Emerson Rosemount Oxymitter DR Reference Manual
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Emerson Rosemount Oxymitter DR Reference Manual

Emerson Rosemount Oxymitter DR Reference Manual

In-situ oxygen probe for general purpose locations
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Reference Manual
00809-0100-4884, Rev AC
April 2022
™
Rosemount
Oxymitter DR
In-Situ Oxygen Probe for General Purpose Locations

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  • Page 1 Reference Manual 00809-0100-4884, Rev AC April 2022 ™ Rosemount Oxymitter DR In-Situ Oxygen Probe for General Purpose Locations...
  • Page 2 Warranty Seller warrants that the firmware will execute the programming instructions provided by Seller and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expiration of the applicable warranty period.
  • Page 3 WARNING Adequate earth connections should be made to all earthing points, internal and external, where provided. 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. Main supply cords should comply with the requirements of IEC227 or IEC245.

  • Page 5: Table Of Contents

    5.6 Probe passes calibration, but still appears to read too high............62 5.7 Probe passes calibration, but still appears to read too low............63 Chapter 6 Return material......................65 Chapter 7 Replacement parts....................67 Appendix A Optional accessories....................77 Rosemount Oxymitter DR...
  • Page 6 C.1 Directive information........................ 81 C.2 Ordinary location certification....................81 C.3 Installing equipment in North America..................81 C.4 Rosemount OXT4A Oxymitter for general purpose locations and OXT4C general locations certification..........................81 Appendix D Declaration of Conformity..................83 Appendix E China RoHS table......................85 Emerson.com/Rosemount...

  • Page 7: Description And Specifications

    Also use the following tables to compare your order number against your unit. The title of the table defines the model. The rest of the table defines the various options and features of the Rosemount Oxymitter DR. Ensure the features and options specified by your order ™...
  • Page 8 Description and specifications Reference Manual April 2022 00809-0100-4884 Table 1-1: Rosemount Oxymitter DR Ordering Information (continued) ANSI probe with flame arrestor and ceramic diffuser ANSI probe with snubber diffuser DIN (European standard) probe with ceramic diffuser DIN probe with flame arrestor and snubber diffuser...
  • Page 9 Applications: pulverized coal, recovery boilers, lime kiln. Regardless or application, Emerson recommends abrasive shields with support brackets for 9 ft. (2,74 m), 12 ft. (3,66 m), 15 ft. (4,57 m), and 18 ft. (5,49 m) probe installations, particularly horizontal installations.

  • Page 10: Overview

    Manual applicable to your electronics. 1.2.2 Description Emerson designed the Oxymitter DR to measure the net concentration of oxygen in an industrial combustion process (i.e., the oxygen remaining after all fuels have been oxidized). The probe is permanently positioned within an exhaust duct or stack and performs its task without a sampling system.
  • Page 11 15 ft. (4,57 m) • 18 ft. (5,49 m) Emerson offers abrasive shields for applications where abrasive particulates are present. Acid-resistant cells are available for SO and HCl environments. Bypass and probe mounting jacket options are available for process temperatures above 1300 °F (705 °C).
  • Page 12 Upgrading the Rosemount Oxymitter DR You can easily upgrade the Rosemount Oxymitter DR to a full Oxymitter 4000 or 5000. This provides an economical upgrade path for customers looking to preserve their probe investment upon the eventual failure of the signal conditioning electronics. To upgrade, add a small electronics package to the existing termination housing of the probe.

  • Page 13: Probe Options

    Figure 1-2: Ceramic Diffusion Assembly Snubber diffusion assembly The snubber diffusion assembly is satisfactory for most applications. This element is also available with a dust seal for use with an abrasive shield. Figure 1-3: Snubber Diffusion Assembly Rosemount Oxymitter DR...
  • Page 14 The shield protects against particle abrasion and condensations, provides a guide for ease of insertion, and acts as a positive support, especially for longer probes. The abrasive shield assembly uses a modified diffusor and vee deflector assembly, fitted with dual dust seal packing. Emerson.com/Rosemount...
  • Page 15 G. Ø 0.75 in. (19 mm) through four places equally spaced on Ø 4.75 in. (120.65 mm) B.C. Note In highly abrasive applications, rotate the shield 90 degrees at normal service intervals to present a new wear surface to the abrasive flow stream. Rosemount Oxymitter DR...

