recognized by the system, but is not reported to the operator.

2 An alarm condition with a priority of 2 is reported to the operator, but does not require operator attention (such as diagnostics and system alerts).

3-7 Alarm conditions of priority 3 to 7 are advisory alarms of increasing priority.

8-15 Alarm conditions of priority 8 to 15 are critical alarms of increasing priority.

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Advanced Features The AI function block provided with Fisher-Rosemount fieldbus devices provides added capability through the addition of the following parameters:

ALARM_TYPE – Allows one or more of the process alarm conditions detected by the AI function block to be used in setting its OUT_D parameter.

OUT_D – Discrete output of the AI function block based on the detection of process alarm condition(s). This parameter may be linked to other function blocks that require a discrete input based on the detected alarm condition.

VAR_SCAN – Time period in seconds over which the variability index (VAR_INDEX) is computed.

VAR_INDEX – Process variability index measured as the integral of average absolute error between PV and its mean value over the previous evaluation period. This index is calculated as a percent of OUT span and is updated at the end of the time period defined by VAR_SCAN.

Application Information The configuration of the AI function block and its associated output channels depends on the specific application. A typical configuration for the AI block involves the following parameters:

CHANNEL If the device supports more than one measurement, verify that the selected channel contains the appropriate measurement or derived value.

L_TYPE Select Direct when the measurement is already in the engineering units that you want for the block output. Select Indirect when you want to convert the measured variable into another, for example, pressure into level or flow into energy.Select Indirect Square Root when the block I/O parameter value represents a flow measurement made using differential pressure, and when square root extraction is not performed by the transducer.

SCALING XD_SCALE provides the range and units of the measurement and OUT_SCALE provides the range and engineering units of the output.

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FIE

LDB

US

-FB

US

_04A

Application Example: Temperature Transmitter

SituationA temperature transmitter with a range of –200 to 450 ˚C.

SolutionTable B-3 lists the appropriate configuration settings, and Figure B-3 illustrates the correct function block configuration.

TABLE B-3. Analog Input Function Block Configuration for a Typical Temperature Transmitter.

.

FIGURE B-3. Analog Input Function Block Diagram for a Typical Temperature Transmitter.

Parameter Configured Values

L_TYPE Direct

XD_SCALE Not Used

OUT_SCALE Not Used

Temperature Measurement

To Another Function Block

OUT_D

OUTAI Function Block

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Application Example: Pressure Transmitter used to Measure Level in an Open Tank

Situation #1The level of an open tank is to be measured using a pressure tap at the bottom of the tank. The level measurement will be used to control the level of liquid in the tank. The maximum level at the tank is 16 ft. The liquid in the tank has a density that makes the level correspond to a pressure of 7.0 psi at the pressure tap (see Figure B-4).

FIGURE B-4. Situation #1 Diagram.

Solution to Situation #1Table B-4 lists the appropriate configuration settings, and Figure B-5 illustrates the correct function block configuration.

TABLE B-4. Analog Input Function Block Configuration for a Pressure Transmitter used in Level Measurement (situation #1).

FIGURE B-5. Function Block Diagram for a Pressure Transmitter used in Level Measurement.

16 ft 7.0 psi measured at the transmitter

Full Tank


L_TYPE Indirect

XD_SCALE 0 to 7 psi

OUT_SCALE 0 to 16 ft

AnalogMeasurement

AI Function

Block

OUT_D

OUT

PID Function

Block

AOFunction

Block

BKCAL_IN

CAS_IN

CAS_INOUT

BKCAL_OUT

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Situation #2The transmitter in situation #1 is installed below the tank in a position where the liquid column in the impulse line, when the tank is empty, is equivalent to 2.0 psi (see Figure B-6).

FIGURE B-6. Situation #2 Diagram.

SolutionTable B-5 lists the appropriate configuration settings.

TABLE B-5. Analog Input Function Block Configuration for a Pressure Transmitter used in Level Measurement (Situation #2).

16 ft

0 ft

2.0 psi measured at the transmitter

Empty Tank


L_TYPE Indirect

XD_SCALE 2 to 9 psi

OUT_SCALE 0 to 16 ft

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Application Example: Differential Pressure Transmitter to Measure Flow

SituationThe liquid flow in a line is to be measured using the differential pressure across an orifice plate in the line, and the flow measurement will be used in a flow control loop. Based on the orifice specification sheet, the differential pressure transmitter was calibrated for 0 to 20 inH20 for a flow of 0 to 800 gal/min, and the transducer was not configured to take the square root of the differential pressure.

SolutionTable B-6 lists the appropriate configuration settings, and Figure B-7 illustrates the correct function block configuration.

TABLE B-6. Analog Input Function Block Configuration for a Differential Pressure Transmitter.

FIGURE B-7. Function Block Diagram for a Differential Pressure Transmitter Used in a Flow Measurement.


L_TYPE Indirect Square Root

XD_SCALE 0 to 20 in.

OUT_SCALE 0 to 800 gal/min.

AI Function

Block

PID Function

Block

AO Function

Block

OUT_D

OUT

AnalogMeasurement BKCAL_IN BKCAL_OUT

IN

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Troubleshooting Refer to Table B-7 to troubleshoot any problems that you encounter.

TABLE B-7. Troubleshooting.

Symptom Possible Causes Corrective Action

Mode will not leave OOS

1.Target mode not set. 1. Set target mode to something other than OOS.

