Emerson Rosemount 6888C User manual

Manual
00809-0100-4891, Rev AB
January2023
Rosemount™ 6888C In Situ Oxygen
Analyzer
For Hazardous Areas

Essential instructions
Read this page before proceeding!
Emerson™ designs, manufactures, and tests its products to meet many national and international standards. Because
these instruments are sophisticated technical products, you must properly install, use, and maintain them to ensure
they continue to operate within their normal specifications. The following instructions must be adhered to and
integrated into your safety program when installing, using, and maintaining Emerson products. Failure to follow 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 Emerson representative 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 maintenance of the product.
•Install equipment as specified in the installation instructions of the appropriate instruction manual and per
applicable local and national codes. Connect all products to the proper electrical and pressure sources.
•To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the
product.
•Use only factory documented components for repair. Tampering and unauthorized substitution and parts can
affect product performance and cause unsafe operation of your process.
NOTICE
The Field Communicator must be upgraded to System Software 2.0 with graphic license for operation with the
Rosemount™ 6888C O2 Transmitter. The AMS software must be upgraded to AMS 8.0 or above. Contact Emerson's
Global Service Center (GSC) at [phone] to upgrade the Field Communicator software to System Software 2.0
with graphic license.
Symbols
Earth (ground) terminal
Protective conductor terminal
Risk of electrical shock
Hot surface
Refer to Manual.
The following definitions apply to Warnings, Cautions, and Notices found throughout this publication.
WARNING
Highlights an operation or maintenance procedure, practice, condition, statement, etc., which if not strictly observed,
could result in injury, death, or long-term health hazards of personnel.
CAUTION
Highlights an operation or maintenance procedure, practice, condition, statement, etc., which if not strictly observed,
could result in damage to or destruction of equipment or loss of effectiveness.
2

NOTICE
Highlights an essential operating procedure, condition, or statement.
WARNING
EXPLOSION
Do not open when an explosive atmosphere may be present.
WARNING
ELECTRIC SHOCK
Do not open while energized.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end users’
equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict
physical access by unauthorized personnel to protect end users’ assets. This is true for all systems used within the
facility.
CAUTION
EQUIPMENT DAMAGE
For the standard housing probe and direct replacement probe, only use supply cables & certified cable glands rated >
105 °C (221 °F).
CAUTION
EQUIPMENT DAMAGE
For the autocal housing, only use supply cables and certified cable glands rated > 85 °C (185 °F).
Special conditions for safe use (ATEX) and conditions of acceptability (CSA)
1. The unit is to be connected to the supply mains by qualified personnel in accordance with local and national
codes.
2. Mounting flange temperature shall not exceed 190 °C during combustion process.
3. The 6888C O2 Analyzers are used with the 6888 Xi Advanced Electronics (associated equipment not part of this
certification) which must be installed in a safe area.
4. Calibration air lines and reference air lines shall not contain pure oxygen or combustible gas other than inert/
oxygen gas mixture of which oxygen represents no more than that normally present in air.
5. The pressure within the enclosure and gas lines shall not be higher than 1.1 times the atmospheric pressure
during the normal operations of the equipment.
6. Fasteners property class must be A2-70 Stainless Steel
7. Flameproof joints are not intended to be repaired.
3

Safety instructions
SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS
The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order
to ensure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless
superseded by local or national standards.
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. Main 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 (167 °F).
5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.
6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a
circuit breaker which will disconnect all circuits carrying conductors during a fault 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 provided and clearly marked as such. Circuit breakers or switches must
comply with a recognized standard, such as IEC947. All wiring must conform with any local standards.
7. All graphical symbols used in this product are from one or more of the following standards: EN61010, IEC417,
and ISO3864.
8. Where equipment or labels are marked "Do Not Open While Energized" or similar, there is a danger of ignition
in areas where an explosive atmosphere is present. This equipment should only be opened when the power
is removed and adequate time as specified on the label or in the instruction manual has been allowed for the
equipment to cool down - and then only by trained service personnel.
The following table illustrates symbols used on equipment or covers and explains the meaning of each.
Description Symbol
Where equipment or covers are marked with the symbol to the right,
hazardous voltages are likely to be present beneath. These covers should
only be removed when power is removed from the equipment - and then
only by trained service personnel.
Where equipment or covers are marked with the symbol to the right, there
is a danger of hot surfaces beneath. These covers should only be removed
by trained service personnel when power is removed from the equipment.
Certain surfaces may remain hot to the touch.
Where equipment or covers are marked with the symbol to the right, refer to
the Manual for instructions.
4