  • Page 16: Specifications

    Materials of Transmitter probe: Process-wetted materials are 316L or 304 construction stainless steel. Non-wetted parts: 304 stainless steel, low-copper aluminum Termination housing: Low-copper aluminum Process 2-in. 150# (4.75-in. [121 mm] bolt circle); DIN (5.71-in. [145 mm] connections bolt circle) Emerson.com/Rosemount...
  • Page 17 6 ft. (1.83 m) 27 lb. (12.2 kg) 9 ft. (2.74 m) 33 lb. (15.0 kg) 12 ft. (3.66 m) 39 lb. (17.7 kg) 15 ft. (4.57 m) 45 lb. (20.5 kg) 18 ft. (5.49 m) 51 lb. (23 kg) Rosemount Oxymitter DR...
  • Page 18 Description and specifications Reference Manual April 2022 00809-0100-4884 Emerson.com/Rosemount...

  • Page 19: Chapter 2 Install

    Table 2-1: Calibration Gas and Reference Air Calibration gas Reference air ANSI 6.34 (¼) tube 6.35 (¼) tube Table 2-2: Mounting Flange (Gasket Included) ANSI Flange diameter 190 (7.5) 210 (8.25) Rosemount Oxymitter DR...
  • Page 20 Install Reference Manual April 2022 00809-0100-4884 Table 2-2: Mounting Flange (Gasket Included) (continued) ANSI Hole diameter 19 (0.75) 18 (0.71) 4 holes equally spaced on BC 152,4 (6.00) 170 (6.69) Emerson.com/Rosemount...
  • Page 21 Reference Manual Install 00809-0100-4884 April 2022 Figure 2-1: Rosemount Oxymitter DR Installation All dimensions are in inches with millimeters in parentheses. A. Dimension A B. Dimension B C. 0.062 THK gasket ANSI: 3535B18H02 JIS: 3535B46H01 DIN: 3535B45H01 D. Insulate if exposed to ambient weather conditions.
  • Page 22 142 (3607) 157.8 (406) 15 ft. 178 (4521) 193.8 (4923) 18 ft. 214 (5436) 229.8 (5387) Figure 2-2: Remote Electronics with Membrane Keypad and Blind Cover Note All dimensions are in millimeters with inches in parentheses. A. Pipe mount configuration Emerson.com/Rosemount...
  • Page 23 Reference Manual Install 00809-0100-4884 April 2022 Figure 2-3: Remote Electronics with LOI and Window Cover, Wall Mount Configuration Rosemount Oxymitter DR...
  • Page 24 Reference Manual April 2022 00809-0100-4884 Figure 2-4: Rosemount Oxymitter DR with Abrasive Shield These flat-faced flanges are manufactured to ANSI, DIN, and JIS bolt patterns and are not pressure rated. All dimensions are in inches with millimeters in parentheses. A. Dimension A B.
  • Page 25 B. Dimension B C. Dimension C D. Four studs, lockwashers, and nuts equally spaced on C diameter B.C. Table 2-6: Adapter Plate Dimensions for Rosemount Oxymitter DR Part numbers for adapter plates include attaching hardware. Dimensions: mm (in.) ANSI (PN...
  • Page 26 Install Reference Manual April 2022 00809-0100-4884 Figure 2-6: Mounting Plate for Rosemount Oxymitter DR with Abrasive Shield Note Dimensions are in inches with millimeters in parentheses. A. Dimension A. B. Dimension B. C. Dimension C. D. Crosshatched area in four corners may be used to provide additional holes for field bolting of plate to outside wall service.
  • Page 27 Note Emerson recommends an abrasive shield for high velocity particulates in the flue stream (such as those in coal-fired boilers, kilns, and recovery boilers). Emerson provides vertical and horizontal brace clamps for 9 ft. and 12 ft. (2.75 m and 3.66 m) probes to provide mechanical support for the transmitter.
  • Page 28 April 2022 00809-0100-4884 Figure 2-7: Rosemount Oxymitter DR Bracing Installation Bracing is for vertical and horizontal transmitter installation. External bracing is required for 9 ft. (2.74 m), 12 ft. (3.66 m), 15 ft. (4.57 m), and 18 ft. (5.49 m) probes as shown below.
  • Page 29 3. In vertical installations, ensure the system cable drops vertically from the transmitter and the conduit is routed below the level of the electronics housing. This drip loop minimizes the possibility that moisture will damage the electronics. Rosemount Oxymitter DR...
  • Page 30 5. Insert probe through the opening in the mounting plate and bolt the unit to the plate. When probe lengths selected are 9 to 18 ft. (2.74 to 5.49 m), Emerson provides special brackets to provide additional support for the probe inside the flue or stack.