2.Configuration error 2.BLOCK_ERR will show the configuration error bit set. The following are parameters that must be set before the block is allowed out of OOS:

a. CHANNEL must be set to a valid value and cannot be left at initial value of 0.

b. XD_SCALE.UNITS_INDX must match the units in the transducer block channel value.

c. L_TYPE must be set to Direct, Indirect, or Indirect Square Root and cannot be left at initial value of 0.

3.Resource block 3.The actual mode of the Resource block is OOS. See Resource Block Diagnostics for corrective action.

4.Schedule 4.Block is not scheduled and therefore cannot execute to go to Target Mode. Schedule the block to execute.

Process and/or block alarms will not work.

1.Features 1.FEATURES_SEL does not have Alerts enabled. Enable the Alerts bit.

2.Notification 2.LIM_NOTIFY is not high enough. Set equal to MAX_NOTIFY.

3.Status Options 3.STATUS_OPTS has Propagate Fault Forward bit set. This should be cleared to cause an alarm to occur.

Value of output does not make sense

1.Linearization Type 1.L_TYPE must be set to Direct, Indirect, or Indirect Square Root and cannot be left at initial value of 0.

2.Scaling 2.Scaling parameters are set incorrectly:a. XD_SCALE.EU0 and EU100 should

match that of the transducer block channel value.

b. OUT_SCALE.EU0 and EU100 are not set properly.

Cannot set HI_LIMIT, HI_HI_LIMIT, LO_LIMIT, or LO_LO_LIMIT Values

1.Scaling 1.Limit values are outside the OUT_SCALE.EU0 and OUT_SCALE.EU100 values. Change OUT_SCALE or set values within range.

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B-14

Appendix

C PID Function Block

field

bus-

fbus

_34a

The PID function block combines all of the necessary logic to perform proportional/integral/derivative (PID) control. The block supports mode control, signal scaling and limiting, feedforward control, override tracking, alarm limit detection, and signal status propagation.

The block supports two forms of the PID equation: Standard and Series. You can choose the appropriate equation using the FORM parameter. The Standard ISA PID equation is the default selection.

BKCAL_IN = The analog input value and status from another block’s BKCAL_OUT output that is used for backward output tracking for bumpless transfer and to pass limit status.

CAS_IN = The remote setpoint value from another function block.

FF_VAL = The feedforward control input value and status.IN = The connection for the process variable from

another function block.

PIDOUT

BKCAL_OUTBKCAL_IN

CAS_IN

FF_VAL

IN

TRK_IN_D

TRK_VAL

TRK_IN_D = Initiates the external tracking function.TRK_VAL = The value after scaling applied to OUT in

Local Override mode.BKCAL_OUT = The value and status required by the

BKCAL_IN input of another function block to prevent reset windup and to provide bumpless transfer to closed loop control.

OUT = The block output and status.

Standard Out GAIN e 1 1τ rs 1+----------------

τds

α τ ds 1+×---------------------------+ +

× F+×=

Series Out GAIN e× 11

τ rs-------

+×

τds 1+

α τ ds 1+×---------------------------

+ F+=

Where

GAIN: proportional gain valueτ r: integral action time constant (RESET parameter) in secondss: laplace operatorτd: derivative action time constant (RATE parameter)α: fixed smoothing factor of 0.1 applied to RATEF: feedforward control contribution from the feedforward input (FF_VAL parameter)e: error between setpoint and process variable

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To further customize the block for use in your application, you can configure filtering, feedforward inputs, tracking inputs, setpoint and output limiting, PID equation structures, and block output action. Table C-1 lists the PID block parameters and their descriptions, units of measure, and index numbers, and Figure C-1 on page C-5 illustrates the internal components of the PID function block.

TABLE C-1. PID Function Block System Parameters.


Units Description

ACK_OPTION 46 None Used to set auto acknowledgment of alarms.

ALARM_HYS 47 Percent The amount the alarm value must return to within the alarm limit before the associated active alarm condition clears.

ALARM_SUM 45 None The summary alarm is used for all process alarms in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the Active status in the Status parameter. As soon as the Unreported status is cleared by the alert reporting task, another block alert may be reported without clearing the Active status, if the subcode has changed.

ALERT_KEY 04 None The identification number of the plant unit. This information may be used in the host for sorting alarms, etc.

ALG_TYPE 74 None Selects filtering algorithm as Backward or Bilinear.

BAL_TIME 25 Seconds The specified time for the internal working value of bias to return to the operator set bias. Also used to specify the time constant at which the integral term will move to obtain balance when the output is limited and the mode is AUTO, CAS, or RCAS.

BIAS 66 EU of OUT_SCALE The bias value used to calculate output for a PD type controller.

BKCAL_HYS 30 Percent The amount the output value must change away from the its output limit before limit status is turned off.

BKCAL_IN 27 EU of OUT_SCALE The analog input value and status from another block’s BKCAL_OUT output that is used for backward output tracking for bumpless transfer and to pass limit status.

BKCAL_OUT 31 EU of PV_SCALE The value and status required by the BKCAL_IN input of another block to prevent reset windup and to provide bumpless transfer of closed loop control.

BLOCK_ALM 44 None The block alarm is used for all configuration, hardware, connection failure, or system problems in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the active status in the status parameter. As soon as the Unreported status is cleared by the alert reporting task, and other block alert may be reported without clearing the Active status, if the subcode has changed.

BLOCK_ERR 06 None This parameter reflects the error status associated with the hardware or software components associated with a block. It is a bit string so that multiple errors may be shown.

