Rosemount Oxymitter 4000 Instruction Bulletin
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Rosemount Oxymitter 4000 Instruction Bulletin

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OXYMITTER 4000
OXYGEN TRANSMITTER
Instruction Bulletin IB-106-340
Revision 2.2
Oxymitter 4000
Part no.
____________
Serial no.
____________
Order no.
____________
STAY OFF THE STACK!
26170020

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Summary of Contents for Rosemount Oxymitter 4000

  • Page 1 OXYMITTER 4000 OXYGEN TRANSMITTER Instruction Bulletin IB-106-340 Revision 2.2 Oxymitter 4000 Part no. ____________ Serial no. ____________ Order no. ____________ STAY OFF THE STACK! 26170020...
  • Page 2 Indicated that heater thermocouple and diffusion element are field replaceable (paragraph 1-2.d.4). Page 1-3 Added paragraph 1-2.d.9(c) to indicate a third method to calibrate and troubleshoot an Oxymitter 4000. Page 1-8 Added 0 to 40% O range via HART. Added manual to calibration types. Updated signal specifications.
  • Page 3 Pages 7-4, 7-5, and 7-6 Modified HART menu tree (Figure 7-3). Page 7-7 Added WARNING about removing the Oxymitter 4000 from any automatic control loops prior to performing a calibration. Page 7-8 Added paragraph 7-8 to explain the procedure to enter a timed calibration via HART.
  • Page 4 HIGHLIGHTS OF CHANGES (Continued) Effective Feb., 1999 Rev. 2.2 PAGE SUMMARY Pages 1-10 and 1-11 Modified the product matrix in Table 1-1. Removed the disposable gas bottles and flow regulators from the matrix and created Table 1-2 to distinguish these components as separate order items because the calibration gas bottles cannot be shipped via airfreight.
  • Page 5 Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B.
  • Page 6 PURPOSE The purpose of this manual is to provide a comprehensive understanding of the Oxymitter 4000 components, functions, installation, and maintenance. This manual is designed to provide information about the Oxymitter 4000. We recommend that you thoroughly familiarize yourself with the Description and Installation sections before installing your transmitter.
  • Page 7 IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be 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 National Standards.
  • Page 8 BELANGRIJK Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel. De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften.
  • Page 9 VIGTIGT Sikkerhedsinstruktion for tilslutning og installering af dette udstyr. Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bør også følges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse forefindes.
  • Page 10 BELANGRIJK Veiligheidsinstructies voor de bedrading en installatie van dit apparaat. Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving anders voorschrijft.
  • Page 11 TÄRKEÄÄ Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa. Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive) yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta, elleivät kansalliset standardit estä sitä. Riittävät maadoituskytkennät on tehtävä...
  • Page 12 IMPORTANT Consignes de sécurité concernant le raccordement et l’installation de cet appareil. Les consignes de sécurité ci-dessous s’adressent particulièrement à tous les états membres de la communauté européenne. Elles doivent être strictement appliquées afin de satisfaire aux directives concernant la basse tension. Les états non membres de la communauté européenne doivent également appliquer ces consignes sauf si elles sont en contradiction avec les standards locaux ou nationaux.
  • Page 13 Wichtig Sicherheitshinweise für den Anschluß und die Installation dieser Geräte. Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der Niederspannungsrichtlinie zu genügen. Nichtmitgliedsstaaten der europäischen Gemeinschaft sollten die national gültigen Normen und Richtlinien einhalten. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden.
  • Page 14 IMPORTANTE Norme di sicurezza per il cablaggio e l’installazione dello strumento. Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all’Unione Europea, salvo quanto disposto dalle vigenti normative locali o nazionali.
  • Page 15 VIKTIG Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret. Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder.
  • Page 16 IMPORTANTE Instruções de segurança para ligação e instalação deste aparelho. As seguintes instruções de segurança aplicam-se especificamente a todos os estados membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tensão. Relativamente aos estados que não pertençam à UE, deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação local a tiver substituído.
  • Page 17 IMPORTANTE Instrucciones de seguridad para el montaje y cableado de este aparato. Las siguientes instrucciones de seguridad , son de aplicacion especifica a todos los miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en aquellos terminales previstos al efecto.
  • Page 18 VIKTIGT Säkerhetsföreskrifter för kablage och installation av denna apparat. Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varje avseende för att överensstämma med Lågspännings direktivet. Icke EU medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala eller nationella föreskrifter.
  • Page 19 IB-106-340...
  • Page 20 CERAMIC FIBER PRODUCTS MATERIAL 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.
  • Page 21 SECTION II. PHYSICAL DATA APPEARANCE AND ODOR Cream to white colored fiber shapes. With or without optional white to gray granular surface coating and/or optional black surface coating. SPECIFIC WEIGHT: 12-25 lb./cubic foot BOILING POINT: N.A. VOLATILES (% BY WT.): N.A. WATER SOLUBILITY: N.A.
  • Page 22 SECTION V. HEALTH HAZARD DATA THRESHOLD LIMIT VALUE (See Section III) EFFECTS OF OVER EXPOSURE Avoid contact with eyes. Slightly to moderately irritating. Abrasive action may cause damage to outer surface of eye. INHALATION May cause respiratory tract irritation. Repeated or prolonged breathing of particles of respirable size may cause inflammation of the lung leading to chest pain, difficult breathing, coughing and possible fibrotic change in the lung (Pneumoconiosis).
  • Page 23 4) Pleural plaques (thickening along the chest wall) have been observed in a small number of employees who had a long duration of employment. There are several occupational and non- occupational causes for pleural plaque. It should be noted that plaques are not “pre-cancer” nor are they associated with any measurable effect on lung function.
  • Page 24 INCOMPATIBILITY/MATERIALS TO AVOID Incompatible with hydrofluoric acid and concentrated alkali. HAZARDOUS DECOMPOSITION PRODUCTS N.A. 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 suppressant where sweeping if necessary.
  • Page 25 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 described in this MSDS must be strictly followed. In particular, when handling refractory ceramic fiber in any application, special caution should be taken to avoid unnecessary cutting and tearing of the material to minimize generation of airborne dust.
  • Page 26 Insulation surface should be lightly sprayed with water before removal to suppress airborne dust. As water evaporates during removal, additional water should be sprayed on surfaces as needed. Only enough water should be sprayed to suppress dust so that water does not run onto the floor of the work area.
  • Page 27 1-6. Specifications ........................INSTALLATION ........................2-1. Mechanical Installation ....................2-2. Electrical Installation (for Oxymitter 4000 without SPS 4000) ........2-3. Electrical Installation (for Oxymitter 4000 with SPS 4000) ........... 2-10 2-4. Pneumatic Installation (for Oxymitter 4000 without SPS 4000) ........
  • Page 28 7-3. HART Communicator PC Connections ................7-4. Off-line and On-line Operations ..................7-5. Logic I/O Configurations ....................7-6. Menu Tree For HART Communicator/Oxymitter 4000 Applications ......7-7. HART Communicator O2 CAL Method ................ 7-8. Defining a Timed Calibration via HART ................
  • Page 29 LIST OF ILLUSTRATIONS Figure Page Typical System Package ......................Oxymitter 4000 Autocalibration System Options ..............Oxymitter 4000 HART Connections and AMS Application ............ Typical System Installation ......................SPS 4000 ............................ Model 751 Remote Powered Loop LCD Display ..............Oxymitter 4000 Installation .......................
  • Page 30 Calibration Gas and Reference Air Components ............... 6-21 Signal Line Connections, ≥ 250 Ohms Lead Resistance ............Signal Line Connections, < 250 Ohms Lead Resistance ............Menu Tree for HART/AMS on the Oxymitter 4000 ..............Cell Replacement Kit ......................... Probe Disassembly Kit ....................... IB-106-340...
  • Page 31 LIST OF TABLES Table Page Product Matrix ........................... 1-10 Calibration Components ......................1-11 Intelligent Multiprobe Test Gas Sequencer Versions ..............1-12 Z-Purge Option for Use with IMPS 4000 .................. 1-12 Single Probe Autocalibration Sequencer Coding ..............1-12 Logic I/O Configuration ......................Diagnostic/Unit Alarm Fault Definitions ...................

