Emerson Rosemount Oxymitter DR User manual

Reference Manual
00809-0100-4884, Rev AC
April 2022
Rosemount™ Oxymitter DR
In-Situ Oxygen Probe for General Purpose Locations

Warranty
Seller warrants that the firmware will execute the programming instructions provided by Seller and that the Goods manufactured
or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expiration
of the applicable warranty period. Goods are warranted for twelve (12) months from the date of initial installation or eighteen (18)
months from the date of shipment by Seller, whichever period expires first. Consumables, such as glass electrodes, membranes,
liquid junctions, electrolyte, O-rings, catalytic beads, etc., and Services are warranted for a period of 90 days from the date of
shipment or provision.
Products purchased by Seller from a third party for resale to Buyer ("Resale Products") shall carry only the warranty extended by the
original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort
to arrange for procurement and shipping of the Resale Products.
If Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period, Seller shall, at
its option, promptly correct any errors that are found by Seller in the firmware or Services, or repair or replace F.O.B. point of
manufacture that portion of the Goods or firmware found by Seller to be defective, or refund the purchase price of the defective
portion of the Goods/Services.
All replacements or repairs necessitated by inadequate maintenance, normal wear and usage, unsuitable power sources,
unsuitable environmental conditions, accident, misuse, improper installation, modification, repair, storage or handling, or any
other cause not the fault of Seller are not covered by this limited warranty and shall be at Buyer's expense. Seller shall not be
obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by
an authorized Seller representative. All costs of dismantling, re-installation and freight, and the time and expenses of Seller's
personnel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Seller.
Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original warranty
period or ninety (90) days, whichever is longer. This limited warranty is the only warranty made by Seller and can be amended only
in a writing signed by an authorized representative of Seller. Except as otherwise expressly provided in the Agreement, THERE ARE
NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR
PARTICULAR PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES.
Safety instructions
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.
2

WARNING
Adequate earth connections should be made to all earthing points, internal and external, where provided.
After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals
must be maintained at all times.
Main supply cords should comply with the requirements of IEC227 or IEC245.
All wiring shall be suitable for use in an ambient temperature of greater than 221 °F (105 °C).
All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.
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 it does 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.
Where equipment or covers are marked with the symbol below, 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 below, 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 below, refer to the reference manual for instructions.
All graphical symbols used in this product are from one or more of the following standards: EN61010, IEC417, and ISO3864.
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 Reference Manual has been allowed for the equipment to cool down - and then only by trained
service personnel.
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.
3

4

Contents
Chapter 1 Description and specifications....................................................................................7
1.1 Components checklist................................................................................................................. 7
1.2 Overview................................................................................................................................... 10
1.3 Probe options............................................................................................................................ 13
1.4 Specifications............................................................................................................................ 16
Chapter 2 Install.......................................................................................................................19
2.1 Mechanical installation.............................................................................................................. 19
2.2 Electrical installation..................................................................................................................31
2.3 Pneumatic installation............................................................................................................... 34
2.4 Set up probe with electronics package.......................................................................................36
Chapter 3 Startup and operate................................................................................................. 45
Chapter 4 Maintenance and service..........................................................................................47
4.1 Overview................................................................................................................................... 47
4.2 Calibrate....................................................................................................................................47
4.3 Remove probe........................................................................................................................... 48
4.4 Replace probe............................................................................................................................49
4.5 Replace terminal block...............................................................................................................49
4.6 Replace entire probe (excluding electronics)............................................................................. 50
4.7 Replace heater strut...................................................................................................................50
4.8 Replace cell................................................................................................................................53
4.9 Replace ceramic diffusion element............................................................................................ 55
4.10 Wire termination housing........................................................................................................56
Chapter 5 Troubleshoot........................................................................................................... 59
5.1 No response to oxygen concentration change when heater is cold and thermocouple mV
output is less than setpoint......................................................................................................... 59
5.2 No response to oxygen concentration change when heater is hot and thermocouple mV
output is at setpoint ±0.2 mV......................................................................................................59
5.3 Good response with incorrect indication....................................................................................60
5.4 Probe does not give accurate indication of applied test gas....................................................... 61
5.5 Probe heater temperature unstable........................................................................................... 61
5.6 Probe passes calibration, but still appears to read too high........................................................ 62
5.7 Probe passes calibration, but still appears to read too low..........................................................63
Chapter 6 Return material........................................................................................................65
Chapter 7 Replacement parts................................................................................................... 67
Appendix A Optional accessories................................................................................................ 77
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Rosemount Oxymitter DR 5