BYPASS 17 None Used to override the calculation of the block. When enabled, the SP is sent directly to the output.

CAS_IN 18 EU of PV_SCALE The remote setpoint value from another block.

CONTROL_OPTS 13 None Allows you to specify control strategy options. The supported control options for the PID block are Track enable, Track in Manual, SP-PV Track in Man, SP-PV Track in LO or IMAN, Use PV for BKCAL OUT, and Direct Acting

DV_HI_ALM 64 None The DV HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm.

DV_HI_LIM 57 EU of PV_SCALE The setting for the alarm limit used to detect the deviation high alarm condition.

DV_HI_PRI 56 None The priority of the deviation high alarm.

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DV_LO_ALM 65 None The DV LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm.

DV_LO_LIM 59 EU of PV_SCALE The setting for the alarm limit use to detect the deviation low alarm condition.

DV_LO_PRI 58 None The priority of the deviation low alarm.

ERROR 67 EU of PV_SCALE The error (SP-PV) used to determine the control action.

FF_ENABLE 70 None Enables the use of feedforward calculations

FF_GAIN 42 None The feedforward gain value. FF_VAL is multiplied by FF_GAIN before it is added to the calculated control output.

FF_SCALE 41 None The high and low scale values, engineering units code, and number of digits to the right of the decimal point associated with the feedforward value (FF_VAL).

FF_VAL 40 EU of FF_SCALE The feedforward control input value and status.

GAIN 23 None The proportional gain value. This value cannot = 0.

GRANT_DENY 12 None Options for controlling access of host computers and local control panels to operating, tuning, and alarm parameters of the block. Not used by the device.

HI_ALM 61 None The HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm.

HI_HI_ALM 60 None The HI HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm.

HI_HI-LIM 49 EU of PV_SCALE The setting for the alarm limit used to detect the HI HI alarm condition.

HI_HI_PRI 48 None The priority of the HI HI Alarm.

HI_LIM 51 EU of PV_SCALE The setting for the alarm limit used to detect the HI alarm condition.

HI_PRI 50 None The priority of the HI alarm.

IN 15 EU of PV_SCALE The connection for the PV input from another block.

LO_ALM 62 None The LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm.

LO_LIM 53 EU of PV_SCALE The setting for the alarm limit used to detect the LO alarm condition.

LO_LO_ALM 63 None The LO LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm.

LO_LO_LIM 55 EU of PV_SCALE The setting for the alarm limit used to detect the LO LO alarm condition.

LO_LO_PRI 54 None The priority of the LO LO alarm.

LO_PRI 52 None The priority of the LO alarm.

MATH_FORM 73 None Selects equation form (series or standard).

MODE_BLK 05 None The actual, target, permitted, and normal modes of the block.Target: The mode to “go to”Actual: The mode the “block is currently in”Permitted: Allowed modes that target may take onNormal: Most common mode for target

OUT 09 EU of OUT SCALE The block input value and status.

OUT_HI_LIM 28 EU of OUT_SCALE The maximum output value allowed.


Units Description

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OUT-LO_LIM 29 EU of OUT_SCALE The minimum output value allowed

OUT_SCALE 11 None The high and low scale values, engineering units code, and number of digits to the right of the decimal point associated with OUT.

PV 07 EU of PV_SCALE The process variable used in block execution.

PV_FTIME 16 Seconds The time constant of the first-order PV filter. It is the time required for a 63 percent change in the IN value.

PV_SCALE 10 None The high and low scale values, engineering units code, and number of digits to the right of the decimal point associated with PV.

RATE 26 Seconds The derivative action time constant.

RCAS_IN 32 EU of PV_SCALE Target setpoint and status that is provided by a supervisory host. Used when mode is RCAS.

RCAS_OUT 35 EU of PV_SCALE Block setpoint and status after ramping, filtering, and limiting that is provided to a supervisory host for back calculation to allow action to be taken under limiting conditions or mode change. Used when mode is RCAS.

RESET 24 Seconds per repeat The integral action time constant.

ROUT_IN 33 EU of OUT_SCALE Target output and status that is provided by a supervisory host. Used when mode is ROUT.

ROUT_OUT 36 EU of OUT_SCALE Block output that is provided to a supervisory host for a back calculation to allow action to be taken under limiting conditions or mode change. Used when mode is RCAS.

SHED_OPT 34 None Defines action to be taken on remote control device timeout.

SP 08 EU of PV_SCALE The target block setpoint value. It is the result of setpoint limiting and setpoint rate of change limiting.

SP_FTIME 69 Seconds The time constant of the first-order SP filter. It is the time required for a 63 percent change in the IN value.

SP_HI_LIM 21 EU of PV_SCALE The highest SP value allowed.

SP_LO_LIM 22 EU of PV_SCALE The lowest SP value allowed.

SP_RATE_DN 19 EU of PV_SCALE per second

Ramp rate for downward SP changes. When the ramp rate is set to zero, the SP is used immediately.

SP-RATE_UP 20 EU of PV_SCALE per second

Ramp rate for upward SP changes. When the ramp rate is set to zero, the SP is used immediately.

SP_WORK 68 EU of PV_SCALE The working setpoint of the block after limiting and filtering is applied.

STATUS_OPTS 14 None Allows you to select options for status handling and processing. The supported status option for the PID block is Target to Manual if Bad IN.

STRATEGY 03 None The strategy field can be used to identify grouping of blocks. This data is not checked or processed by the block.

