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Rosemount Analytical

MODEL 7003M

PERCENT O XYGEN

A NALYZER

INSTRUCTION MANUAL

748223-J

N OTICE

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

Manual Part Number 748223-J December 2000 Printed in U.S.A.

Rosemount Analytical Inc. 4125 East La Palma Avenue Anaheim, California 92807-

C ONTENTS

ii Model 7003M Percent Oxygen Analyzer December 2000 Rosemount Analytical Inc. 748223-J

C ONTENTS

• SAFETY SUMMARY ..........................................................................................P PREFACE
• SPECIFICATIONS - PERFORMANCE...............................................................P
• SPECIFICATIONS - PHYSICAL.........................................................................P
• SPECIFICATIONS - ELECTRICAL ....................................................................P
• SPECIFICATIONS - SENSORS .........................................................................P
• CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE............P
• RETURNING PARTS TO THE FACTORY .........................................................P
• TRAINING ......................................................................................................P
• DOCUMENTATION ............................................................................................P
• COMPLIANCES .................................................................................................P
• 1.1 OVERVIEW ................................................................................................. SECTION 1. INTRODUCTION
• 1.2 PRINCIPLE OF MEASUREMENT...............................................................
• 1.3 SENSORS ...................................................................................................
• 1.4 CONDITIONS AFFECTING MEASUREMENT ............................................
  • 1.4.1 Gas Composition ...........................................................................
  • 1.4.2 Sample and Cal Gas Pressures.....................................................
  • 1.4.3 Environmental Factors ...................................................................
• 1.5 FEATURES .................................................................................................
• 2.1 UNPACKING............................................................................................... SECTION 2. INSTALLATION
  • 2.1.1 Storage
• 2.2 ANALYZER INSTALLATION.......................................................................
• 2.3 SENSOR INSTALLATION
  • 2.3.1 Analyzer/Sensor Jumper Configuration.........................................
• 2.4 ELECTRICAL CONNECTIONS
  • 2.4.1 Sensor Cable.................................................................................
  • 2.4.2 Power Connections
  • 2.4.3 Current Output Connections..........................................................
  • 2.4.4 Voltage Output Connections
  • 2.4.5 Relay Contacts for Alarms or ON/OFF-Controls
• 3.1 OVERVIEW SECTION 3. OPERATION
• 3.2 KEYPAD OPERATION
  • 3.2.1 Changing Parameters With The Keypad.......................................
  • 3.2.2 Single and Double Keystroke
  • 3.2.3 Display Prompts
  • 3.2.4 Error Messages
  • 3.2.5 Automatic Return to RUN Mode....................................................
  • 3.2.6 Preventing Unauthorized Access
  • 3.2.7 Sensor Equilibrium
• 3.3 START-UP
  • 3.3.1 Initial Power-Up
  • 3.3.2 System Restart..............................................................................
  • 3.3.3 Automatic Restart - Due to Power Failure
  • 3.3.4 Manual Restart
• 3.4 RUN MODE.................................................................................................
  • 3.4.1 Display Oxygen Concentration/Sensor Temperature
  • 3.4.2 Acknowledge Alarms.....................................................................
  • 3.4.3 Access Other Modes
• 3.5 SETUP MODE
  • 3.5.1 Security Code................................................................................
  • 3.5.2 Current Output Range - 0-20mA or 4-20mA
  • 3.5.3 Range Endpoint Adjustments........................................................
  • 3.5.4 Zero Offset Adjustment
• 3.6 ALARM MODE VS. ON/OFF-CONTROL MODE
  • 3.6.1 Relay Configured as Alarm
  • 3.6.2 Relay Configured as ON/OFF-Controller.......................................
  • 3.6.3 Relay Contacts
  • 3.6.4 Fail Safe Operation ........................................................................ 748223-J Rosemount Analytical Inc. December 2000 Model 7003M Percent Oxygen Analyzer iii
  • 3.6.5 Relay Reset Upon Fatal Error........................................................
  • 3.6.6 Pressure Effects on Alarms ...........................................................
  • 3.6.7 Setting Alarm and ON/OFF-Controller Relays ...............................
  • 3.6.8 Setting Alarm Setpoints .................................................................
  • 3.6.9 Setting Alarm ON and OFF Levels ................................................
• 4.1 FREQUENCY OF CALIBRATION ............................................................... SECTION 4. CALIBRATION AND ADJUSTMENTS
• 4.2 CALIBRATION MODE .................................................................................
  • 4.2.1 Zero Calibration .............................................................................
  • 4.2.2 Span Calibration ............................................................................
    • Differences.................................................................... 4.2.3 Pressure Compensation - Correction for Constant Pressure
• 4.3 HOLD MODE ...............................................................................................
• 4.4 DIAGNOSTICS MODE ................................................................................
  • 4.4.1 Raw Sensor Voltage ......................................................................
  • 4.4.2 Test Current Output .......................................................................
  • 4.4.3 Linearizing Current Output.............................................................
  • 4.4.4 Test Alarm Relays..........................................................................
• 4.5 ADJUSTMENTS AND SETTINGS...............................................................
• 5.1 PRINCIPLES OF OPERATION ................................................................... SECTION 5. THEORY
  • 5.1.1 Electrochemical Theory .................................................................
• 5.2 EFFECTS OF SAMPLE CONDITIONS .......................................................
  • 5.2.1 Barometric Pressure ......................................................................
  • 5.2.2 Humidity ......................................................................................
  • 5.2.3 Sample Temperature .....................................................................
  • 5.2.4 Interfering Gases ...........................................................................
• 5.3 CIRCUIT DESCRIPTIONS ..........................................................................
  • 5.3.1 Signal Board ..................................................................................
  • 5.3.2 Power Supply Board ......................................................................
  • 5.3.3 Microprocessor Board....................................................................
  • 5.3.4 Alarm Circuits.................................................................................
• 6.1 ROUTINE SERVICING................................................................................ SECTION 6. ROUTINE SERVICING AND T ROUBLESHOOTING

