Emerson Rosemount Xi User manual

Reference Manual
00809-0100-4889, Rev AB
October 2022
Rosemount™ Xi
Advanced Electronics for Zirconium Oxide Flue Gas O2 Probes

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. You must adhere to the following instructions and integrate them into your safety
program when installing, using, and maintaining Emerson's Rosemount 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 Quick Start Guide 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.
•When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.
Unauthorized parts and procedures can affect the product's performance, 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.
Note
The information contained in this document is subject to change without notice.
Preface
The purpose of this manual is to provide information concerning the components, functions, installation, and maintenance of the
Rosemount Xi Electronics.
Some sections may describe equipment not used in your configuration. You should become thoroughly familiar with the
operation of this module before operating it. Read this instruction manual completely.
Definitions
The following definitions apply to warnings, cautions, and notes found throughout this publication.
WARNING
Highlights an operation or maintenance procedure, condition, statement, etc. that 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. that if not strictly observed, could result in
damage to or destruction of equipment or loss of effectiveness.
Note
Highlights an essential operating procedure, condition, or statement.
2

Symbols
:
Earth (ground) terminal
:
Protective conduit or terminal
:
Risk of electrical shock
:
Warning: Refer to Instruction Manual
NOTICE
The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number
and is not related to the illustration in any technical manner.
Overview
The Rosemount Xi is specifically designed to control a zirconium oxide probe for measuring oxygen, usually the O2 remaining from
a combustion process. Call Emerson's Rosemount Customer Central to get recommendations for other oxygen probes:
800 999 9307 (US and Canada).
The Rosemount Xi electronics has several main functions:
1. Heater Control: The electronics receives a type K thermocouple input from an O2 probe and switches power on and off to
the probe's heater in order to maintain a temperature setpoint of 1357 °F (736 °C).
2. Signal Conditioning: The electronics receives the raw millivolt signal from the O2 sensing cell and then linearizes and
amplifies the signal to provide a linear 4-20 mA output signal used for recording or as in input into a DCS system for
control purposes.
3. Calibration: A bottled calibration gas of known value is typically flowed into the probe's sensor to verify that it is reading
correctly. If the signal is out of calibration, the calibration gas is used to adjust the 4-20 mA output signal. During
calibration, the Rosemount Xi prompts the technician to flow two calibration gases into the probe and, with the
calibration gases flowing, automatically adjusts the O2 signal. With the addition of a Single Probe Sequencer (SPS), the
Rosemount Xi electronics can also switch the calibration gases on and off.
4. Diagnostics: Multiple alarms are available for display. The alarm displays are intended to assist a technician in locating
where an instrument problem may reside.
The electronics has been verified to operate the following probes:
•Westinghouse 218 and World Class
•Rosemount Oxymitter
•Yokogawa
Technical support hotline
For assistance with technical problems, call the North American Response Center. The Response Center is staffed 24 hours a day, 7
days a week.
Phone: [phone]-RSMT (1-800-654-7768)
Emerson may also be reached via the Internet through email and the following websites:
Email: [email protected]
Websites:
•Emerson.com/RosemountCombustionAnalysis
•Emerson.com/Rosemount-Gas-Analysis
•Emerson.com/Rosemount
•Emerson.com
3

Warranty
Emerson warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or
material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment,
Emerson shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B.
factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of
Emerson with respect to the quality of the equipment.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY, WHETHER WRITTEN, ORAL, OR
IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE).
The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure of Emerson to comply with the warranty
provisions, whether claims by the purchaser are based in contract or in tort (including negligence).
Emerson does not warrant equipment against normal deterioration due to environment. Factors, such as corrosive gases and solid
particulates, can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the
warranty period.
Equipment supplied by Emerson but not manufactured by it will be subject to the same warranty as is extended to Emerson by the
original manufacturer.
At the time of installation, it is important that the required services are supplied to the system and that the electronic controller is
set up at least to the point where it is controlling the sensor heater. This will ensure that, should there be a delay between
installation and full commissioning, the sensor being supplied with ac power and reference air will not be subjected to component
deterioration.