ST_REV 01 None The revision level of the static data associated with the function block. The revision value will be incremented each time a static parameter value in the block is changed.

STRUCTURE.CONFIG

75 None Defines PID equation structure to apply controller action.

TAG_DESC 02 None The user description of the intended application of the block.

TRK_IN_D 38 None Discrete input that initiates external tracking.


Units Description

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FIGURE C-1. PID Function Block Schematic.

TRK_SCALE 37 None The high and low scale values, engineering units code, and number of digits to the right of the decimal point associated with the external tracking value (TRK_VAL).

TRK_VAL 39 EU of TRK SCALE The value (after scaling from TRK_SCALE to OUT_SCALE) applied to OUT in LO mode.

UBETA 72 Percent Used to set disturbance rejection vs. tracking response action for a 2.0 degree of freedom PID.

UGAMMA 71 Percent Used to set disturbance rejection vs. tracking response action for a 2.0 degree of freedom PID.

UPDATE_EVT 43 None This alert is generated by any changes to the static data.


Units Description

field

bus-

fbus

_13a

FF_VAL

BKCAL_IN

TRK_IN_D

CAS_IN

IN

TRK_VAL

FF_GAINFF_SCALE

RCAS_OUT

RCAS_IN

SP_HI_LIMSP_LO_LIMSP_RATE_DNSP_RATE_UPSP_FTIME

GAINRATERESET

FeedforwardCalculation

MODE

SetpointLimiting

and Filtering

PIDEquation Output

Limiting

ROUT_OUT

ROUT_IN

OUT_HI_LIMOUT_LO_LIMOUT_SCALE

OperatorOutput

Alarm Detection

Scalingand

Filtering

PV_SCALEPV_FTIME

HI_HI_LIMHI_LIMDV_HI_LIMDV_LO_LIMLO_LIMLO_LO_LIM

TRK_SCALEOUT_SCALE

BKCAL_OUT

OUT

Convert

OperatorSetpoint

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Setpoint Selection and Limiting

The setpoint of the PID block is determined by the mode. You can configure the SP_HI_LIM and SP_LO_LIM parameters to limit the setpoint. In Cascade or RemoteCascade mode, the setpoint is adjusted by another function block or by a host computer, and the output is computed based on the setpoint.

In Automatic mode, the setpoint is entered manually by the operator, and the output is computed based on the setpoint. In Auto mode, you can also adjust the setpoint limit and the setpoint rate of change using the SP_RATE_UP and SP_RATE_DN parameters.

In Manual mode the output is entered manually by the operator, and is independent of the setpoint. In RemoteOutput mode, the output is entered by a host computer, and is independent of the setpoint.

Figure C-2 illustrates the method for setpoint selection.

FIGURE C-2. PID Function Block Setpoint Selection.

Filtering The filtering feature changes the response time of the device to smooth variations in output readings caused by rapid changes in input. You can configure the filtering feature with the FILTER_TYPE parameter, and you can adjust the filter time constant (in seconds) using the PV_FTIME or SP_FTIME parameters. Set the filter time constant to zero to disable the filter feature.

Feedforward Calculation The feedforward value (FF_VAL) is scaled (FF_SCALE) to a common range for compatibility with the output scale (OUT_SCALE). A gain value (FF_GAIN) is applied to achieve the total feedforward contribution.

Tracking You enable the use of output tracking through the control options. You can set control options in Manual or Out of Service mode only.

The Track Enable control option must be set to True for the track function to operate. When the Track in Manual control option is set to True, tracking can be activated and maintained only when the block is in Manual mode. When Track in Manual is False, the operator can override the tracking function when the block is in Manual mode. Activating the track function causes the block’s actual mode to revert to Local Override.

The TRK_VAL parameter specifies the value to be converted and tracked into the output when the track function is operating. The TRK_SCALE parameter specifies the range of TRK_VAL.

When the TRK_IN_D parameter is True and the Track Enable control option is True, the TRK_VAL input is converted to the appropriate value and output in units of OUT_SCALE.

field

bus-

fbus

_01a

Operator Setpoint

SP_HI_LIMSP_LO_LIM

SP_RATE_UPSP_RATE_DN

SetpointLimiting

RateLimiting

AutoMan

AutoMan

CasCas

C-6


OUNDATION


Output Selection and Limiting

Output selection is determined by the mode and the setpoint. In Automatic, Cascade, or RemoteCascade mode, the output is computed by the PID control equation. In Manual and RemoteOutput mode, the output may be entered manually (see also Setpoint Selection and Limiting on page C-6). You can limit the output by configuring the OUT_HI_LIM and OUT_LO_LIM parameters.

Bumpless Transfer and Setpoint Tracking

You can configure the method for tracking the setpoint by configuring the following control options (CONTROL_OPTS):

SP-PV Track in Man — Permits the SP to track the PV when the target mode of the block is Man.

SP-PV Track in LO or IMan — Permits the SP to track the PV when the actual mode of the block is Local Override (LO) or Initialization Manual (IMan).

When one of these options is set, the SP value is set to the PV value while in the specified mode.

You can select the value that a master controller uses for tracking by configuring the Use PV for BKCAL_OUT control option. The BKCAL_OUT value tracks the PV value. BKCAL_IN on a master controller connected to BKCAL_OUT on the PID block in an open cascade strategy forces its OUT to match BKCAL_IN, thus tracking the PV from the slave PID block into its cascade input connection (CAS_IN). If the Use PV for BKCAL_OUT option is not selected, the working setpoint (SP_WRK) is used for BKCAL_OUT.