  • Page 31: Electrical Installation

    Note To maintain CE compliance, ensure a good connection exists between the mounting flange bolt and earth. 2.2.1 Wire transmitter WARNING To maintain CE compliance, ensure a good connection exists between the mounting flange bolts and earth. Rosemount Oxymitter DR...
  • Page 32 Not all parts shown. Not all parts shown are available for individual sale. Heater strut assembly Screw Diffusion assembly (snubber) Lock washer Retainer screw Cable clamp Cell and flange assembly Terminal block Corrugated seal Captive screw Probe tube assembly Left housing cover Emerson.com/Rosemount...
  • Page 33 Figure 2-11: Terminal Block A. Terminal block B. Heater power port C. Ground lugs D. Signal port E. Left side of Rosemount Oxymitter DR F. Oxygen signal G. Type K thermocouple H. Heater power 3. Connect O and heater thermocouple signals.

  • Page 34: Pneumatic Installation

    During outages, if possible, leave all transmitter units running. CAUTION If washing down the ducts during outage, make sure to power down the transmitter units and remove them from the wash area. System considerations. Install the reference air set in accordance with Figure 2-12. Emerson.com/Rosemount...
  • Page 35 I. 0.250 or 6 mm O.D. tube compression fitting J. Drain valve K. Flow set point knob Table 2-8: Replacement Parts Number in Figure Part name Pressure Part number 2-12 Flowmeter 0.2-2.0 scfh 771B635H02 2-in. (50.8 mm) 0-15 psig 275431-006 pressure gauge Rosemount Oxymitter DR...

  • Page 36: Set Up Probe With Electronics Package

    (analog) electronics ™ Change the probe heater setpoint of the existing electronics to support the Rosemount Oxymitter DR probe. Procedure 1. Open electronics enclosure. 2. On temperature controller card, connect jumper wire from TP3 to either Pin 2 or Pin Emerson.com/Rosemount...
  • Page 37 7. Remove jumper wire. 2.4.2 Set up Westinghouse Model 218A electronics Before beginning operation, it is important to change the probe heater setpoint of the ™ existing electronics to support the Rosemount Oxymitter DR probe. To convert the Rosemount Oxymitter DR...
  • Page 38 Reference Manual April 2022 00809-0100-4884 Model 218A digital electronics package for use with the Rosemount Oxymitter DR porbe, you need to change the EPROM. Prerequisites Remove main PCB and check back of board to identify unit as G02 or G04. The replacement EPROM needed is identified below.
  • Page 39 3. On the main PCB, locate and remove old EPROMs, U11 and U12. Figure 2-15: Main PCB (Model TC200) EPROM Replacement 4. Replace with new EPROMs (part number 1M03154G02), being careful to install U11 and U12 in their proper locations. 5. Close electronics enclosure and power up system. Rosemount Oxymitter DR...
  • Page 40 The replacement EPROM needed is IM0322G01. Procedure 1. Shut off and lock out power to the electronics package. 2. Open electronics enclosure. 3. On the main PCB, locate and remove old EPROM. Figure 2-16: Main PCB (Model 132) EPROM Replacement Emerson.com/Rosemount...
  • Page 41 Heater power supply (HPS 3000) jumper configuration WARNING Always disconnect line voltage from heater power supply and analog electronics (if used) before changing jumpers. Line voltage selection Jumper (install) 100/120 Vac JM4, JM1 220/240 Vac 100 Vac operation requires transformer part number 1M03961G02. Rosemount Oxymitter DR...
  • Page 42 ™ You can wire the Rosemount Oxymitter DR probe to work with the Yokogawa ZA8C and AV8C converters. Connect the cabling from the ZA8C or AV8C terminal to the probe terminal in the junction box as shown in . Emerson.com/Rosemount...
  • Page 43 Install 00809-0100-4884 April 2022 Figure 2-17: Rosemount Oxymitter DR probe wired to the ZA8C or AV8C converter Heater temperature set to 1380 °F (750 °C). The greater mass of the Rosemount Oxymittter DR probe requires a longer time to heat up.
  • Page 44 Install Reference Manual April 2022 00809-0100-4884 L. Stack wall M. Shield N. Cold junction device Emerson.com/Rosemount...