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Contents
Chapter 1 Description and specifications....................................................................................7
1.1 Component checklist...................................................................................................................7
1.2 System overview..........................................................................................................................8
1.3 Specifications............................................................................................................................ 12
Chapter 2 Install.......................................................................................................................15
2.1 System considerations...............................................................................................................16
2.2 Mechanical installation.............................................................................................................. 16
2.3 Electrical installation..................................................................................................................20
Chapter 3 Configure.................................................................................................................27
3.1 Verify installation.......................................................................................................................27
3.2 Set test gas values......................................................................................................................29
3.3 Alarm relay output configuration...............................................................................................29
3.4 Autocalibration setup................................................................................................................ 30
3.5 Optional advanced features inside the Rosemount Xi................................................................ 31
Chapter 4 Startup and operation.............................................................................................. 33
4.1 Overview................................................................................................................................... 33
4.2 Startup...................................................................................................................................... 33
4.3 System parameter descriptions................................................................................................. 38
4.4 Probe parameter descriptions....................................................................................................41
4.5 Operation via HART/AMS........................................................................................................... 44
4.6 Offline and online operations.....................................................................................................45
4.7 Calibration - general.................................................................................................................. 46
4.8 O2 calibration............................................................................................................................ 46
4.9 D/A trim.....................................................................................................................................48
Chapter 5 Troubleshoot........................................................................................................... 51
5.1 Overview of operating principles............................................................................................... 51
5.2 General......................................................................................................................................52
5.3 Alarm indications.......................................................................................................................53
5.4 Identifying and correcting fault indications................................................................................54
5.5 Calibration passes, but still reads incorrectly..............................................................................55
Chapter 6 Maintenance and service..........................................................................................59
6.1 Overview................................................................................................................................... 59
6.2 Maintenance intervals................................................................................................................59
6.3 Calibration.................................................................................................................................60
6.4 Replacement parts.....................................................................................................................60
6.5 Rosemount Xi components replacement...................................................................................60
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Chapter 7 Replacement parts................................................................................................... 75
7.1 Rosemount Xi electronics.......................................................................................................... 75
7.2 Calibration components............................................................................................................ 76
Chapter 8 Optional accessories................................................................................................ 77
8.1 HART handheld Field Communicator......................................................................................... 77
8.2 Asset Management Solutions (AMS).......................................................................................... 78
8.3 By-Pass Packages....................................................................................................................... 78
8.4 Rosemount™ SPS 4001B Single Probe Autocalibration Sequencer.............................................. 79
8.5 O2 calibration gas...................................................................................................................... 80
Appendix A Service support........................................................................................................ 81
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1 Description and specifications
1.1 Component checklist
A typical Rosemount O2 Combustion Flue Gas Transmitter should contain all the items
shown in Figure 1-1. A complete Oxygen Analyzer system will include some or all of the
equipment shown. However, this manual describes item H only.
Use the product matrix (Table 1-1) at the end of this section to compare your order
number against your unit. The first part of the matrix defines the model. The last part
defines your options and features. Ensure the features and options specified by your order
number are on or included with the unit.
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Figure 1-1: Typical system package
A. Quick Start Guide
B. Weld plate
C. Traditional architecture cable
D. O2 probe
E. Reference Air Set (not used if SPS 4001B is used)
F. Field Communicator package (optional)
G. Optional SPS 400 1B Single Probe Autocalibration Sequencer
H. Rosemount Xi Advanced Electronics
1.2 System overview
1.2.1 Scope
This Reference Manual supplies details needed to install, start up, operate, and maintain
the Rosemount .
Signal conditioning electronics output a 4-20 mA signal representing the O2 value. This
information, plus additional details, can be accessed with the Field Communicator or Asset
Management Solutions (AMS) software.
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1.2.2 System configurations
Traditional architecture, HART ,and Rosemount Xi communications
Some customers prefer not to mount electronics onto the probe, so a traditional
architecture version is offered. This probe sends raw millivolt signals via a 7-conductor
cable to the Rosemount Xi electronics, Figure 1-2, which does all heater control and signal
conditioning in addition to its display/keypad functions. The Rosemount Xi Advanced
Electronics is offered to support direct replacement probes with either 120 volt or 44 volt
heaters.
Figure 1-2: Direct replacement probe with traditional architecture electronics
Figure 1-3: O2 probe with Rosemount Xi Electronics and autocalibration sequencer
1.2.3 Automatic calibration
Calibrations consist of introducing bottled gases of known value into the probe so the
electronics can make automatic adjustments to the O2 readings to match the bottled gas
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value. 0.4% O2 and 8% O2 (balance nitrogen) gases are recommended. Never use nitrogen
or instrument air as calibration gases.