You can set control options in Manual or Out of Service mode only. When the mode is set to Auto, the SP will remain at the last value (it will no longer follow the PV.

PID Equation Structures Configure the STRUCTURE parameter to select the PID equation structure. You can select one of the following choices:

• PI Action on Error, D Action on PV• PID Action on Error• I Action on Error, PD Action on PV

Set RESET to zero to configure the PID block to perform integral only control regardless of the STRUCTURE parameter selection. When RESET equals zero, the equation reduces to an integrator equation with a gain value applied to the error:

Reverse and Direct Action To configure the block output action, enable the Direct Acting control option. This option defines the relationship between a change in PV and the corresponding change in output. With Direct Acting enabled (True), an increase in PV results in an increase in the output.

You can set control options in Manual or Out of Service mode only.

GAIN e s( )×s

-------------------------------

Where

GAIN: proportional gain valuee: errors: laplace operator

C-7


OUNDATION


NOTETrack Enable, Track in Manual, SP-PV Track in Man, SP-PV Track in LO or IMan, Use PV for BKCAL_OUT, and Direct Acting are the only control options supported by the PID function block. Unsupported options are not grayed out; they appear on the screen in the same manner as supported options.

Reset Limiting The PID function block provides a modified version of feedback reset limiting that prevents windup when output or input limits are encountered, and provides the proper behavior in selector applications.

Block Errors Table C-2 lists conditions reported in the BLOCK_ERR parameter. Conditions in italics are inactive for the PID block and are given here only for your reference.

TABLE C-2. BLOCK_ERR Conditions .

Modes The PID function block supports the following modes:

Manual (Man)—The block output (OUT) may be set manually.

Automatic (Auto)—The SP may be set manually and the block algorithm calculates OUT.

Cascade (Cas)—The SP is calculated in another block and is provided to the PID block through the CAS_IN connection.

RemoteCascade (RCas)—The SP is provided by a host computer that writes to the RCAS_IN parameter.

RemoteOutput (Rout)—The OUT is provided by a host computer that writes to the ROUT_IN parameter.

Local Override (LO)—The track function is active. OUT is set by TRK_VAL. The BLOCK_ERR parameter shows Local override.

Condition Number

Condition Name and Description

0 Other

1 Block Configuration Error: The BY_PASS parameter is not configured and is set to 0, the SP_HI_LIM is less than the SP_LO_LIM, or the OUT_HI_LIM is less than the OUT_LO_LIM.

2 Link Configuration Error

3 Simulate Active

4 Local Override: The actual mode is LO.

5 Device Fault State Set

6 Device Needs Maintenance Soon

7 Input Failure/Process Variable has Bad Status: The parameter linked to IN is indicating a Bad status.

8 Output Failure

9 Memory Failure

10 Lost Static Data

11 Lost NV Data

12 Readback Check Failed

13 Device Needs Maintenance Now

14 Power Up

15 Out of Service: The actual mode is out of service.

C-8


OUNDATION


Initialization Manual (IMan)—The output path is not complete (for example, the cascade-to-slave path might not be open). In IMan mode, OUT tracks BKCAL_IN.

Out of Service (O/S)—The block is not processed. The OUT status is set to Bad: Out of Service. The BLOCK_ERR parameter shows Out of service.

You can configure the Man, Auto, Cas, and O/S modes as permitted modes for operator entry.

Alarm Detection A block alarm will be generated whenever the BLOCK_ERR has an error bit set. The types of block error for the AI block are defined above.

Process alarm detection is based on the PV value. You can configure the alarm limits of the following standard alarms:

• High (HI_LIM)• High high (HI_HI_LIM)• Low (LO_LIM)• Low low (LO_LO_LIM)

Additional process alarm detection is based on the difference between SP and PV values and can be configured via the following parameters:

• Deviation high (DV_HI_LIM)• Deviation low (DV_LO_LIM)

In order to avoid alarm chattering when the variable is oscillating around the alarm limit, an alarm hysteresis in percent of the PV span can be set using the ALARM_HYS parameter. The priority of each alarm is set in the following parameters:

• HI_PRI• HI_HI_PRI• LO_PRI• LO_LO_PRI• DV_HI_PRI• DV_LO_PRI

Alarms are grouped into five levels of priority:

Priority Number

Priority Description

0 The priority of an alarm condition changes to ) after the condition that caused the alarm is corrected.

1 An alarm condition with a priority of 1 is recognized by the system, but is not reported to the operator.

2 An alarm condition with a priority of 2 is reported to the operator, but does not require operator attention (such as diagnostics and system alerts).

3-7 Alarm conditions of priority 3 to 7 are advisory alarms of increasing priority.

8-15 Alarm conditions of priority 8 to 15 are critical alarms of increasing priority.

C-9


OUNDATION


Status Handling If the input status on the PID block is Bad, the mode of the block reverts to Manual. In addition, you can select the Target to Manual if Bad IN status option to direct the target mode to revert to manual. You can set the status option in Manual or Out of Service mode only.

NOTETarget to Manual if Bad IN is the only status option supported by the PID function block. Unsupported options are not grayed out; they appear on the screen in the same manner as supported options.

Application Information The PID function block is a powerful, flexible control algorithm that is designed to work in a variety of control strategies. The PID block is configured differently for different applications. The following examples describe the use of the PID block for closed-loop control (basic PID loop), feedforward control, cascade control with master and slave, and complex cascade control with override.