A.1 Rosemount™ By-Pass Package....................................................................................................77
A.2 Rosemount™ O2 calibration gas sequencer................................................................................ 77
Appendix B Upgrade Rosemount™ Oxymitter DR to full Oxymitter............................................. 79
Appendix C Rosemount Oxymitter™ product certifications.........................................................81
C.1 Directive information................................................................................................................ 81
C.2 Ordinary location certification................................................................................................... 81
C.3 Installing equipment in North America...................................................................................... 81
C.4 Rosemount OXT4A Oxymitter for general purpose locations and OXT4C general locations
certification................................................................................................................................ 81
Appendix D Declaration of Conformity........................................................................................83
Appendix E China RoHS table......................................................................................................85
Contents Reference Manual
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1 Description and specifications
1.1 Components checklist
Also use the following tables to compare your order number against your unit. The title of
the table defines the model. The rest of the table defines the various options and features
of the Rosemount Oxymitter DR. Ensure the features and options specified by your order
number are on or included with the unit.A typical Rosemount™ Oxymitter DR should
contain the items shown in Figure 1-1. Record the part number, serial number, and order
number for each component of your system.
Figure 1-1: Typical System Package
A. Quick Start Guide
B. Adapter plate with mounting hardware and gasket
C. Oxymitter DR
Table 1-1: Rosemount Oxymitter DR Ordering Information
OXT4ADR Oxymitter DR In-Situ Oxygen Transmitter
Code Sensing probe type
1 ANSI (North American standard) probe with ceramic diffuser
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Rosemount Oxymitter DR 7

Table 1-1: Rosemount Oxymitter DR Ordering Information (continued)
2 ANSI probe with flame arrestor and ceramic diffuser(1)
3 ANSI probe with snubber diffuser
4 DIN (European standard) probe with ceramic diffuser
5 DIN probe with flame arrestor and snubber diffuser(1)
6 DIN probe with snubber diffuser
7 JIS (Japanese standard) probe with ceramic diffuser
8 JIS probe with flame arrestor and ceramic diffuser(1)
9 JIS probe with snubber diffuser
Code Probe assembly
0 18-in. (457 mm) probe
1 18-in. (457 mm) probe with abrasive shield(2)
2 3-ft. (0.91 m) probe
3 3-ft. (0.91 m) probe with abrasive shield(2)
4 6-ft. (1.83 m) probe
5 6-ft. (1.83 m) probe with abrasive shield(2)
6 9-ft. (2.74 m) probe
7 9-ft. (2.74 m) probe with abrasive shield(2)
8 12-ft. (3.66 m) probe
9 12-ft. (3.66 m) probe with abrasive shield(2)
A 15-ft. (4.57 m) probe with abrasive shield(2)
B 18-ft. (5.49 m) probe with abrasive shield(2)
Code Mounting hardware: stack side
0 No mounting hardware (You must choose 0 under Mounting
Hardware - Probe Side below.)
1 New installation: square weld plate with studs
2 Mounting to Model 218 mounting plate (with Model 218 shield
removed)
3 Mounting to existing Model 218 support shield
4 Mounting to other mounting(3)
5 Mounting to Model 132 adapter plate
Code Mounting hardware: probe side
0 No mounting hardware
1 Probe only (ANSI) (North American standard)
2 New bypass or abrasive shield (ANSI)
4 Probe only (DIN) (European standard)
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Table 1-1: Rosemount Oxymitter DR Ordering Information (continued)
5 New bypass or abrasive shield (DIN)
7 Probe only (JIS) (Japanese standard)
8 New bypass or abrasive shield (JIS)
Code Housing and customer termination
11 Standard filtered termination
12 Transient protected filtered termination
Code Arrangment: existing electronics
03 For use with existing analog electronics (including
Westinghouse/Rosemount 132/218/225)
04 Westinghouse/Rosemount digital (218A) or universal electronics
05 VeriTrim electronics
07 Model 132 digital electronics
08 For use with Yokogawa electronics (cold junction comp. in probe
junction box)
09 For use with other competitive oxygen transmitter systems
(1) No agency approvals. See Rosemount Hazardous Area Oxymitter 4000 Reference Manual for
hazardous area certified probes.
(2) Recommended usages: High velocity particulates in flue stream, installation within 11.5 ft. (3,5
m) of soot blowers or heavy salt cake buildup. Applications: pulverized coal, recovery boilers,
lime kiln. Regardless or application, Emerson recommends abrasive shields with support
brackets for 9 ft. (2,74 m), 12 ft. (3,66 m), 15 ft. (4,57 m), and 18 ft. (5,49 m) probe
installations, particularly horizontal installations.
(3) Where possible, specify SPS number; otherwise, provide details of the existing mounting plate as
follows. See #unique_6/unique_6_Connect_42_table_x2d_lkk_chb.
Note
1. High sulfur service: For high sulfur applications, please add an additional line item to
your purchase order requesting high sulfur cell part number 4847B63G02 in lieu of
the standard ZrO2 cell.
Cell replacement kits for high sulfur service are also available.
2. Where possible, specify ANSI or DIN designation; otherwise, provide details of
existing mounting plate as follows:
Plate with studs Bolt circle diameter, number and arrangement of studs,
stud thread, and stud height above mounting plate
Plate without studs Bolt circle diameter, number, and arrangement of holes,
threads, and depth of stud mounting plate with accessories
Reference Manual Description and specifications
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Rosemount Oxymitter DR 9