  • Page 32: Typical System Package

    26170008 ITEM DESCRIPTION Instruction Bulletin IMPS 4000 Intelligent Multiprobe Test Gas Sequencer (Optional) Oxymitter 4000 with Integral Electronics SPS 4000 Single Probe Autocalibration Sequencer (Optional) - (Shown with reference air option) Adapter Plate with Mounting Hardware and Gasket ® HART...

  • Page 33: I Introduction

    The first part of the matrix defines the NOTE model. The last part defines the various options and features of the Oxymitter 4000. Ensure the features For best results, use clean, dry, instrument and options specified by your order number are on or air (20.95% oxygen) as the reference air.

  • Page 34: Oxymitter 4000 Autocalibration System Options

    5. The Oxymitter 4000 is constructed of rugged 316 L stainless steel for all wetted parts. Two calibration gas sequencers are available to the Oxymitter 4000: the IMPS 4000 and the SPS 4000 (Figure 1-2). Systems with multiprobe applications may employ...
  • Page 35 See Section VII, HART/ AMS, for additional information. System Considerations. Prior to installing your Personal Computer (PC) - The use Oxymitter 4000, make sure you have all the of a personal computer requires components necessary to make the system installa- software...

  • Page 36: Imps 4000 (Optional)

    4-20 MA OUTPUT (TWISTED PAIR) OXYMITTER 4000 WITH INTEGRAL ELECTRONICS 2 CALIBRATION GAS LINES TERMINATION IN BY CUSTOMER CONTROL ROOM [300 FT (90 M) MAX] ASSET MANAGEMENT SOLUTIONS LINE VOLTAGE 26170032 Figure 1-3. Oxymitter 4000 HART Connections and AMS Application IB-106-340...

  • Page 37: Typical System Installation

    STANDARD GASES DUCT STACK OXYMITTER ADAPTER 4000 PLATE LINE INSTRUMENT VOLTAGE AIR SUPPLY (REFERENCE AIR) PRESSURE FLOWMETER LOGIC I/O REGULATOR 4 TO 20 mA CALIBRATION SIGNAL GASES IMPS 4000 OPTION DUCT STACK ADAPTER PLATE CALIBRATION OXYMITTER 4000 LINE VOLTAGE 4 TO 20 mA LOGIC I/O SIGNAL REFERENCE...

  • Page 38: Sps 4000 (Optional)

    Mounting. The SPS 4000 can be mounted either power and signal connections and calibration directly to an Oxymitter 4000 or at a remote loca- gases to and from the sequencer. In addition, the tion if space is limited. In addition, the integrally...

  • Page 39: Model 751 Remote Powered Loop Lcd Display

    4-20 mA line from the regulator ensures the instrument air (reference Oxymitter 4000 (Figure 1-6). air) flowing to the Oxymitter 4000 is at a con- stant pressure [20 psi (138 kPa)]. The regulator also has a filter to remove particulates in the ref-...