Closed Loop Control To implement basic closed loop control, compute the error difference between the process variable (PV) and setpoint (SP) values and calculate a control output signal using a PID (Proportional Integral Derivative) function block.

The proportional control function responds immediately and directly to a change in the PV or SP. The proportional term GAIN applies a change in the loop output based on the current magnitude of the error multiplied by a gain value.

The integral control function reduces the process error by moving the output in the appropriate direction. The integral term RESET applies a correction based on the magnitude and duration of the error. Set the RESET parameter to zero for integral-only control. To reduce reset action, configure the RESET parameter to be a large value.

The derivative term RATE applies a correction based on the anticipated change in error. Derivative control is typically used in temperature control where large measurement lags exist.

The MODE parameter is a switch that indicates the target and actual mode of operation. Mode selection has a large impact on the operation of the PID block:

• Manual mode allows the operator to set the value of the loop output signal directly.

• Automatic mode allows the operator to select a setpoint for automatic correction of error using the GAIN, RESET, and RATE tuning values.

• Cascade and Remote Cascade modes use a setpoint from another block in a cascaded configuration.

• Remote Out mode is similar to Manual mode except that the block output is supplied by an external program rather than by the operator.

• Initialization Manual is a non-target mode used with cascade configurations while transitioning from manual operation to automatic operation.

• Local Override is a non-target mode that instructs the block to revert to Local Override when the tracking or fail-safe control options are activated.

• Out of Service mode disables the block for maintenance.

C-10

Model 4081FG Oxygen Analyzer with FOUNDATION fieldbus Communications

field

bus-

fbus

_14a

Abrupt changes in the quality of the input signal can result in unexpected loop behavior. To prevent the output from changing abruptly and upsetting the process, select the SP-PV Track in Man I/O option. This option automatically sets the loop to Manual if a Bad input status is detected. While in manual mode, the operator can manage control manually until a Good input status is reestablished.

Application Example: Basic PID Block for Steam Heater Control

SituationA PID block is used with an AI block and an AO block to control the flow steam used to heat a process fluid in a heat exchanger. Figure C-3 illustrates the process instrumentation diagram.

FIGURE C-3. PID Function Block Steam Heater Control Example.

SolutionThe PID loop uses TT101 as an input and provides a signal to the analog output TCV101. The BKCAL_OUT of the AO block and the BKCAL_IN of the PID block communicate the status and quality of information being passed between the blocks. The status indication shows that communications is functioning and the I/O is working properly. Figure C-4 illustrates the correct function block configuration.

Steam Supply

TCV101

Steam Heater

Condensate

TC101

TT101

TT100

FIGURE C-4. PID Function Block Diagram for Steam Heater Control Example.

field

bus-

fbus

_15a

Outlet Temperature

Input

AIFunction

Block

PID Function

Block

AOFunction

Block

TT101 TC101 TCV101

BKCAL_IN BKCAL_OUT

OUT INCAS_INOUT OUT

C-11


field

bus-

fbus

_17a

Application Example: Feedforward Control

SituationIn the previous example, control problems can arise because of a time delay caused by thermal inertia between the two flow streams (TT100 and TT101). Variations in the inlet temperature (TT100) take an excessive amount of time to be sensed in the outlet (TT101). This delay causes the product to be out of the desired temperature range.

SolutionFeedforward control is added to improve the response time of the basic PID control. The temperature of the inlet process fluid (TT100) is input to an AI function block and is connected to the FF_VAL connector on the PID block. Feedforward control is then enabled (FF_ENABLE), the feedforward value is scaled (FF_SCALE), and a gain (FF_GAIN) is determined. Figure C-5 illustrates the process instrumentation diagram, and Figure C-6 illustrates the correct function block configuration.

FIGURE C-5. PID Function Block Feedforward Control Example.

field

bus-

fbus

_16a

Steam Supply

TCV101

Steam Heater

Condensate

TC101

TT101

TT100

FF

FIGURE C-6. Function Block Diagram for Feedforward Control.

Outlet Temperature

Input

Inlet Temperature

Input

BKCAL_IN BKCAL_OUT

OUT

OUT

OUT OUTIN CAS_IN

FF_VAL

AIFunction

Block

AIFunction

Block

PIDFunction

Block

AO Function

Block

TT101 TC101 TCV101

TT100

C-12


Application Example: Cascade Control with Master and Slave Loops

SituationA slave loop is added to a basic PID control configuration to measure and control steam flow to the steam heater. Variations in the steam pressure cause the temperature in the heat exchanger to change. The temperature variation will later be sensed by TT101. The temperature controller will modify the valve position to compensate for the steam pressure change. The process is slow and causes variations in the product temperature. Figure C-7 illustrates the process instrumentation diagram.

FIGURE C-7. PID Function Block Cascade Control Example.

SolutionIf the flow is controlled, steam pressure variations will be compensated before they significantly affect the heat exchanger temperature. The output from the master temperature loop is used as the setpoint for the slave steam flow loop. The BKCAL_IN and BKCAL_OUT connections on the PID blocks are used to prevent controller windup on the master loop when the slave loop is in Manual or Automatic mode, or it has reached an output constraint. Figure C-8 illustrates the correct function block configuration.

field

bus-

fbus

_18a

Steam Supply

FC101

Steam Heater

Condensate

TC101

TT101

FT101

TT100

TCV101

C-13


FIGURE C-8. PID Function Block Diagram for Cascade Control Example.