Flowmeters (for calibration gases) and regulators and flowmeters (for reference air) are
available as loose components, mounted into an optional manual calibration switching
panel or as a fully automated calibration system, Figure 1-3, where calibration solenoids
are switched from the Rosemount Xi Electronics. See IM-106-340AC, SPS 4000B Single
Probe Autocalibration Sequencer for additional details.
1.2.4 Communication options
Data communications
An operator can configure and troubleshoot the O2 probe system in one of two ways:
1. Using the Rosemount Xi Advanced Electronics; the Rosemount Xi carries the
following optional advanced features:
•Fully automatic calibration
•Flame safety interface
•High temperature operation [above 1292 °F (700 °C) standard temperature]
•Stoichiometer feature provides the ability to indicate O2 efficiency when the
combustion process goes into reducing conditions (0% O2).
•Programming reference provides advanced accuracy when measuring at or near
O2 level (20.95% O2).
2. Using the HART interface, the Rosemount Xi's 4-20 mA output line transmits an
analog signal proportional to the oxygen level. The HART output is superimposed
on the 4-20 mA output line. This information can be accessed through the
following:
•Rosemount Field Communicator - The handheld communicator requires Device
Description (DD) software specific to the Rosemount Xi. The DD software will be
supplied with many Field Communicator units, but can also be programmed into
existing units at most Emerson service offices. See Startup and operation for
additional information.
•Personal computer (PC) - The use of a personal computer requires AMS software
available from Emerson.
•Delta V and Ovation Distributed Control System (DCS) with AMS-inside
capability.
3. The Rosemount Xi can also transmit HART information wirelessly via a wireless
THUM Adapter, Figure 1-4. The THUM Adapter threads into the Rosemount Xi
conduit ports and converts the 4-20 mA O2 signal to a wireless protocol. All other
HART information is also transmitted.
In addition to the wireless THUM Adapter, a hard-wire connection of the 4-20 mA
signal to the DCS may be used at the same time. More detailed information
regarding the application of the THUM Adapter is available in Product Data Sheet
00813-0100-4075. Note that the THUM Adapter may also be used with the
Oxymitter, mounted integral to the probe, or to the Oxymitter remote electronics.
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Figure 1-4: Wireless THUM Adapter
Optional OxyBalance display and averaging system
Receives up to eight 4-20 mA signals from individual Rosemount Xi units. Trends individual
outputs and calculates four programmable averages as additional 4-20 mA outputs.
OxyBalance graphic displays are shown in Figure 1-5. See IM-106-4050, OxyBalance
Oxygen Display and Averaging System, for additional details.
Figure 1-5: OxyBalance displays
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1.3 Specifications
Table 1-1: Specifications
Measurement specifications
Net O2 range 0 to 50% O2 user scalable
-2 to 50% O2 user scalable with stoichiometer
Lowest detectable limit 0.01% O2
Signal stability ±0.03% O2
Accuracy in reducing conditions ±10% of reading or 0.1% O2
Ambient temperature effect on Rosemount Xi 4-20 mA
signal
Less than 0.0025% O2 per degree Celsius
Environmental specifications
Rosemount Xi Advanced Electronics Type 4X/IP66 polycarbonate material
Ambient temperature limits -4 to 122 °F (-20 to 50 °C)
-4 to 158 °F (-20 to 70 °C) as measured by electronics
Rosemount Xi LCD display: ambient temperature limits -4 to 131 °F (-20 to 55 °C)
General purpose certifications
Installation specifications
Mounting Panel, wall, or pipe
Reference air 0.5 scfh (0.25 l/min), clean, dry, instrument-quality air
(20.95% O2), regulated to 5 psi (34 kPa)
Calibration Semi-automatic or automatic
Cal gases 0.4% O2 and 8% O2, balance N2
Traditional architecture cable 200 ft (61 m) maximum length
Transmitter electrical power 12 - 24 Vdc (loop-powered from control room or
Rosemount Xi)
Electrical power for Rosemount Xi 100 - 240 Vac ±10%, 50/60 Hz
Power consumption of Rosemount Xi 12 VA maximum or 776 VA maximum with traditional
archtecture, 120 V probes
450 VA maximum with traditional architecture, 44 V probes
Alarm relay outputs Two provided - 2 Amperes, 30 Vdc, Form-C
Optional loss of flame input Internally powered input to remove heater power actuated
via dry contact output from user's flame scanner
Emerson has satisfied all obligations from the European
legislation to harmonize the product requirements in
Europe. All static performance characteristics are with
operating variables constant. Specifications subject to
change without notice.