  • Page 40: Specifications

    1-6. SPECIFICATIONS. Oxymitter 4000 Range: Standard ............0 to 10% O 0 to 25% O 0 to 40% O (via HART) Accuracy ..............±0.75% of reading or 0.1% O , whichever is greater System Response to Calibration Gas ....... Initial response in less than 3 seconds T90 in less than 8...
  • Page 41 Piping Distance between SPS 4000 and Oxymitter 4000 ......... Maximum 300 ft (91 m) Approximate Shipping Weight ........ 10 lbs (4.5 kg) Fisher-Rosemount has satisfied all obligations coming from the European legislation to harmonize the product requirements in Europe. IB-106-340...

  • Page 42: Product Matrix

    Table 1-1. Product Matrix. OXT4A Oxymitter 4000 In Situ Oxygen Transmitter Oxygen Transmitter - Instruction Book Code Sensing Probe Type ANSI (N. American Std.) Probe with Ceramic Diffuser ANSI Probe with Flame Arrestor and Ceramic Diffuser ANSI Probe with Snubber Diffuser DIN (European Std.) Probe with Ceramic Diffuser...

  • Page 43: Calibration Components

    Calibration Accessories No Hardware Calibration Gas Flowmeter and Reference Air Set Intelligent Multiprobe Sequencer (Refer to Table 1-3) Single Probe Sequencer - mounted to Oxymitter 4000 (Refer to Table 1-5) Cont’d Example NOTES: Recommended usages: High velocity particulates in flue stream, installation within 11.5 ft (3.5 m) of soot blowers or heavy salt cake buildup.

  • Page 44: Intelligent Multiprobe Test Gas Sequencer Versions

    Table 1-4. Z-Purge Option for Use with IMPS 4000. PART NUMBER DESCRIPTION 4513C24G03 Z-Purge System for IMPS used with Oxymitter 4000 4513C24G03 Z-Purge System for IMPS used with Oxymitter 4000, includes loss of purge switch (WPS) Table 1-5. Single Probe Autocalibration Sequencer Coding.

  • Page 45: Ii Installation

    Oxymitter 4000 integral electronics to a. Selecting Location. exceed 149°F (65°C) or damage to the unit may result. 1. The location of the Oxymitter 4000 in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. b. Installation.

  • Page 46: Oxymitter 4000 Installation

    29340003 Figure 2-1. Oxymitter 4000 Installation IB-106-340...

  • Page 47: Oxymitter 4000 Installation (With Sps 4000)

    REFERENCE AIR NOMINAL FLOWMETER (OPTIONAL) TO VIEW AND (REFERENCE AIR OUT OPERATE TO OXYMITTER 4000) OXYMITTER 4000 KEYPAD CALIBRATION GAS 10 (254) FLOWMETER NOMINAL (CALIBRATION GAS OUT 26170003 TO OXYMITTER 4000) Figure 2-2. Oxymitter 4000 Installation (with SPS 4000) IB-106-340...

  • Page 48: Oxymitter 4000 With Abrasive Shield

    29340001 Figure 2-3. Oxymitter 4000 with Abrasive Shield IB-106-340...

  • Page 49: Oxymitter 4000 Adapter Plate Dimensions

    29340004 Figure 2-4. Oxymitter 4000 Adapter Plate Dimensions IB-106-340...

  • Page 50: Oxymitter 4000 Adapter Plate Installation

    BE AIRTIGHT MASONRY STACK WALL OUTSIDE WALL WELD OR BOLT ADAPTER SURFACE PLATE TO METAL WALL OF STACK OR DUCT. NOTE: DIMENSIONS IN INCHES WITH JOINT MUST BE AIRTIGHT. MILLIMETERS IN PARENTHESES. 29340002 Figure 2-5. Oxymitter 4000 Adapter Plate Installation IB-106-340...

  • Page 51: Oxymitter 4000 Bracing Installation

    (143) 1.00 (25) MAX 36.00 (914) NOTE: BRACING IS FOR VERTICAL AND HORIZONTAL OXYMITTER 4000 INSTALLATION. EXTERNAL BRACING REQUIRED FOR 9 FT AND 12 FT (2.75 M AND 3.66 M) PROBES AS SHOWN ABOVE. 26170034 Figure 2-6. Oxymitter 4000 Bracing Installation 4.

  • Page 52: Installation With Drip Loop And Insulation Removal

    180°. Also, make probe inside the flue or stack (Figure 2-6). sure the gaskets are in the hub grooves as the Oxymitter 4000 slides into the 15° forcing cone in the abrasive shield. Uninsulated stacks or ducts may cause...

  • Page 53: Electrical Installation (For Oxymitter 4000 Without Sps 4000)

    Connect Line Voltage. Connect the line, or L1, wire to the L1 terminal and the neutral, or L2 wire, to the N terminal (Figure 2-9). The Oxymitter 4000 automatically will configure Install all protective equipment covers itself for 90-250 VAC line voltage and 50/60 Hz.

  • Page 54: Electrical Installation (For Oxymitter 4000 With Sps 4000)

    340 ohm series resistance. An interposing The SPS 4000 autocalibration system utilizes the relay will be required if this contact is to be Oxymitter 4000’s bidirectional logic contact as a utilized to annunciate a higher voltage “handshake” signal. Therefore, this signal is not device, such as a light or horn, and may also available for alarming purposes.