Table 1-2: Calibration Components
Part number Description
1A99119G01 Calibration gas kit: Contains 0.4% and 8.0% O2 bottles, 145.3 gal.
(550 L) each (requires two CGA-590 regulators)(1)
1A99119G02 Calibration gas regulators kit: Contains two CGA-590 regulators
1A99119G03 Bottle rack
(1) Calibration gas bottles cannot be shipped via air freight.
1.2 Overview
1.2.1 Scope
This Reference Manual provides information needed to install, start up, operate, and
maintain the Rosemount™ Oxymitter DR.
You can interface the Oxymitter DR to a number of different earlier model electronics
packages. This manual does not cover these electronic packages. For specification
information concerning calibration and operation of the system, refer to the Reference
Manual applicable to your electronics.
1.2.2 Description
Emerson designed the Oxymitter DR to measure the net concentration of oxygen in an
industrial combustion process (i.e., the oxygen remaining after all fuels have been
oxidized).
The probe is permanently positioned within an exhaust duct or stack and performs its task
without a sampling system.
The equipment measures oxygen percentage by reading the voltage developed across a
heated electrochemical cell, which consists of a small yttria-stabilized, zironcia disc. Both
sides of the disc are coated with porous metal electrodes. When operated at the proper
temperature, the millivolt output voltage of the cell is given by the following Nernst
equation:
EM = KT log10(P1/P2) + C
Where:
P2 is the partial pressure of the oxygen in the measured gas on one side of the cell.
P1 is the partial pressure of the oxygen in the reference air on the opposite side of the ce3ll.
T is the absolute temperature.
C is the cell constant.
K is an arithmetic constant.
When the cell is at an operating temperature and there are unequal oxygen
concentrations across the cell, oxygen ions will travel from the high oxygen partial
pressure side to the low oxygen partial pressure side of the cell. The resulting logarithmic
Description and specifications Reference Manual
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output voltage is approximately 50 mV per decade. The output is proportional to the
inverse logarithm of the oxygen concentration. Therefore, the output signal increases as
the oxygen concentration of the sample gas decreases. This characteristic enables the
transmitter to provide exceptional sensitivity at low oxygen concentrations.
The transmitter measures net oxygen concentration in the presence of all the products of
combustion, including water vapor. Therefore, you can think of it as an analysis on a wet
basis. In comparison with older methods, such as the portable apparatus, which provides
an analysis on a dry gas basis, the wet analysis will, in general, indicate a lower percentage
of oxygen. The difference is proportional to the water content of the sample stream.
1.2.3 Configuration
Rosemount™ Oxymitter DR Transmitters are available in seven length options, giving the
operator flexibility to use an in situ penetration appropriate to the size of the stack or duct.
The options are:
•18 in. (457 mm)
•3 ft. (0,91 m)
•6 ft. (1,83 m)
•9 ft. (2,7 m)
•12 ft. (3,66 m)
•15 ft. (4,57 m)
•18 ft. (5,49 m)
Emerson offers abrasive shields for applications where abrasive particulates are present.
Acid-resistant cells are available for SO2 and HCl environments. Bypass and probe
mounting jacket options are available for process temperatures above 1300 °F (705 °C).
1.2.4 Features
The cell output voltage and sensitivity increase as the oxygen concentration decreases.
The Rosemount™ Oxymitter DR includes:
•Field replaceable cell, heater, thermocouple, and diffusion element.
•Rugged 316L stainless steel wetted parts.
•Membrane keypad
•Local operator interface (LOI)
•Optional HART® interface
Reference Manual Description and specifications
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Rosemount Oxymitter DR 11