C ONTENTS

748223-J Rosemount Analytical Inc. December 2000 (^) Model 7003M Percent Oxygen Analyzer v

T ABLES

2-1. Sensor Cables............................................................................................ 2-2. Analyzer Cable Connections ...................................................................... 3-1. Key Functions............................................................................................. 3-2. Display Indicators ....................................................................................... 3-3. Security Access Prompts and Responses.................................................. 3-4. Alarm Settings Prompts and Responses.................................................... 3-5. Calibration Prompts and Responses .......................................................... 3-6. System Setup Prompts and Responses..................................................... 3-7. System Hold and Diagnostics Codes ......................................................... 3-8. Data Displayed in DIAGNOSTICS Mode.................................................... 3-9. Miscellaneous Prompts and Responses .................................................... 3-10. Power ON, Reset Diagnostics Errors (Fatal Errors) ................................. 3-11. RUN Mode Errors (Non-Fatal Errors) ....................................................... 3-12. Signal Board Errors .................................................................................. 3-13. Microprocessor Errors That Reset The System ....................................... 3-14. Default Settings at Power-Up ................................................................... 3-15. RUN Mode Key Functions ........................................................................ 3-16. SETUP Mode Key Functions................................................................... 3-17. ALARM Mode Key Functions .................................................................. 3-18. Alarm Relay Contact Positions/Terminal Locations.................................. 4-1. CALIBRATION Mode Key Functions......................................................... 4-2. Composition of Dry Atmospheric Air........................................................... 4-3. Composition of Humid Atmospheric Air...................................................... 4-4. Barometric Pressure Effect on Apparent Oxygen Concentration ............... 4-5. PRESSURE COMPENSATION Mode Key Functions ............................... 4-6. HOLD Mode Key Functions....................................................................... 4-7. Caret Readings .......................................................................................... 4-8. DIAGNOSTICS Mode Key Functions ........................................................