  • Page 55: Sps 4000 Electrical Connections

    1/2 in. NPT signal conduit port (Figure 2-2) connections are available to signal when the and out through the bottom of the manifold. Oxymitter 4000 is in calibration or when Connect the (+) and (-) signal leads to terminals 3 calibration failed.

  • Page 56: Pneumatic Installation (For Oxymitter 4000 Without Sps 4000)

    10-225 PSIG MAX PRESSURE REF AIR SET 0.250 OR 6 MM O.D. TUBING 263C152G01 (SUPPLIED BY CUSTOMER) SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYMITTER 4000 PROBE HEAD. 26170035 Figure 2-11. Air Set, Plant Air Connection 2-4. PNEUMATIC INSTALLATION (FOR OXY- MITTER 4000 WITHOUT SPS 4000).

  • Page 57: Pneumatic Installation (For Oxymitter 4000 With Sps 4000)

    4000 as instructed in paragraph 2-4. NOTE Upon completing installation, make sure that the Oxymitter 4000 is turned on and operating prior to firing up the combustion process. Damage can result from having a cold Oxymitter 4000 exposed to the process gases.

  • Page 58: Iii Startup

    (34, Figure injury or death. 6-1), gasket (33), and screw (32). 3-1. GENERAL. 4. For an Oxymitter 4000 with an integrally a. Verify Mechanical Installation. Ensure the mounted SPS 4000, remove screws (26, Oxymitter 4000 is installed correctly (Section II, Figure 6-11) and terminal cover (27).
  • Page 59 Located on the microprocessor board, the top board, are two switches that configure outputs for Typically, the probe’s sensing cell, which the Oxymitter 4000 (Figure 3-2). SW1 deter- is in direct contact with the process gases, mines if the 4-20 mA signal is internally or ex- is heated to approximately 1357°F...

  • Page 60: Oxymitter 4000 Defaults

    HEATER T/C HEATER DIAGNOSTIC O2 CELL ALARMS CALIBRATION CALIBRATION RECOMMENDED O2 CELL mV + O2 CELL mV - TEST HEATER T/C + POINTS HEATER T/C - HIGH TEST GAS + PROCESS - % O2 26170026 Figure 3-2. Oxymitter 4000 Defaults IB-106-340...

  • Page 61: Logic I/O

    RECOMMENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4000. *The default condition for an Oxymitter 4000 without an IMPS 4000 or SPS 4000. **The default condition for an Oxymitter 4000 with an IMPS 4000 or SPS 4000.

  • Page 62: Recommended Configuration

    4-20 mA Signal Upon Critical Alarm. Oxymitter 4000. Rosemount recommends that the factory default be utilized. The 4-20 mA signal will go to the 2. IN CALIBRATION. One contact per probe...

  • Page 63: Power Up

    3-4. POWER UP. 3-5. START OXYMITTER 4000 CALIBRA- TION. Refer to Section VI, MAINTENANCE AND SERVICE, for calibration instructions. a. Startup Display. When power is applied to the probe, the cell heater turns on. It takes approx- 3-6. IMPS 4000 CONNECTIONS. See the IMPS 4000 imately one half hour for the cell to heat to operat- Intelligent Multiprobe Test Gas Sequencer Instruction ing temperature.

  • Page 64: Iv Operation

    SECTION IV. OPERATION 4-1. GENERAL. 4. CAL LED. The CAL LED is on steady or flashing during calibration. Further informa- a. Overview. Ensure the Oxymitter 4000 is at tion available Section normal operation. The diagnostic LEDs will dis- MAINTENANCE AND SERVICE.

  • Page 65: Normal Operation

    HEATER T/C HEATER T/C HEATER HEATER DIAGNOSTIC ALARMS O2 CELL O CELL CALIBRATION CALIBRATION CALIBRATION RECOMMENDED O2 CELL mV + O2 CELL mv - TEST POINTS HEATER T/C + HEATER T/C - LIGHTING SEQUENCE DURING NORMAL OPERATION HIGH CAL LED TEST GAS + PROCESS - % O2...

  • Page 66: V Troubleshooting

    DCS input cards. A Potter & Brumfield b. Electrical Noise. The Oxymitter 4000 has been R10S-E1Y1-J1.0K 3.2 mA DC or an equal inter- designed to operate in the type of environment posing relay will be mounted where the contact normally found in a boiler room or control room.

  • Page 67: Identifying And Correcting Alarm Indications

    (b) One contact per IMPS 4000 for “high calibration gas flowing”. 5-4. IDENTIFYING AND CORRECTING ALARM INDICATIONS. Faults in the Oxymitter 4000 are indicated using the four diagnostic, or unit, alarms. NOTE The pattern of repeating blinks will define the prob- lem.

  • Page 68: Fault 1, Open Thermocouple

    a. Fault 1, Open Thermocouple. The HEATER T/C LED flashes once, pauses for three seconds, and repeats (Figure 5-1). HEATER T/C 1. Check connector J1. Ensure the connector is HEATER DIAGNOSTIC properly seated. O2 CELL ALARMS CALIBRATION CALIBRATION RECOMMENDED 2. Using a multimeter, measure TP3+ to TP4-. If the reading is 1.2 VDC ±0.1 VDC, the O2 CELL mV + O2 CELL mv -...