Contents
Chapter 1 General information.................................................................................................. 7
1.1 Overview.......................................................................................................................................7
1.2 System configurations................................................................................................................ 7
Chapter 2 Typical system package.......................................................................................... 11
2.1 Rosemount 6888C Hazardous Area Probe product matrix..................................................12
Chapter 3 Specifications............................................................................................................15
3.1 Measurement specifications....................................................................................................15
3.2 Environmental specifications...................................................................................................16
3.3 Optional General Purpose 6888 Xi Electronics...................................................................... 16
3.4 Installation specifications - probe........................................................................................... 17
3.5 Installation specifications - Rosemount 6888 Xi with Rosemount 6888C Transmitter
probe............................................................................................................................................ 18
3.6 Installation specifications for traditional architechture Rosemount 6888 Xi for use
with DR or other probe.............................................................................................................. 19
Chapter 4 Install.........................................................................................................................21
4.1 Mechanical installation............................................................................................................. 21
4.2 Mounting the Rosemount 6888 Xi General Purpose Advanced Electronics...................... 21
4.3 Electrical installation................................................................................................................. 25
4.4 Connecting the Hazardous Area Transmitter Probe to the Rosemount General
Purpose 6888 Xi Electronics...................................................................................................... 26
4.5 Connecting the analyzer probe to the single-channel safe area Xi and flame safety
interlock....................................................................................................................................... 28
4.6 Connect the analyzer probe with integral autocalibration to HART® communications...33
4.7 Connect the analyzer probe with integral autocalibration to FOUNDATION™ Fieldbus
communications......................................................................................................................... 35
4.8 Connecting the traditional architecture to the direct replacement hazardous area
replacement probe (no electronics inside)..............................................................................41
4.9 Connect traditional architecture system to the direct replacement probe....................... 43
4.10 Pneumatic installation............................................................................................................ 48
Chapter 5 Power up................................................................................................................... 51
5.1 Powering up the standalone Rosemount 6888 Transmitter probe (without
Rosemount 6888 Xi)....................................................................................................................51
5.2 Power up the Rosemount 6888 Analyzer with single/dual channel or single
channel and flame safety interlock Rosemount 6888Xi.........................................................52
5.3 Power up the Rosemount 6888C direct replacement probe (no electronics inside)
with traditional architecture Rosemount 6888Xi....................................................................52
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5.4 Run Rosemount 6888Xi Quick Start Wizard........................................................................... 53
5.5 Re-initiating Rosemount 6888 Xi wizard.................................................................................54
Chapter 6 Calibration................................................................................................................ 55
6.1 Manual/semi-automatic calibration........................................................................................55
6.2 Fully automatic calibration.......................................................................................................56
Chapter 7 HART® menu trees...................................................................................................59
Chapter 8 Maintenance and service........................................................................................ 65
8.1 Overview.....................................................................................................................................65
8.2 Maintenance intervals.............................................................................................................. 65
8.3 Repair..........................................................................................................................................66
Chapter 9 Replacement parts...................................................................................................81
Chapter 10 Service support.........................................................................................................83
Appendix A Product certifications..............................................................................................85
Contents Manual
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6 Rosemount 6888C

1 General information
1.1 Overview
The 6888 is Rosemount's latest combustion flue gas oxygen analyzer. This
product is intended for measuring the flue gases resulting from any combustion
process.
This product uses an in situ sensor, i.e., the sensor is placed at the end of the
probe, and the probe extends directly into the flue gas duct or stack at a given
length. The sensor is like a thermocouple, generating its own millivolt signal
based on the difference between a reference gas (ambient or instrument air -
always 20.95% O2) and the flue gases being measured. This manual covers the
Rosemount 6888C, which is the hazardous area probe version.
This probe can be configured as a blind stand-alone transmitter where HART® or
FOUNDATION Fieldbus™ communications can be used as a method of accessing
the electronics for setup, operation, and diagnostics or with one of several remote
electronics options, as noted below in System configurations. Wiring diagrams for
each of these configurations follow in Electrical installation.
There are several different arrangements of probes, electronics, and features that
are explained below and in the wiring diagrams.
1.2 System configurations
1.2.1 Hazardous Area Transmitter probe only
The Rosemount 6888 probe has the electronics in the blue housing that controls
the heater temperature and also amplifies the raw O2 millivolt signal to a linear
4-20 mA. The 4-20 mA signal lines can be run directly to the control room and also
power the transmitter electronics. As with most other Rosemount transmitters
measuring pressure, temperature, and flow, setup is conducted through HART
communications via a Field Communicator or Asset Management Solutions (AMS).
1.2.2 Standard housing Hazardous Area Transmitter
probe with General Purpose Rosemount 6888 Xi
Electronics
The Rosemount 6888 Xi Electronics serve as a local operator interface unit,
with a back-lit display and keypad. It is capable of two channels, serving two
Rosemount 6888 probes. The Rosemount 6888 Xi also carries these optional
advanced features:
•Fully automatic calibration. Requires Rosemount 6888 Xi O2 Cal Auto
calibration system
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Manual 7