DRAWINGS

652542 Outline and Mounting - Panel Mount 652543 Outline and Mounting - Wall Mount 652544 Outline and Mounting - Pipe Mount 652682 Pictorial Wiring Diagram 652683 Interconnect Diagram 652699 Installation Drawing

C ONTENTS

vi Model 7003M Percent Oxygen Analyzer December 2000 Rosemount Analytical Inc. 748223-J

NOTES

PREFACE

P2 Model 7003M Percent Oxygen Analyzer December 2000 Rosemount Analytical Inc. 748223-J

WARNING: OXYGEN LEVEL WILL NOT BE MONITORED

WARNING: ERRONEOUS OXYGEN READINGS

WARNING: PARTS INTEGRITY

WARNING: HIGH PRESSURE GAS CYLINDERS

WARNING: SENSOR NOT INTRINSICALLY SAFE

The instrument will not return automatically to the RUN mode from HOLD or DIAGNOSTICS modes. Operator must manually return instrument to RUN mode to continue monitoring oxygen.

If the pressure compensation function is not applied correctly, erroneous readings can be displayed. The display using span gas during calibration should be the same as the reading using the same gas in RUN mode if the pressure values are correctly entered.

Tampering or unauthorized substitution of components may adversely affect safety of this product. Use only factory documented components for repair

If gas cylinders are used for supplying drying or carrier gases, refer to "General Precautions for Handling and Storing High Pressure Gas Cylinders" in the rear of this manual.

The oxygen sensors used with this analyzer are not intrinsically safe. Use of the sensors in or near flammable liquids, gases or vapors or in Class I, Division 1, Hazardous Locations should be carefully evaluated by qualified personnel at the site and is entirely the responsibility of the user.

The sensor is approved as non-incendive for use in Class I, Division 2 locations.

PREFACE

748223-J Rosemount Analytical Inc. December 2000 (^) Model 7003M Percent Oxygen Analyzer P

SPECIFICATIONS - PERFORMANCE

ACCURACY ±0.25% oxygen

O PERATING RANGE 0 to 25% oxygen (endpoints set by user)

LINEARITY ±0.25% oxygen (with constant sample temperature after sensor zero offset correction) ZERO S TABILITY ±0.25% oxygen/week at 25°C

S PAN S TABILITY ±0.25% oxygen/24 hours at 25°C

NOISE ±0.25% oxygen

RESPONSE TIME 90% of reading in 20 seconds at 25°C

TEMPERATURE E FFECTS 32 to 110°F (0 to 44°C): 60 to 90°F (15 to 32°C): other 30°F (16°C) ranges:

±6% reading ±3% reading +4% reading

SPECIFICATIONS - PHYSICAL

MOUNTING Standard: Panel Mount Optional: Wall Mount, Pipe Mount DIMENSIONS 5.7 x 5.7 x 7.6 inches (14 x 14 x 19 cm) HxWxD

WEIGHT Approximately 3.0 pounds (1.36 kg)

E NCLOSURE ABS Plastic, Black, NEMA Type 4X, IP

AMBIENT HUMIDITY 95% relative humidity, non-condensing (maximum)

AMBIENT TEMPERATURE 14 to 122°F (-10 to 50°C)

PREFACE

748223-J Rosemount Analytical Inc. December 2000 (^) Model 7003M Percent Oxygen Analyzer P

SPECIFICATIONS - SENSORS

TYPES Rechargeable and Disposable

P ROCESS CONNECTIONS Refer to flow chamber (if supplied)

S AMPLE P RESSURE 0 to 50 psig (0 to 345 kPa)

S AMPLE TEMPERATURE 32 to 110°F (0 to 44°C)

AMBIENT TEMPERATURE 32 to 110°F (0 to 44°C)

AMBIENT HUMIDITY 95% relative humidity, non-condensing (maximum)

ALSO REFER TO INSTRUCTIONS SUPPLIED WITH SENSOR.

PREFACE

P6 Model 7003M Percent Oxygen Analyzer December 2000 Rosemount Analytical Inc. 748223-J

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE

For order administration, replacement Parts, application assistance, on-site or factory repair, service or maintenance contract information, contact:

Rosemount Analytical Inc. Process Analytical Division Customer Service Center 1-800-433-

RETURNING PARTS TO THE F ACTORY

Before returning parts, contact the Customer Service Center and request a Returned Materials Authorization (RMA) number. Please have the following information when you call: Model Number, Serial Number, and Purchase Order Number or Sales Order Number.