  • Page 69: Fault 2, Shorted Thermocouple

    b. Fault 2, Shorted Thermocouple. The HEATER T/C LED flashes twice, pauses for three seconds, and repeats (Figure 5-2). HEATER T/C 1. Using a multimeter, measure across TP3+ HEATER DIAGNOSTIC and TP4-. O2 CELL ALARMS CALIBRATION 2. If the reading is 0 ±0.5 mV, then a shorted CALIBRATION RECOMMENDED thermocouple is likely.

  • Page 70: Fault 3, Reversed Thermocouple

    c. Fault Reversed Thermocouple. HEATER T/C LED flashes three times, pauses for three seconds, and repeats (Figure 5-3). HEATER T/C 1. Using a multimeter, measure TP3+ to TP4-. HEATER DIAGNOSTIC O2 CELL ALARMS CALIBRATION 2. If the reading is negative, the thermocouple wiring is reversed.

  • Page 71: Fault 4, Open Heater

    d. Fault 4, Open Heater. The HEATER LED flashes once, pauses for three seconds, and re- peats (Figure 5-4). HEATER T/C 1. Remove power. Remove the electronic HEATER DIAGNOSTIC assembly per paragraph 6-5b, Electronic As- ALARMS O2 CELL CALIBRATION sembly Replacement. CALIBRATION RECOMMENDED 2.

  • Page 72: Fault 5, High High Heater Temp

    TEST be at fault. HEATER T/C + POINTS HEATER T/C - 3. Remove power. Allow Oxymitter 4000 to cool for five minutes. Restore power. HIGH 4. If the condition repeats, replace the TEST GAS + electronic assembly per paragraph 6-5b, PROCESS - Electronic Assembly Replacement.

  • Page 73: Fault 6, High Case Temp

    2. This signifies that the environment where HEATER T/C + POINTS HEATER T/C - the Oxymitter 4000 is installed exceeds the ambient temperature requirements or that heat due to convection is causing case tem- HIGH perature to rise above the limit.

  • Page 74: Fault 7, Low Heater Temp

    g. Fault 7, Low Heater Temp. The HEATER LED flashes four times, pauses for three seconds, and repeats (Figure 5-7). HEATER T/C 1. The low heater temperature alarm is active HEATER DIAGNOSTIC when the thermocouple reading has dropped O2 CELL ALARMS below 28.6 mV.

  • Page 75: Fault 8, High Heater Temp

    h. Fault 8, High Heater Temp. The HEATER LED flashes five times, pauses for three seconds, and repeats (Figure 5-8). HEATER T/C 1. If the thermocouple produces a voltage in HEATER DIAGNOSTIC excess of approximately 30.7 mV, the high O2 CELL ALARMS CALIBRATION heater temp alarm activates.

  • Page 76: Fault 9, High Cell Mv

    Fault 9, High Cell mV. The O2 CELL flashes once, pauses for three seconds, and repeats (Figure 5-9). HEATER T/C 1. Using a multimeter, measure across TP1+ to HEATER DIAGNOSTIC TP2-. O2 CELL ALARMS CALIBRATION 2. If you measure 1.2 VDC, the cell wires, CALIBRATION RECOMMENDED either orange or green, have become de- O2 CELL mV +...

  • Page 77: Fault 10, Bad Cell

    Fault 10, Bad Cell. The O2 CELL flashes three times, pauses for three seconds, and repeats (Figure 5-10). HEATER T/C 1. The bad cell alarm activates when the cell HEATER DIAGNOSTIC exceeds the maximum resistance value. O2 CELL ALARMS CALIBRATION 2.

  • Page 78: Fault 11, Eeprom Corrupt

    k. Fault 11, EEPROM Corrupt. The O2 CELL LED flashes four times, pauses for three seconds, and repeats (Figure 5-11). HEATER T/C 1. This alarm can occur if the EEPROM is DIAGNOSTIC HEATER changed for a later version. At power up, ALARMS O2 CELL CALIBRATION...

  • Page 79: Fault 12, Invalid Slope

    % O2 ≈ 23 mV 8% O ≈ 85 mV 0.4% O 22220044 3. Power down the Oxymitter 4000 and remove it from the stack. Figure 5-12. Fault 12, Invalid Slope 4. Replace the cell per paragraph 6-8, Cell Replacement. IB-106-340...

  • Page 80: Fault 13, Invalid Constant

    HEATER T/C + POINTS verify the last calibration was performed HEATER T/C - correctly. 3. Power down the Oxymitter 4000 and HIGH remove it from the stack. TEST GAS + PROCESS - 4. Replace the cell per paragraph 6-8, Cell % O2 Replacement.

  • Page 81: Fault 14, Last Calibration Failed

    n. Fault 14, Last Calibration Failed. The CALIBRATION LED flashes three times, pauses for three seconds, and repeats (Figure 5-14). HEATER T/C 1. The last calibration failed alarm activates DIAGNOSTIC HEATER when the slope and constant values calcu- ALARMS O2 CELL CALIBRATION lated are out of range and the unit reverts to using the previous calibration values.

  • Page 82: Sps 4000 Troubleshooting

    4000 site or using HART/AMS. This HART/AMS STATUS sub-menu, the failure condition may indicate an aging cell in the is due to either a bad Oxymitter 4000 cell or Oxymitter 4000. a calibration gas flow problem. IB-106-340 5-17...

  • Page 83: Sps 4000 Fault Finding

    Logic I/O Oxymitter 4000 logic I/O not Set logic I/O to mode 8 via HART/AMS. set for calibration handshaking with SPS 4000 Calibration gas lines between Clogged calibration gas line Replace clogged calibration gas line.