Outlet Temperature

Input

AIFunction

Block

PIDFunction

Block

AIFunction

Block

Steam FlowInput

PIDFunction

BlockAO

ModuleBlock

OUT IN

OUT IN

OUT INCAS_IN

BKCAL_OUTBKCAL_IN

BKCAL_OUTBKCAL_IN

OUT

FT 101 FC 101 TCV 101

TT 101 TC 101

C-14


field

bus-

fbus

_20a

Application Example: Cascade Control with Override

You can use the PID function block with other function blocks for complex control strategies. Figure C-9 illustrates the function block diagram for cascade control with override.

When configured for cascade control with override, if one of the PID function blocks connected to the selector inputs is deselected, that PID block filters the integral value to the selected value (the value at its BKCAL_IN). The selected PID block behaves normally and the deselected controller never winds up. At steady state, the deselected PID block offsets its OUT value from the selected value by the proportional term. When the selected block becomes output-limited, it prevents the integral term from winding further into the limited region.

When the cascade between the slave PID block and the Control Selector block is open, the open cascade status is passed to the Control Selector block and through to the PID blocks supplying input to it. The Control Selector block and the upstream (master) PID blocks have an actual mode of IMan.

If the instrument connected to the AI block fails, you can place the AI block in Manual mode and set the output to some nominal value for use in the Integrator function block. In this case, IN at the slave PID block is constant and prevents the integral term from increasing or decreasing.

PIDFunction

Block

AOFunction

Block

PIDFunction

Block

Control SelectorFunction

Block

PIDFunction

Block

PIDFunction

Block

AIFunction

Block

Configured for High Selection

Master Controller

Slave Controller

Master Controller

OUT

OUT

OUT

OUT OUT

IN_1

CAS_IN

CAS_IN

IN

SEL_1

SEL_2BKCAL_SEL_2

BKCAL_SEL_1

BKCAL_OUTBKCAL_INFIGURE C-9. Function Block Diagram for Cascade Control with Override.

C-15


Troubleshooting Refer to Table C-3 to troubleshoot any problems that you encounter.

TABLE C-3. Troubleshooting.


Mode will not leave OOS


2.Configuration error 2.BLOCK_ERR will show the configuration error bit set. The following are parameters that must be set before the block is allowed out of OOS:

a. BYPASS must be off or on and cannot be left at initial value of 0.

b. OUT_HI_LIM must be less than or equal to OUT_LO_LIM.

c. SP_HI_LIM must be less than or equal to SP_LO_LIM.

3.Resource block 3.The actual mode of the Resource block is OOS. See Resource Block Diagnostics for corrective action.

4.Schedule 4.Block is not scheduled and therefore cannot execute to go to Target Mode. Schedule the block to execute.

Mode will not leave IMAN

1.Back Calculation 1.BKCAL_INa. The link is not configured (the status

would show “Not Connected”). Configure the BKCAL_IN link to the downstream block.

b. The downstream block is sending back a Quality of “Bad” or a Status of “Not Invited”. See the appropriate downstream block diagnostics for corrective action.

Mode will not change to AUTO


2. Input 2. INa. The link is not configured (the status

would show “Not Connected”). Configure the IN link to the block.

b. The upstream block is sending back a Quality of “Bad” or a Status of “Not Invited”. See the appropriate upstream block diagnostics for corrective action.

Mode will not change to CAS


2.Cascade input 2.CAS_INa. The link is not configured (the status

would show “Not Connected”). Configure the CAS_IN link to the block.

b. The upstream block is sending back a Quality of “Bad” or a Status of “Not Invited”. See the appropriate up stream block diagnostics for corrective action.

Mode sheds from RCAS to AUTO

1.Remote Cascade Value 1.Host system is not writing RCAS_IN with a quality and status of “good cascade” within shed time (see 2 below).

2.Shed Timer 2.The mode shed timer, SHED_RCAS in the resource block is set too low. Increase the value.

C-16


Mode sheds from ROUT to MAN

1.Remote output value 1.Host system is not writing ROUT_IN with a quality and status of “good cascade” within shed time (see 2 below).

2.Shed timer 2.The mode shed timer, SHED_RCAS, in the resource block is set too low. Increase the value.

Process and/or block alarms will not work.

1.Features 1.FEATURES_SEL does not have Alerts enabled. Enable the Alerts bit.

2.Notification 2.LIM_NOTIFY is not high enough. Set equal to MAX_NOTIFY.

3.Status Options 3.STATUS_OPTS has Propagate Fault Forward bit set. This should be cleared to cause an alarm to occur.


C-17


C-18


April 2001

Rosemount Analytical Inc. A Division of Emerson Process Management Index 10-1

Oxymitter 5000

SECTION 10INDEX

This index is an alphabetized listing of parts, terms, and procedures having to do with the Haz-ardous Area Oxygen/Combustibles Transmitter. Every item listed in this index refers to a locationin the manual by one or more page numbers.