•Loss of flame contact for powering down the heater in the event of a flame-out
condition in a furnace.
•Heaterless operation at process temperatures above 550 °C (1022 °F). This
feature will also permit operation above the heater setpoint of 736 °C (1357
°F). Sensing cell life will be shortened by operation above 800 °C (1472 °F),
however.
•The plugged diffuser diagnostic operates by measuring the return-to-process
rate after calibration gas has been stopped. This feature also includes auto gas
switching when the reading settles out versus waiting for configured gas flow
time to expire.
•Stoichiometer - If a furnace goes into a reducing condition (0% O2), this feature
will determine how far.
•Programmable reference - Permits more accurate readings at near-ambient O2
levels (20.95% O2).
•A cal check capability. New calibration values are not automatically stored after
a calibration. An accept/reject calibration feature can be enabled or disabled so
that the technician or operator can decide to accept or reject a potentially large
change in calibration values.
•Tolerance check that will alarm if the wrong test gases are being used or if a
bottle runs out in the middle of a calibration. Care must be taken to ensure gas
1 and gas 2 calibration gases are properly configured if the tolerance check
feature is enabled.
1.2.3 Hazardous Area Rosemount 6888C probe with
General Purpose Rosemount Xi Electronics with
flame safety interlock
A flame safety interlock by Emerson™ is available for heater power disconnect
whenever there is a loss of the process flame or a heater runaway condition
(heater over-temperature) in the O2 probe. This input is internally powered by the
Rosemount 6888 Xi and is actuated via a dry contact input from the user's flame
scanner. A closed contact indicates a flame is present. An open contact indicates a
loss of flame. This feature is also available with the Integral autocal housing.
1.2.4 Hazardous Area Rosemount 6888C probe with
Integral Autocal General Purpose Rosemount 6888
Xi Electronics
This probe contains gas-switching solenoids so that the Rosemount 6888 Xi
Electronics can control the introduction of calibration gases. Calibrations can be
intiated via a calibration recommended diagnostic, time since last calibration,
manually via external dry contact, HART communications, or from the Rosemount
6888 Xi local operator interface keypad. The integral autocal feature can only be
implemented when the probe is used with a Rosemount 6888 Xi.
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1.2.5 Hazardous Area Rosemount 6888C probe with
Integral Autocal and Foundation Fieldbus (FF)
communications
This probe contains gas-switching solenoids that can control the introduction of
calibration gases for calibration. Calibrations can be initiated automatically via
a calibration recommended diagnostic, time since last calibration, or manually
via optional Xi keypad, FF communications via the Field Communicator, or AMS
console. Unlike the HART transmitter electronics, the FF version can execute
automatic calibrations either with or without the optional Rosemount 6888 Xi
Electronics. Likewise, advanced features can be implemented either with or
without the optional Xi.
1.2.6 Hazardous Area Rosemount 6888C direct
replacement (DR) probe with General Purpose
Traditional Architecture Rosemount 6888 Xi
Electronics
Here there are no electronics inside the probe head, so the raw sensor signals for
the heater thermocouple and zirconium oxide O2 sensor are sent to a remote
Rosemount 6888 Xi Electronics. The Rosemount 6888 Traditional Architecture
Electronics will also directly apply power to the probe heater in order to maintain
the correct sensor temperature. This arrangement calls for a 7-conductor cable
to carry this power and the sensor signals. Maximum length for this cable is
200 feet. This probe will also operate on previous Westinghouse/Rosemount
electronics (World Class and Oxymitter), as well as many competitive electronics.
WARNING
HAZARDOUS AREAS
Cables are supplied with Exd Rated Glands; the cable is not ExD rated, and
installation in a hazardous area is the responsibility of the installer/customer.
Cables must be installed in accordance with national and local electrical codes.
1.2.7 Wireless capability
Both the analyzer electronics in the head of the probe and the Rosemount 6888Xi