  • Page 84: Sps 4000 Troubleshooting Flowchart

    SYMPTOM — NO TEST GAS FLOW CHECK ALL WIRING BETWEEN OXYMITTER 4000 AND SPS 4000. WIRING PROPERLY CONNECT WIRING OR PROPERLY SECURE LOOSE WIRING CON- CONNECTED NECTIONS; REPLACE DAMAGED WIRING. SECURE? CHECK LOGIC I/O SETTING VIA HART/AMS. LOGIC I/O SET LOGIC I/O TO MODE 8 VIA SET FOR HART/AMS.
  • Page 85 SYMPTOM — NO TEST GAS FLOW (CONTINUED) NOTE 1: SECURELY TIGHTEN ALL J3 SCREW TERMINALS ON POWER SUPPLY BOARD TO MAKE CONNECTIONS. CONTINUED FROM SHEET NOTE 2: USE A SIMPSON MODEL 260 OR EQUIVALENT 1 OF 2 MULTIMETER. NOTE 3: IF REPLACING THE CHECK VALVE DOES NOT PLACE JUMPER BETWEEN CAL CORRECT THE PROBLEM, A CLOG COULD EXIST IN...

  • Page 86: Vi Maintenance And Service

    The best calibration is required. way to detect a plugged diffusion element is to note the time it takes the Oxymitter 4000 to return (b) Enter a “time since last cal” parameter to the normal process reading after the last...

  • Page 87: Oxymitter 4000 Exploded View

    25. Terminal Block 26. Captive Screw Note: Not all parts shown. 27. Left Housing Cover 28. Silicon Tube 29. Tube Clamp 30. Screw 31. Washer 32. Screw 33. Gasket 34. Cover Lock 26170019 Figure 6-1. Oxymitter 4000 Exploded View IB-106-340...

  • Page 88: Membrane Keypad

    Then, the sequencer 3. Manual Calibration. Manual calibrations begins to sequence the calibration gases. must be performed at the Oxymitter 4000 site and require operator intervention throughout 2. Semi-Automatic Calibration. Semi-automatic the process. calibrations only require operator initiation.

  • Page 89: Inside Right Cover

    When the timer BRATION RECOMMENDED times out, the Oxymitter 4000 has LED will come on and the CAL taken the readings using the first LED will be on solid. If a mul- calibration gas and the CAL LED timeter is attached across TP5 and will flash continuously.

  • Page 90: Led Status Indicators

    If the calibration was invalid, gas. (Electronics will abort the the Oxymitter 4000 will return to calibration if step 6 is not done normal operation, as it was before a within 30 minutes). calibration was initiated, and the parameters will not be updated.

  • Page 91: Oxymitter 4000 Removal/Replacement

    4000. It is recommended that the Oxymitter 4000 be removed from the stack for all (d) While facing the Oxymitter 4000 and service activities. The unit should be looking at the Rosemount label, remove allowed to cool and be taken to a clean screw (32, Figure 6-1), gasket (33) and work area.
  • Page 92 2. Replace. (d) Remove the screws securing the ter- minal cover to the SPS 4000 manifold. Bolt the Oxymitter 4000 to the stack Remove the terminal cover to expose and install insulation. the terminal strip. (b) Insert the logic I/O and 4-20 mA leads...

  • Page 93: Electronics Replacement

    Oxymitter 4000/ SPS 4000 assembly, contact Rosemount for further instructions. 1. Follow the instructions in paragraph 6-4a1 to remove the Oxymitter 4000 from the stack or duct. If removing an Oxymitter 4000/ 22220061 SPS 4000 assembly, follow the instructions in paragraph 6-4b1.
  • Page 94 (top board). 13. Follow the instructions in paragraph 6-4a2 to 8. Replace the housing cover and ensure it is install the Oxymitter 4000 into the stack or tight. IB-106-340...

  • Page 95: Fuse Location

    Terminal Block Replacement (Figure 6-4). POWER 1. Loosen the mounting screws on the terminal SUPPLY block and carefully lift the block out of the BOARD housing. 2. Carefully align the new terminal block on the pins so that it sits flat in the housing. The round end of the terminal block should be on 250VAC TIME LAG...

  • Page 96: Heater Strut Replacement

    12. Replace the housing cover and ensure that it is tight. a. Follow the instructions in paragraph 6-4a1 to remove the Oxymitter 4000 from the stack or duct. If removing an Oxymitter 4000/SPS 4000 assem- 6-6. ENTIRE PROBE...

  • Page 97: Heater Strut Assembly

    Follow the instructions in paragraph 6-4a2 to strut with the calibration gas line. When the hole install the Oxymitter 4000 into the stack or duct. If and the calibration gas line are aligned correctly, installing an Oxymitter 4000/SPS 4000 assembly, the strut will slide in the rest of the way.

  • Page 98: Cell Replacement

    (Table 8-1). a. Follow the instructions in paragraph 6-4a1 to remove the Oxymitter 4000 from the stack or duct. The cell replacement kit (Figure 6-9) contains a cell If removing an Oxymitter 4000/SPS 4000...

  • Page 99: Ceramic Diffusion Element Replacement

    Follow the instructions in paragraph 6-4a2 to away from the probe. Note that the contact pad install the Oxymitter 4000 into the stack or duct. If inside of the probe will sometimes fuse to the oxy- installing an Oxymitter 4000/SPS 4000 assembly, gen sensing cell.

  • Page 100: Ceramic Diffusion Element Replacement

    1. Follow the instructions in paragraph 6-4a to fillet of cement to form a uniform fillet. (A remove the Hazardous Area Oxymitter 4000 cotton swab is useful for this.) Clean any from the stack or duct.