  • Page 45: Startup And Operate

    For startup and operation instructions, refer to the Reference Manual provided with your electronics package. WARNING Failure to install covers and ground leads could result in serious injury or death. Install all protective covers and safety ground leads before equipment startup. Rosemount Oxymitter DR...
  • Page 46 Startup and operate Reference Manual April 2022 00809-0100-4884 Emerson.com/Rosemount...

  • Page 47: Maintenance And Service

    Disconnect and lock out power before working on any electrical components. Under normal circumstances, the probe will not require frequent calibration. When calibration is required, follow the procedure in the Reference Manual applicable to your electronics package. Use Calibration record to track probe performance. Rosemount Oxymitter DR...

  • Page 48: Remove Probe

    3. Disconnect the calibration gas and instrument air lines from the transmitter. 4. While facing the probe and looking at the Rosemount label, remove screw (25), gasket (26), and cover lock (27) securing left housing cover (20). Remove the cover to expose the terminal block (Figure 2-11). Emerson.com/Rosemount...

  • Page 49: Replace Probe

    The round end of the terminal block should be on the opposite side of the housing conduit ports and should not be able to rotate. 3. Tighten the three mounting screws and ensure the terminal block is secure in the housing. Rosemount Oxymitter DR...

  • Page 50: Replace Entire Probe (Excluding Electronics)

    The probe can be as hot as 800 °F (427 °C). This can cause severe burns. Wear heat resistant gloves and clothing when removing probe. Do not attempt to work on the probe until it has cooled to room temperature. Emerson.com/Rosemount...
  • Page 51 6. Loosen, but do not remove, the three screws (23) on the strut in the finned housing. The spring tension should release as the strut moves up. 7. Grasp the wire loop and carefully slide the strut out of the probe tube (Figure 4-2). Rosemount Oxymitter DR...
  • Page 52 11. Replace the CAL and REF gas silicone tubes. 12. Install the termination housing per Replace terminal block. 13. Follow the instructions in Replace probe to install the probe in the stack or duct. Emerson.com/Rosemount...

  • Page 53: Replace Cell

    (Figure 4-3) contains a cell and flange assembly, corrugated seal, setscrews, socket head cap screws, and anti-seize compound. Emerson carefully packages the items to preserve precise surface finishes. Do not remove items from the packaging until you are ready to use them. A special tools kit contains spanner and hex wrenches.
  • Page 54 20. Reinstall the hub on the cell assembly. 21. Using pin spanner wrenches, torque to 10 ft.-lb. (14 N-m). 22. If applicable, reinstall the vee deflector, orienting apex toward gas flow. Secure with the setscrew and anti-seize compound. Torque to 25 in.-lb. (2.8 N-m). Emerson.com/Rosemount...

  • Page 55: Replace Ceramic Diffusion Element

    ⅜-in. (9.5 mm) pin punch through cement port. 6. Break out remaining ceramic diffusion element by tapping lightly around hub with hammer. Clean grooves with pointed tool if necessary. 7. Replace ceramic diffusion element using the ceramic diffusion element replacement kit in Replacement parts. Rosemount Oxymitter DR...

  • Page 56: Wire Termination Housing

    This side of the housing contains two connectors for hookup of wiring from the heater strut assembly to the termination housing. You do not need to disconnect the mating plugs from the housing unless the wiring, connectors, or mating components are damaged. Refer to Figure 4-4. Emerson.com/Rosemount...
  • Page 57 Reference Manual Maintenance and service 00809-0100-4884 April 2022 Figure 4-4: Termination Housing Connections A. Heater (black) B. Heater (black) C. Oxygen cell - (green) D. Thermocouple - (yellow) E. Thermocouple + (red) F. Oxygen cell + (orange) Rosemount Oxymitter DR...
  • Page 58 Maintenance and service Reference Manual April 2022 00809-0100-4884 Emerson.com/Rosemount...