1.2.5 Handling
CAUTION
The Rosemount Oxymitter DR is designed for industrial applications. Some probe
components are made from ceramics, which are susceptible to shock when mishandled.
Treat each component of the system with care to prevent physical damage.
1.2.6 System considerations
Prior to installing your transmitter, make sure you have all the components necessary to
make the system installation. Ensure all components are properly integrated to make the
system functional.
After verifying that you have all the components, select mounting locations and
determine how each component will be placed in terms of available line voltage, ambient
temperatures, environmental considerations, convenience, and serviceability.
Instrument air for reference air is optional for most applications. Ambient air passively
diffuses into the inside of the probe in sufficient quantity for an accurate measurement.
Instrument air is required for applications where the ambient air at the probe location may
not contain the typical 20.95 percent O2. An example would be an installation into a
positive pressure flue gas duct which has many leaks into the surrounding air.
If the calibration gas bottles will be permanently connected, use a blocking valve or check
valve next to the calibration fittings on the termination housing. This blocking valve or
check valve is to prevent breathing of the calibration gas line and subsequent flue gas
condensation and corrosion.
Note
Keep the packaging in which the transmitter arrived from the factory in case you need to
ship any components to another site. Emerson has designed this packaging to protect the
product.
1.2.7 Upgrading the Rosemount™ Oxymitter DR
You can easily upgrade the Rosemount Oxymitter DR to a full Oxymitter 4000 or 5000.
This provides an economical upgrade path for customers looking to preserve their probe
investment upon the eventual failure of the signal conditioning electronics. To upgrade,
add a small electronics package to the existing termination housing of the probe. The
converted unit will be a full Rosemount Oxymitter 4000 or 5000 Oxygen Transmitter that
can provide a 4-20 mA oxygen signal without an external signal conditioning electronics
package. The Rosemount Oxymitter electronics comes with HART® or FOUNDATION™
Fieldbus communications. See Upgrade Rosemount™ Oxymitter DR to full Oxymitter for
upgrade information.
Description and specifications Reference Manual
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1.3 Probe options
1.3.1 Diffusion elements
Ceramic diffusion assembly
The ceramic diffusion assembly is the traditional design for the probe.
Used for over 25 years, the ceramic diffusion assembly provides a greater filter surface
area. This element is also available with a flame arrestor and with a dust shield to use with
an abrasive shield.
Figure 1-2: Ceramic Diffusion Assembly
Snubber diffusion assembly
The snubber diffusion assembly is satisfactory for most applications. This element is also
available with a dust seal for use with an abrasive shield.
Figure 1-3: Snubber Diffusion Assembly
Reference Manual Description and specifications
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Rosemount Oxymitter DR 13

Cup type diffusion assembly
Use the cup type diffusion assembly in high temperature applications where frequent
diffusion element plugging is an option.
Figure 1-4: Cup Type Diffusion Assembly
The assembly is available with either a 5 micron or 40 micron sintered Hastelloy element.
This diffusion element offers the greater surface area of the ceramic element, but is much
more rugged. This element is also available with a dust seal for use with an abrasive shield.
Abrasive shield assembly
The abrasive shield assembly is a stainless steel tube that surrounds the probe assembly.
The shield protects against particle abrasion and condensations, provides a guide for ease
of insertion, and acts as a positive support, especially for longer probes. The abrasive
shield assembly uses a modified diffusor and vee deflector assembly, fitted with dual dust
seal packing.
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Figure 1-5: Abrasive Shield Assembly
Dimensions are millimeters with inches in parentheses.
A. View A.
B. View B.
C. Before welding, butt item 02 with item 01 as shown.
D. Weld on both sides with expanding chill block.
E. On inside Ø break for smooth rounded edge on both ends of chamber.
F. Skin cut face for 90°.
G. Ø 0.75 in. (19 mm) through four places equally spaced on Ø 4.75 in. (120.65 mm) B.C.
Note
In highly abrasive applications, rotate the shield 90 degrees at normal service intervals to
present a new wear surface to the abrasive flow stream.
Reference Manual Description and specifications
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Rosemount Oxymitter DR 15