  • Page 101: Sps 4000 Maintenance And Component Replacement

    4000 maintenance and component replacement proce- 3. Remove manifold cover (14). dures. Replacement parts referenced are available from Rosemount. Refer to Section VIII, REPLACEMENT 4. Remove two screws (11) attaching spacers (9) PARTS, for part numbers and ordering information. to manifold (5).

  • Page 102: Sps 4000 Manifold Assembly

    1. Screw 2. Attaching Bracket 3. Bushing 4. Bushing Gasket 5. Manifold 6. Manifold Cover Lock 7. Screw 8. O-Ring 9. Spacer 10. Screw 11. Screw 12. Pressure Switch 13. Calibration Gas 2 Solenoid 14. Manifold Cover 15. Cover O-Ring 16.

  • Page 103: Power Supply Board And Interface Board Connections

    SWITCH TO CALIBRATION GAS 1 SOLENOID LINE IN LINE TO CALIBRATION VOLTAGE NEUTRAL GAS 2 INPUT GROUND SOLENOID GROUND VAC INPUT TO OXYMITTER 4000 INTERFACE BOARD BLACK REMOTE CAL INITIATE WHITE CONTACT INPUT CAL FAIL BLUE RELAY ORANGE OUTPUTS GREEN...
  • Page 104 6. Being careful not to disconnect the board 6. Being careful not to disconnect the board wiring, carefully lift the board and spacer wiring, carefully lift the board and spacer assembly from manifold (5) and set aside. Do assembly from manifold (5) and set aside. Do not lose O-rings (8) from the bottom of not lose O-rings (8) from the bottom of spacers (9).
  • Page 105 (25). diffusion element is to note the time it takes 7. Remove flowmeter (16 or 17), with installed the Oxymitter 4000 to return to the normal process reading after the last calibration gas is fittings, from flowmeter bracket (25). removed and the calibration gas line is blocked off.

  • Page 106: Calibration Gas And Reference Air Components

    NOTE: A STANDARD SPS 4000 IS EQUIPPED WITH TEFLON TUBING AND BRASS FITTINGS. OPTIONAL STAINLESS STEEL TUBING AND FITTINGS ARE ALSO AVAILABLE. REFER TO SECTION VIII, REPLACEMENT PARTS, FOR ORDERING INFORMATION. (REF.) 26170012 1. Elbow Fitting 9. Straight Fitting (Optional) 18.

  • Page 107: Vii Hart/Ams

    CONNECTIONS. The HART Communicator can Communicator requires a termination point along the connect to the Oxymitter 4000 analog output signal line 4-20 mA current loop and a minimum load resistance at any wiring termination in the 4-20 mA current loop.

  • Page 108: Signal Line Connections, < 250 Ohms Lead Resistance

    7-3. HART COMMUNICATOR CONNEC- Communicator in parallel to the Oxymitter 4000. TIONS. There is an option to interface the HART Use any wiring termination points in the analog Communicator with a personal computer. Load the output 4-20 mA signal line.

  • Page 109: Off-Line And On-Line Operations

    RECOMMENDED will not initiate the calibration cycle with the IMPS 4000 or SPS 4000. * The default condition for an Oxymitter 4000 without an IMPS 4000 or SPS 4000. ** The default condition for an Oxymitter 4000 with an IMPS 4000 or SPS 4000.

  • Page 110: Menu Tree For Hart/Ams On The Oxymitter 4000

    Present O2 Cal slope LAST Cal const CALCONSTANTS Cell Imp (CONTINUED ON SHEET 2) Reset RESET CalConstants CALCONSTANTS method... D/A TRIM D/A trim method 26170028 Figure 7-3. Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 1 of 3) IB-106-340...
  • Page 111 OP locks SHEET 3) OPtrak TG? CALIBRATION OP tracks TGtime PurgeTime Manual Cal Mode Auto Cal Intrvl h Next CalTime h O2 ALARMS LoAlarmSP 26170029 Figure 7-3. Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 2 of 3) IB-106-340...
  • Page 112 Imp Delta DEVICE SETUP PV AO Slope DEVICE CONFIG PV LRV Constant PV URV LoAlarmSP OUTPUTS I/O Pin Mode CONFIG Poll addr Num req preams 26170030 Figure 7-3. Menu Tree for HART/AMS on the Oxymitter 4000 (Sheet 3 of 3) IB-106-340...

  • Page 113: Hart Communicator O2 Cal Method

    STATUS, view menu item CALSTATE; menu item 2, TIMEREMAIN; and Failure to remove the Oxymitter 4000 from menu item 3, PRESENT O2, as the calibration automatic control loops prior to performing status updates. this procedure may result in a dangerous operating condition.

  • Page 114: Defining A Timed Calibration Via Hart

    DEFINING A TIMED CALIBRATION VIA a. From the DEVICE SETUP screen, select HART. Use the following procedure to specify a DETAILED SETUP. time interval (in hours) at which the Oxymitter 4000 will be automatically calibrated. b. From the DETAILED SETUP screen, select O2 CALIBRATION.