  • Page 59: Chapter 5 Troubleshoot

    Potential cause Electronics failure Recommended actions 1. Triac O/P to heater. 2. Check electronics package. No response to oxygen concentration change when heater is hot and thermocouple mV output is at setpoint ±0.2 mV Potential cause Recorder failure Rosemount Oxymitter DR...

  • Page 60: Good Response With Incorrect Indication

    2. Recalibrate recorder or remote indicator. Reference recorder manual. 3. Check system calibration. 4. Recalibrate system. 5. Replace cell if necessary. Potential cause Air ingress into duct Recommended actions 1. Check probe mounting and condition of duct. 2. Stop air leaks or resite probe. Emerson.com/Rosemount...

  • Page 61: Probe Does Not Give Accurate Indication Of Applied Test Gas

    Recommended actions 1. Check ceramic diffusion element. 2. Replace diffusion element. Probe heater temperature unstable Potential cause Wrong heater Recommended actions 1. Check to see if the proper voltage heater is installed. 2. Change heater to proper voltage. Rosemount Oxymitter DR...

  • Page 62: Probe Passes Calibration, But Still Appears To Read Too High

    Acid condensation inside the probe can degrade the red silcone tube that carries the cal gas to the cell. 2. Remove the housing to inspect this hose. Maintenance and service. Emerson.com/Rosemount...

  • Page 63: Probe Passes Calibration, But Still Appears To Read Too Low

    1. Flow calibration gas to the probe until reading stabilizes. Shut off calibration gas and note the time required to return to process gas values. The time should be less than 20 seconds (less than 30 seconds for hazardous area probes). 2. Replace plugged diffusion element. Rosemount Oxymitter DR...
  • Page 64 Troubleshoot Reference Manual April 2022 00809-0100-4884 Emerson.com/Rosemount...

  • Page 65: Chapter 6 Return Material

    For equipment no longer under warranty, Rosemount will repair the equipment at the factory and return it as directed by the purchase order and shipping instructions. Rosemount Oxymitter DR...
  • Page 66 Return material Reference Manual April 2022 00809-0100-4884 Emerson.com/Rosemount...

  • Page 67: Replacement Parts

    3D39648G15 3D39649G15 12-ft. (3,7 m) DIN probe 9, 21 through 24 with ceramic diffuser Figure 2-10, 1 through 6, 8, 3D39648G17 3D39649G17 18-in. (457,2 mm) ANSI 9, 21 through 24 probe with flame arrestor and ceramic diffuser Rosemount Oxymitter DR...
  • Page 68 3D39649G28 3-ft. (0,9 m) DIN probe with 9, 21 through 24 flame arrestor and snubber diffuser Figure 2-10, 1 through 6, 8, 3D39648G29 3D39649G29 6-ft. (1,8 m) DIN probe with 9, 21 through 24 flame arrestor and snubber diffuser Emerson.com/Rosemount...
  • Page 69 2-10, 1 through 6, 8, 3D39648G46 3D39649G46 9-ft. (2,7 m) DIN probe with 9, 21 through 24 snubber diffuser Figure 2-10, 1 through 6, 8, 3D39648G47 3D39649G47 12-ft. (3,7 m) DIN probe 9, 21 through 24 with snubber diffuser Rosemount Oxymitter DR...
  • Page 70 2-10, 6 3D39644G15 12-ft. (3,7 m) DIN probe tube assembly Figure 2-10, 1 3D39645G01 18-in. (457,2 mm) heater strut assembly Figure 2-10, 1 3D39645G02 3-ft. (0,9 m) heater strut assembly Figure 2-10, 1 3D39645G03 6-ft. (1,8 m) heater strut assembly Emerson.com/Rosemount...
  • Page 71 DIN 18-in. (457,2 mm) cell replacement kit Figure 7-1 4847B61G15 DIN 3-ft. (0,9 m) cell replacement kit Figure 7-1 4847B61G16 DIN 6-ft. (1,8 m) cell replacement kit Figure 7-1 4847B61G17 DIN 9-ft. (2,7 m) cell replacement kit Rosemount Oxymitter DR...
  • Page 72 Figure 1-2 3D39003G28 ANSI 18-ft. (5,5 m) abrasive shield assembly 4513C61G03 18-in. (457,2 mm) contact and thermocouple replacement assembly 4513C61G04 3-ft. (0,9 m) contact and thermocouple replacement assembly 4513C61G05 6-ft. (1,8 m) contact and thermocouple replacement assembly Emerson.com/Rosemount...
  • Page 73 Cup type diffusion assembly, 5 microns Figure 1-4 4851B89G05 Cup type diffusion assembly, 40 microns Figure 1-4 4851B90G04 Cup type diffusion assembly/dust seal, 5 microns Figure 1-4 4851B90G05 Cup type diffusion assembly/dust seal, 40 microns Includes pad and wire. Rosemount Oxymitter DR...
  • Page 74 D. 22 gauge wire E. Closed end connector F. Set screws ™ G. Teflon tubing H. Socket head cap screws I. Cell and flange assembly J. Corrugated seal K. Probe tube (not included in kit) L. Calibration gas passage Emerson.com/Rosemount...
  • Page 75 Reference Manual Replacement parts 00809-0100-4884 April 2022 Figure 7-2: Probe Disassembly Kit A. Hex keys B. Spanner wrench C. Anti-seize compound D. Phillips screwdriver E. Wrench F. Tube insertion tube Rosemount Oxymitter DR...
  • Page 76 Replacement parts Reference Manual April 2022 00809-0100-4884 Emerson.com/Rosemount...

