oxymitter 5000 - emerson · 2018. 12. 26. · instruction manual ib-106-350c rev. 1.0 april 2001...

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]

http://www.processanalytic.com

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 products 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 NOand 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


April 2001

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.

MANUFACTURERS 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 RCFs 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 workers 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 Associations Handbook of Compressed Gasespublished 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 wetanalysis 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 Oxymitter5000s 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 Oxymitters 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% O20 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 N2Calibration 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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Figure 2-2. Hazardous Area Oxymitter 5000 with Abrasive Shield



Oxymitter 5000

22

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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 GNIN

-

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 injur

oxymitter 5000 - emerson · 2018. 12. 26. · instruction manual ib-106-350c rev. 1.0 april 2001...

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