1.4 Specifications
1.4.1 Performance specifications
Temperature limits Process: 32 to 1300 °F (0 to 705 °C), up to 2400 °F (1300 °C) with
optional accessories
Resolution sensitivity 0.01% O2 transmitted signal
Sensing cell repeatability ±0.75% of O2 reading or 0.05% O2(1)
Mounting and mounting
position
Vertical or horizontal
Lowest detectable limit 0.02% O2
System speed of response to
calibration gas
Tintial < 3 seconds
T90 < 8 seconds
Reference air 2 SCFH (1 L/min), clean, dry, instrument quality air (20.95% O2),
regulated to 2.5 psi (34 kPa)
Relative humidity 5 to 95% (non-condensing)
Power requirements Normal operation: 175 W
Maximum (warmup): 500 W
Ambient operating
temperature (junction box)
200 °F (93 °C)
160 °F (71 °C) maximum for YEW replacement
Rosemount has satisfied all obligations coming from the
European legislation to harmonize the product requirements in
Europe.
(1) When used with Rosemount Oxymitter signal conditioning electronics.
1.4.2 Physical specifications
Probe lengths •18 in. (457 mm)
•3 ft. (0.91 m)
•6 ft. (1.83 m)
•9 ft. (2.74 m)
•12 ft. (3.66 m)
•15 ft. (4.57 m)
•18 ft. (5.49 m)
Materials of
construction
Transmitter probe: Process-wetted materials are 316L or 304
stainless steel.
Non-wetted parts: 304 stainless steel, low-copper aluminum
Termination housing: Low-copper aluminum
Process
connections
2-in. 150# (4.75-in. [121 mm] bolt circle); DIN (5.71-in. [145 mm]
bolt circle)
Description and specifications Reference Manual
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Note
Flanges are flat-faced and for mounting only. Flanges are not
pressure-rated. Spool piece part numbers are available to offset
electronics housing from hot ductwork. Many adapter flanges are
available to mate to existing flanges.
Orientation Vertical or horizontal mount
Heater voltage 115 ±10 percent Vac, 50/60 Hz, 200 VA
Thermocouple Type K
Table 1-3: Probe Lengths and Approximate Shipping Weights
Length Weight
18 in. (457 mm) 16 lb. (7.3 kg)
3 ft. (0.91 m) 21 lb. (9.5 kg)
6 ft. (1.83 m) 27 lb. (12.2 kg)
9 ft. (2.74 m) 33 lb. (15.0 kg)
12 ft. (3.66 m) 39 lb. (17.7 kg)
15 ft. (4.57 m) 45 lb. (20.5 kg)
18 ft. (5.49 m) 51 lb. (23 kg)
Reference Manual Description and specifications
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Rosemount Oxymitter DR 17

Description and specifications Reference Manual
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18 Emerson.com/Rosemount

2 Install
WARNING
Failure to follow safety instructions could result in serious injury or death.
Before installing the equipment, read Safety instructions.
2.1 Mechanical installation
2.1.1 Select location
The location of the transmitter in the stack or flue is most important for maximum
accuracy in the oxygen analyzing process.
If the probe will be installed into an existing location, proceed to Install probe.
Procedure
1. Position the transmitter so that the gas it measures is representative of the process.
You will obtain best results by positioning the transmitter near the center of the
duct (40 to 60 percent insertion). Longer ducts may require several transmitter
units since the O2 can vary due to stratification. A point too near the wall of the duct
or the inside radius of a bend may not provide a representative sample because of
the very low flow conditions. Select the sensing point so the process gas
temperature falls within a range of 32 to 1300 °F (0 to 704 °C).
The ambient temperature of the termination housing must not exceed 200 °F (93
°C).
2. Check the flue or stack holes for air leakage. Make any necessary repairs or install
the transmitter upstream of any leakage.
Ducts and stacks that operate under negative pressure will draw air in through any
holes or torn seals, substantially affecting the oxygen reading.
3. Ensure that the area is clear of internal and external obstructions that will interfere
with probe installation and access to the membrane keypad or LOI. Allow adequate
clearance for removal of the transmitter.
Table 2-1: Calibration Gas and Reference Air
Calibration gas Reference air
ANSI 6.34 (¼) tube
DIN 6.35 (¼) tube
Table 2-2: Mounting Flange (Gasket Included)
ANSI DIN
Flange diameter 190 (7.5) 210 (8.25)
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Rosemount Oxymitter DR 19

Table 2-2: Mounting Flange (Gasket Included) (continued)
ANSI DIN
Hole diameter 19 (0.75) 18 (0.71)
4 holes equally spaced on BC 152,4 (6.00) 170 (6.69)
Install Reference Manual
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