  • Page 77: Appendix A Optional Accessories

    Rosemount has carefully designed the O calibration gas and service kits to provide a more convenient and fully portable means of testing, calibrating, and servicing Rosemount's oxygen transmitters. These lightweight, disposable gas cylinders eliminate the need to rent gas bottles. Rosemount Oxymitter DR...
  • Page 78 Optional accessories Reference Manual April 2022 00809-0100-4884 Figure A-2: Rosemount O Calibration Gas Sequencer For more information, contact Rosemount at 1-800-433-6076. Emerson.com/Rosemount...

  • Page 79: Appendix B Upgrade Rosemount Oxymitter Dr To Full Oxymitter

    C. Screws D. Electronic assembly Procedure 1. Remove power from the Rosemount Oxymitter DR. 2. Remove the left and right covers from the Rosemount Oxymitter termination housing. 3. Remove and discard screws and Rosemount OXT adapter board (A and B, Figure B-1) located at the right side of the termination housing.
  • Page 80 Upgrade Rosemount Oxymitter DR to full Oxymitter Reference Manual April 2022 00809-0100-4884 7. Plug the black four-wire connector into the black socket on the microprocessor card. 8. Tighten three screws (D) securing the electronics assembly into the termination housing. Emerson.com/Rosemount...

  • Page 81: Appendix C Rosemount Oxymitter ™ Product Certifications

    OXT4C, OXT4CDR, OXT4CNF, and OXT4CDRNF and Rosemount Oxymitter 4000 series 6A00095G06 and 6A00094G08. C.4.1 USA/Canada CSA Certificate 1238566 Standards CSA C22.2 No. 94.2-15, CAN/CSA-C22.2 No. 61010-1-12, UL 61010-1 (3rd ed.), UL 50E, 2nd ed. Markings Type 4X Rosemount Oxymitter DR...
  • Page 82 ™ Rosemount Oxymitter product certifications Reference Manual April 2022 00809-0100-4884 Emerson.com/Rosemount...

  • Page 83: Appendix D Declaration Of Conformity

    Reference Manual Declaration of Conformity 00809-0100-4884 April 2022 Declaration of Conformity Rosemount Oxymitter DR...
  • Page 84 Declaration of Conformity Reference Manual April 2022 00809-0100-4884 Emerson.com/Rosemount...

  • Page 85: Appendix E China Rohs Table

    Reference Manual China RoHS table 00809-0100-4884 April 2022 China RoHS table Rosemount Oxymitter DR...
  • Page 86 2022 Emerson. All rights reserved. Emerson Terms and Conditions of Sale are available upon request. The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount is a mark of one of the Emerson family of companies. All other marks are the property...

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