Prior authorization by the factory must be obtained before returned materials will be accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic, corrosive or other hazardous material or used in such a hazardous environment, the user must attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification that the material has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc. 4125 East La Palma Avenue Anaheim, California 92807- USA

T RAINING

A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at:

Rosemount Analytical Inc. Phone: 1-714-986- FAX: 1-714-577-

DOCUMENTATION

The following Model 7003M Percent Oxygen Analyzer instruction materials are available. Contact Customer Service or the local representative to order.

748223 Instruction Manual (this document)

PREFACE

P8 Model 7003M Percent Oxygen Analyzer December 2000 Rosemount Analytical Inc. 748223-J

NOTES

I NTRODUCTION

748223-J Rosemount Analytical Inc. December 2000 (^) Model 7003M Percent Oxygen Analyzer 1

1.1 OVERVIEW The Model 7003M Percent Oxygen Analyzer continuously monitors the concentration of oxygen in a gaseous sample. It consists of a sensor and the analyzer. The sensor is housed in a chamber assembly and is connected to the analyzer by a shielded multi-conductor cable.

The Model 7003M Percent Oxygen Analyzer provides direct digital readout, isolated current output, automatic temperature compensation circuitry, and dual relay contact closures for alarms or ON/OFF control devices as standard features. The alarm ranges can be selected independently from the output range, eliminating the need to readjust alarm setpoints if the range is changed.

The analyzer has six modes of operation:

MODE FUNCTION RUN (see Section 3.4) Normal monitoring SETUP (see Section 3.5) Changing parameters ALARM/CONTROL (see Section 3.6) Set alarms or ON/OFF controllers CALIBRATION (see Section 4.2) Gas calibration/pressure inputs HOLD (see Section 4.3) Retain last output value DIAGNOSTICS (see Section 4.4) Electronics checks

The Model 7003M Percent Oxygen Analyzer is housed in a NEMA 4X (CSA enclosure 4), corrosion resistant housing suitable for panel, pipe or wall mounting.

The analyzer has a microprocessor controlled keyboard for operation. Signals from the remote oxygen and temperature sensors are processed to compute real time oxygen concentration corrected for temperature, constant pressure differences and residual sensor current. The oxygen concentration is compared with user-set alarm parameters, and also generates an isolated 4 to 20 or 0 to 20mA signal. Data is stored in a memory circuit that retains the data in case power is removed.

The analyzer is shipped from the factory configured for operation on either 115 VAC or 230 VAC, 50/60 Hz as specified by the customer when ordered.

INTRODUCTION

748223-J Rosemount Analytical Inc. December 2000 (^) Model 7003M Percent Oxygen Analyzer 3

1.4.2 SAMPLE AND CAL GAS PRESSURES

The sample and calibration gases may be at different pressures as long as the pressure of each remains constant. Any variation in the pressure of either gas will result in an incorrect output reading of the same proportion.

Two methods of sample calibration are recommended:

1. Calibrate at the sample pressure, or
2. Calibrated at a different pressure, and enter the two pressure in the analyzer (Section 4.2.3)

Refer to Section 5.2 for a more detailed discussion of the relationship between gas pressures and apparent oxygen concentration.

1.4.3 ENVIRONMENTAL FACTORS

If radio frequency interference (RFI) normally occurs in the operating environment, the sensor cable should be electrically shielded during installation.

1.5 FEATURES

SUPPRESSED RANGES

When setting the Model 7003M to a suppressed output range (15 to 25%, etc.), note that the absolute accuracy, drift, and noise of the oxygen measurement will remain the same for all ranges (see Specifications in Preface).

ALARM M ODE

ALARM Mode is not self-resetting. Operator must press ACK to bring relays back to their no-alarm state. Used when immediate operator action is required.

Note: Operator Can Bypass Alarm Relays When relays are set to ALARM Mode (Section 3.6.1) and an alarm condition has occurred, pressing the ACK key will turn off the relay switch, whether the oxygen level is out of range or not. If you do not want an operator to be able to bypass the relay switches in this way, set the instrument to ON/OFF -CONTROL Mode.

ON/OFF-CONTROLLER M ODE

ON/OFF-CONTROLLER Mode is self-resetting. Pressing ACK has no effect on relay coils. Used when automated action is required.

INTRODUCTION

4 Model 7003M Percent Oxygen Analyzer December 2000 Rosemount Analytical Inc. 748223-J

NOTES