Electronics communicate over HART communications and can implement wireless
communications via Emerson Wireless 775 THUM™ Adapter.
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General information Manual
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2 Typical system package
Figure 2-1: Typical System Package
A. Optional Rosemount SPS 4001B or Rosemount IMPS Autocalibration Sequencer
(Requires use of Rosemount 6888 Xi Advanced Electronics option)
B. Quick Start Guide
C. Optional mounting or adapter plate
D. Optional traditional architecture cable
E. HART® Field Communicator package (optional)
F. Optional reference & calibration gas accessories
G. Rosemount 6888C probe
H. Optional Rosemount 6888 XI Advanced Electronics
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2.1 Rosemount 6888C Hazardous Area Probe
product matrix
Table 2-1: Rosemount 6888C Product Matrix
Model Description
Rosemount
6888C
O2 Transmitter approved for hazardous locations
Measurement
1OXY Oxygen, standard sensing cell
2OXY Oxygen, high sulfur resistant sensing cell
Probe length(1)
1A 18-in. probe, 3-in. ANSI Class 150 flange
1D 18-in. probe, DIN flange
2A 3-ft probe, 3-in. ANSI Class 150 flange
2D 3-ft probe, DIN flange
3A 6-ft probe, 3-in. ANSI Class 150 flange
3D 6-ft probe, DIN flange
Diffuser
1 Snubber diffuser, 400 °C (572 °F) with process flame arrestors
2 Ceramic diffuser, 825 °C (1517 °F) with process flame arrestors
3 Alloy diffuser 705 °C (1301 °F) with both ambient and process flame arrestors
Housing and electronics
1HT Standard housing, transmitter electronics, HART communications
2HT Integral autocal, transmitter electronics, HART communications
4FF Integral autocal, transmitter electronics, FOUNDATION Fieldbus™ communications
5DR Standard housing, direct replacement, requires remote electronics
6DRY Standard housing, direct replacement, for use with YEW Electronics
Certifications
A ATEX/IECEx
C CSA
Mounting Plate
00 None
04 New installation - square weld plate with ANSI 2 in.(50.8 mm)- 150# studs and flange (2.5 in.
(63.5 mm) process hole required)
05 New installation - square weld plate with DIN studs and flange (2.5 in. (63.5 mm) process
hole required)
08 Adapter to existing ANSI 3 in. (76.2 mm), 150# flange
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Table 2-1: Rosemount 6888C Product Matrix (continued)
09 Adapter to existing ANSI 4 in. (101.6 mm), 150# flange
10 Adapter to existing ANSI 6 in. (152.4 mm), 150# flange
11 Adapter to existing ANSI 3 in. (76.2 mm), 300# flange
12 Adapter to existing ANSI 4 in. (101.6 mm), 300# flange
99 Special adapter - provide existing flange dimensions, including thru-hole diameter
Manual calibration accessories
00 None
01 Calibration and reference gas flowmeters and reference regulator/filter diffuser
02 Calibration/reference panel
Stoichiometer function(2)
0 No
1 Yes
Programmable reference function(2)
0 No
1 Yes
Extended temperature reference function(2)
0 No
1 Yes
Diffuser warning function(2)
0 No
1 Yes
(1) Flanges are flat-faced and for mounting only. Flanges are not pressure-rated.
(2) FOUNDATION Fieldbus only (for HART versions, order this feature with Rosemount 6888 Xi Electronics)
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Typical system package Manual
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3 Specifications
3.1 Measurement specifications
3.1.1 Net O2 range
Variable 0 - 10% to 0-50% (Xi electronics of 0-50% range)
3.1.2 Accuracy in oxidizing condition
±0.75% of reading at 0.05% O2, whichever is greater. ±1% of full scale for 0-10%
ranges and above.
3.1.3 Lowest detectable limit
0.02% O2
3.1.4 Process temperature effect
Less than 0.05% O2 from 100 to 700 °C (212 to 1292 °F)
3.1.5 System speed of response to calibration gas
Initial response in less than 3 seconds; T90 in less than 8 seconds. Response to
process gas changes varies depending on process gas velocity and particulate
loading of the diffuser.
3.1.6 Calibration validity
Presentation of calibration gases matches the bottle value to within 0.02% O2
3.1.7 Accuracy in reducing conditions (requires
stoichiometer feature)
±10% of reading or 0.1% O2, whichever is different size
3.1.8 System response in reducing conditions (requires
stoichiometer feature)
Going from oxidizing to reducing - T90 in 120 seconds
Going from reducing to oxidizing - T90 in 30 seconds
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Manual 15