AAbrasive Shield, 2-1, 2-3, 2-6, 2-8Absolute Temperature, 1-3Accuracy, 1-8Adaptor Plate, 1-2, 1-7, 2-1Alarms, Diagnostic, 3-7, 4-7, 5-2Alarms, Unit, 4-7, 5-2Analog Output Signal (4-20 mA), 1-8Arithmetic Constant, 1-3Autocalibration, 5-1Automatic Calibration, 4-3

BBy-Pass Packages, 6-1

CCalibration, 4-1, 5-15, 5-16, 5-17Calibration Gas, 1-6, 1-7, 2-2, 2-3, 2-10, 4-1, 6-1,

6-2Calibration Interval, Timed, 4-3CALIBRATION RECOMMENDATION, 3-4CALIBRATION RECOMMENDED, 1-4, 3-7, 4-3, 4-4,

4-7, 6-1Cell, 1-4, 3-2, 4-14, 5-2, 5-12, 5-13, 5-14Cell Constant, 1-3Cell Replacement Kit, 4-14, 8-2Check Valve, 1-6Contact and Thermocouple Assembly, 4-18

DDiffusion Element, 1-4, 4-1, 4-15Drip Loop, 2-6, 2-7

EEEPROM, 5-14Electrical Noise, 5-1Electronics, 1-2, 1-3, 1-4, 1-6ELECTRONICS, 4-9Electrostatic Discharge, 5-1

FFieldbus, 1-1, 1-3, 2-8, 3-1, 4-4, 4-6Fuse, 4-11

GGrounding, 5-1

HHazardous Area Certifications, 1-8Heater, 1-8, 5-2, 5-7, 5-8, 5-9, 5-10, 5-11Heater Strut, 4-12Heater Thermocouple, 5-2, 5-3, 5-4, 5-5

IIMPS 4000, 1-2, 1-3, 1-5, 1-6, 1-7, 2-8, 2-9, 2-10,

3-4, 3-7, 4-4, 6-1Installation, Electrical, 2-8Installation, Mechanical, 2-1Installation, Pneumatic, 2-9Instrument Air, 1-5, 1-7, 2-9Insulation, 2-6Integrated Circuits, 5-1

KKeypad, Membrane, 1-4, 2-1, 3-2, 3-6, 4-3

LLength, 1-3, 1-8Line Voltage, 1-7, 1-8, 2-8Logic I/O, 1-7, 1-8, 2-8, 3-4

MManual Calibration, 4-4Membrane Keypad, 1-4, 2-1, 3-2, 3-6, 4-3Mounting Flange, 2-5

NNernst Equation, 1-3


10-2 Index Rosemount Analytical Inc. A Division of Emerson Process Management

Oxymitter 5000

OOxygen Range, 1-8

PPackaging, 1-6Partial Pressure, 1-3Power Requirements, 1-8Power Supply, 1-3Probe, 4-12Probe Disassembly Kit, 8-3Product Matrix, 1-1, 1-9, 1-10

RRange, O2, 3-2Reference Air, 1-3, 1-5, 1-7, 2-2, 2-3, 2-9, 3-6Reference Air Set, 1-2Relay Outputs, 1-7Remote Contact, 1-7Replacement Parts, Electronics, 8-4, 8-5Replacement Parts, Probe, 8-1, 8-2, 8-3

SSemi-Automatic Calibration, 4-4Signal, Digital, 1-3, 2-8Specifications, 1-8SPS 4000, 1-2, 1-3, 1-6, 1-7, 2-9, 2-10, 3-4, 3-7, 6-2

Calibration Gas Flowmeter, 4-1Handshake Signal, 3-4Remote Contact, 4-4

TTemperature Limits, 1-8Terminal Block, 2-9, 3-1, 4-11Test Points, 3-7Thermocouple, 1-4Troubleshooting, 5-1

VVee Deflector, 2-6

ZZirconia Disc, 1-3

33103537/4-01

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free fromdefects in workmanship and material under normal use and service for a period of twelve (12)months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquidjunctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship andmaterial under normal use and service for a period of ninety (90) days from date of shipment bySeller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/ormaterial shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that thegoods, part(s) or consumables are returned to Seller's designated factory, transportation chargesprepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and inthe case of consumables, within the ninety (90) day period of warranty. This warranty shall be ineffect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) daywarranty in the case of consumables. A defect in goods, part(s) and consumables of the com-mercial unit shall not operate to condemn such commercial unit when such goods, part(s) andconsumables are capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directlyor indirectly, arising from the use of the equipment or goods, from breach of any warranty, or fromany other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS,SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WAR-RANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIEDWARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DE-LAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WAR-RANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARDWARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF AC-TION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFICGOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYERAGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDEN-TAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUTARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVE-NUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT.IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNERNOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMSCOVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TOBUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDEDHEREUNDER.

Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyondSeller's direct control.


© Rosemount Analytical Inc. 2001

Oxymitter 5000

Emerson Process Management

Rosemount Analytical Inc.Process Analytic Division1201 N. Main St.Orrville, OH 44667-0901T (330) 682-9010F (330) 684-4434E [email protected]

ASIA - PACIFICFisher-RosemountSingapore Private Ltd.1 Pandan CrescentSingapore 128461Republic of SingaporeT 65-777-8211F 65-777-0947


Fisher-Rosemount GmbH & Co.Industriestrasse 163594 HasselrothGermanyT 49-6055-884 0F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICAFisher-Rosemount Ltd.Heath PlaceBognor RegisWest Sussex PO22 9SHEnglandT 44-1243-863121F 44-1243-845354

LATIN AMERICAFisher - RosemountAv. das Americas3333 sala 1004Rio de Janeiro, RJBrazil 22631-003T 55-21-2431-1882

Hazardous Area Oxymitter 5000

Part no.____________

Serial no.____________

Order no.____________

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