  • Page 115: Viii Replacement Parts

    SECTION VIII. REPLACEMENT PARTS Table 8-1. Replacement Parts for Probe. FIGURE and INDEX No. PART NUMBER DESCRIPTION No Dust Seal Dust Seal 6-1, 1 thru 6, 8, 9, 28 thru 31 3D39648G01 3D39649G01 18" ANSI Probe with Ceramic Diffuser 6-1, 1 thru 6, 8, 9, 28 thru 31 3D39648G02 3D39649G02 3' ANSI Probe with Ceramic Diffuser 6-1, 1 thru 6, 8, 9, 28 thru 31 3D39648G03...
  • Page 116 Table 8-1. Replacement Parts for Probe (Continued). FIGURE and INDEX No. PART NUMBER DESCRIPTION 6-1, 6 3D39644G01 18" ANSI Probe Tube Assy. 6-1, 6 3D39644G02 3' ANSI Probe Tube Assy. 6-1, 6 3D39644G03 6' ANSI Probe Tube Assy. 6-1, 6 3D39644G04 9' ANSI Probe Tube Assy.

  • Page 117: Cell Replacement Kit

    ANSI GASKET WIRE AND PAD ASSEMBLY ANTI-SEIZE COMPOUND PROBE TUBE (NOT INCLUDED 22 GA. IN KIT) WIRE CORRUGATED SEAL CLOSED END CONNECTOR CELL AND FLANGE SET SCREWS ASSEMBLY TEFLON SOCKET HEAD TUBING CAP SCREWS CALIBRATION GAS PASSAGE 22220068 Figure 8-1. Cell Replacement Kit IB-106-340...

  • Page 118: Probe Disassembly Kit

    Table 8-1. Replacement Parts for Probe (Continued). FIGURE and INDEX No. PART NUMBER DESCRIPTION 3D39003G09 JIS 9’ Abrasive Shield Assy. 3D39003G10 JIS 12’ Abrasive Shield Assy. 3D39003G11 DIN 9’ Abrasive Shield Assy. 3D39003G12 DIN 12’ Abrasive Shield Assy. 3D39003G13 ANSI 18” Abrasive Shield Assy. 3D39003G14 JIS 18”...

  • Page 119: Replacement Parts For Electronics

    Table 8-2. Replacement Parts for Electronics. FIGURE and INDEX No. PART NUMBER DESCRIPTION 4850B10G01 Electronics English-Standard 6-1, 21, 27 4849B95G01 Housing and Cover 6-1, 12 3D39777G02 Electronic Assembly and keypad English 6-1, 25 08732-0002-0001 Termination Block-Standard 6-1, 11 5R10145G01 Cover 4850B10G02 Electronics German-Standard 6-1, 21, 27...
  • Page 120 Table 8-2. Replacement Parts for Electronics (Continued). FIGURE and INDEX No. PART NUMBER DESCRIPTION 4850B10G09 Electronics Spanish-Transient Protected 6-1, 21 4849B95G01 Housing 6-1, 12 3D39777G05 Electronic Assembly and keypad Spanish 6-1, 25 08732-0002-0002 Termination Block-Transient Protected 6-1, 11 5R10145G01 Cover 4850B10G10 Electronics Italian-Transient Protected 6-1, 21...

  • Page 121: Replacement Parts For Sps 4000

    Table 8-3. Replacement Parts for SPS 4000. FIGURE and INDEX No. PART NUMBER DESCRIPTION 6-11, 4 1A99093H01 Bushing Gasket 6-13, 19 6292A97H03 Check Valve 6-11, 15 1A99089H01 Cover O-ring 6-13, 17 771B635H01 Flowmeter Assembly, Calibration Gas 6-13, 16 771B635H02 Flowmeter Assembly, Reference Air (Optional) 6-13, 8 1A99094H01 Pressure Regulator, Reference Air (Optional)
  • Page 122 American identification in accordance with Rosemount instructions or it will not be accepted. Rosemount Analytical Inc. RMR Department In no event will Rosemount be responsible for 1201 N. Main Street equipment returned without proper authorization Orrville, Ohio 44667 and identification.
  • Page 123 4-20 mA signal line, a technician can diagnose problems and configure and calibrate the Oxymitter 4000 as if he or she were standing in front of the instrument. For more information, call Rosemount Analytical at 1-800-433-6076.
  • Page 124 Autocalibration Sequencer to provide the capability to perform automatic or on-demand Oxymitter 4000 calibrations. The system can be installed either as an integral component to an Oxymitter 4000 or at a remote location if space is limited or corrosive conditions exist at the installation site.
  • Page 125 Rosemount Analytical’s O Calibration Gas and Service Kits have been carefully designed to provide a more convenient and fully portable means of testing, calibrating, and servicing Rosemount Analytical’s oxygen analyzers. These lightweight, disposable gas cylinders eliminate the need to rent gas bottles.
  • Page 126 INDEX This index is an alphabetized listing of parts, terms, and procedures related to the Oxymitter 4000 Oxygen Transmitter. Grounding, 5-1 Every item listed in the index refers to a location in the manual by page number or numbers. HART, 1-0, 1-1, 1-2, 1-3, 3-2, 3-3, 5-17, 6-3, 7-1, 7-3, 7-4,...
  • Page 127 Range, O , 1-8, 3-2, 3-3 SPS 4000 (Cont’d) Reference Air Set, 1-0 Piping Distance, 1-9 Reference Air, 1-1, 1-4, 1-5, 1-7, 1-8, 2-2, 2-3, 2-4, 2-12, Power, 1-9 2-13 Power Supply Board, 5-17, 5-19, 6-16, 6-17, 6-18 Remote Contact, 6-3 Pressure Regulator, 1-7, 6-19 Replacement Parts, Electronics, 8-5, 8-6 Pressure Switch, 1-6, 5-18, 5-20, 6-17, 6-19...

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