3.2 Environmental specifications
3.2.1 Transmitter probe
Process-wetted materials are 316L stainless steel.
3.2.2 Transmitter probe process temperature limits
0 to 705 °C (32 to 1300 °F)
550 to 825 °C (1022 to 1517 °F) with Xi heaterless operation feature(1)
Optional bypass and jacket accessories permit operation to 1050 °C (1922 °F).
3.2.3 Probe electronics ambient temperature limits
-40 to 70 °C (-40 to 158 °F)
3.2.4 Temperature limit as measured inside probe
electronics
-40 to 85 °C (-40 to 185 °F)
3.2.5 DR probe, no electronics inside, ambient
temperature limits
-40 to 90 °C (-40 to 194 °F)
3.3 Optional General Purpose 6888 Xi
Electronics
3.3.1 Material
NEMA® 4X, polycarbonate material
3.3.2 Rosemount 6888 Xi ambient temperature limits
-20 to -50 °C (-4 to 122 °F)
(1) Reduced cell life can be expected if operated continuously at temperatures above 705 °C (1300 °F).
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16 Rosemount 6888C

3.3.3 Rosemount 6888 Xi temperature limits as
measured inside the electronics housing
-20 to 70 °C (-4 to 158 °F)
3.4 Installation specifications - probe
3.4.1 Probe mounting flange
Vertical or horizontal-3 in. 150 6 in. (152.4 mm) bolt circle
CAUTION
Flanges are flat-faced and for mounting only. Flanges are not pressure-rated. A
2.5 in. (63.55 mm) diameter hole in the process is required.
Spool piece P/N 3D39761G02 is available to offset probe electronics housing from
hot ductwork.
Many adapter flanges are available to mate to existing flanges.
3.4.2 Probe lengths and approximate shipping weights
18 in. (457 mm) package: 16 lb (7.3 kg)
3 ft (0.91 m) package: 21 lb (9.5 kg)
6 ft (1.83 m) package: 27 lb (12.2 kg)
9 ft (2.74 m) package: 33 lb (15.0 kg)
12 ft (3.66 m) package: 39 lb (17.7 kg)
3.4.3 Reference air (optional)
Maximum 2 scfh (1 L/min), clean, dry, instrument-quality air (20.95% O2) regulated
to 5 psi (34 kPa)
3.4.4 Calibration
Semi-automatic or automatic
3.4.5 Cal gases
0.4% O2 and 8% O2 balance N2 recommended. Instrument air may be used as a
high cal gas but is not recommended. 100% nitrogen cannot be used as the low
cal gas. No explosive gases or gases with % O2 greater than that found in ambient
air (i.e., 20.95% O2) can be used.
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3.4.6 Calibration gas flow
5 scfh (2.3 L/min) at 15 psi, maximum
3.4.7 Heater electrical power
120/240 V ±10%, 50/60 Hz, 1/2 in. - 14 NPT conduit ports
3.4.8 Traditional architecture cable
200 ft (61 m) maximum length
3.4.9 Power consumption of transmitter probe/integral
autocal probe
776 W maximum during warm-up
3.5 Installation specifications - Rosemount
6888 Xi with Rosemount 6888C Transmitter
probe
3.5.1 Electrical power of optional Rosemount 6888 Xi
Electronics
120/240 V ±10%, 50/60 Hz
3.5.2 Power consumption of Rosemount 6888 Xi
10 W maximum
3.5.3 Rosemount 6888 Xi alarm relays
2 provided- 2 amps, 20 Vdc
3.5.4 Rosemount 6888 Xi optional loss of flame contact
Removes heater power
3.5.5 Electrical noise
3.5.6 Traditional architecture cable
200 ft (61 m) maximum length
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3.5.7 Transmitter electrical 4-20 mA power
12 - 42 Vdc (looped-powered from the control room or from the Rosemount 6888
Xi box)
3.6 Installation specifications for traditional
architechture Rosemount 6888 Xi for use
with DR or other probe
3.6.1 Power consumption of Rosemount 6888 Xi
120/240 V ±10%, 50/60 Hz, 260/1020 VA max for 120 V probes
120 V ±10%, 50/60 Hz, 450 VA max for 44 V probes
3.6.2 Alarm relay outputs
2 provided - 2 Amperes, 30 Vdc, Form-C
3.6.3 Optional loss of flame input
Internally powered input to remove heater power actuated via dry contact output
form proof of flame device.
Emerson has satisfied all obligations coming from the European legislation to
harmonize the product requirements in Europe.
Manual Specifications
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Specifications Manual
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20 Rosemount 6888C