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Table 1-2: Product matrix, Rosemount Xi advanced electronics
Xi Rosemount Xi Advanced Electronics
Code Remote type
01 Single channel(1)
03 Dual channel(1)
04 Single channel traditional architecture for 120 V probes
05 Single channel traditional architecture for 44 V probes
Code Mounting
00 No hardware
01 Panel mount kit with gasket
02 2 in. pipe/wall mount kit
Code Cable
00 No cable
10 20 ft (6 m) cable
11 40 ft (12 m) cable
12 60 ft (18 m cable)
13 80 ft (24 m cable)
14 100 ft (30 m) cable
15 150 ft (45 m) cable
16 200 ft (60 m) cable
Code Stoichiometer function
00 None
01 Single channel
02 Dual channel
Code Programmable reference function
00 None
01 Single channel
02 Dual channel
Code 800 deg C process function
00 None
01 Single channel
02 Dual channel
1. Requires XPS transmitter, P/N 6A00358G03
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Note
All static performance characteristics are with operating variables constant. Specifications
subject to change without notice.
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2 Install
WARNING
Failure to follow the safety instructions could result in serious injury or death.
WARNING
ELECTRICAL HAZARD
Failure to install covers and ground leads could result in serious injury or death.
Install all protective covers and safety ground leads after installation.
WARNING
HAZARDOUS AREAS
The Rosemount can be installed in general purpose areas only.
Do not install the Rosemount in hazardous areas or in the vicinity of flammable liquids.
WARNING
ELECTRICAL HAZARD
If external loop power is used, the power supply must be a safety extra low voltage (SELV)
type.
Note
Plug all unused ports on the probe housing and enclosure with a suitable filling.
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2.1 System considerations
A typical system installation for a Rosemount Xi or O2 probe is shown in Figure 2-1.
Figure 2-1: Typical system installation
A. Gases
B. Duct
C. Adapter plate and flange
D. Instrument air supply (reference air)
E. Pressure regulator
F. Flow meter
G. Calibration gas
H. Line voltage
I. 4 to 20 mA signal
J. Rosemount Xi Advanced Electronics (optional)
K. Stack
L. Traditional architecture cable
2.2 Mechanical installation
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2.2.1 Mount
The Rosemount Xi Advanced Electronics is available in a panel mounting, wall mounting,
or pipe mounting configuration.
Refer to Figure 2-2 or Figure 2-3 for the panel, wall, or pipe mounting details.
1. Ensure all components are available to install the Rosemount Xi.
2. Select a mounting location near or removed from the O2 probe.
Consider the temperature limitations of the Rosemount Xi (see Specifications)
when selecting the mounting location.
3. Mount the Rosemount Xi at a height convenient for viewing and operating the
interface.
Approximately 5 ft (1.5 m) is recommended.
4. The keypad window on the Rosemount Xi may have interior and exterior protective
membranes. Remove the protective membranes prior to use of the Rosemount Xi
enclosure.
NOTICE
Failure to remove the protective membranes may cause the display to appear
distorted. The membrane may be difficult or impossible to remove after extended
use at elevated temperatures.
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Figure 2-2: Rosemount Xi Advanced Electronics - panel mounting details – front and
side view
A. Maximum Panel Thickness 0.375 (9.75)
B. Front View
C. Panel Mount Gasket
D. 4x Mounting Brackets and Screws provided
E. Side View
Figure 2-3: Rosemount Xi Advanced Electronics - panel mounting details – bottom
view
A. 6X ½ in NPT conduit openings
B. Bottom View
C. Panel Cut-Out
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Note
Dimensions are in inches with millimeters in parentheses.
Note
The front panel is hinged at the bottom. The panel swings down for easy access to the
wiring locations.
Figure 2-4: Rosemount Xi Advanced Electronics - wall/surface mounting – front and
side view
A. Front View
B. 4K Cover Screw
C. Side View
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Figure 2-5: Rosemunt Xi Advanced Electronics - pipe mounting – bottom view
A. 6X ½ in NPT conduit openings
B. Front View
C. 6X ½ in NPT Conduit Openings
D. Mounting Bracket
E. U-Bolts
F. 2 in Pipe Supplied by Customer
Note
Dimensions are in inches with millimeters in parentheses.
2.3 Electrical installation
All wiring must conform to local and national codes. Multiple wiring diagrams are shown in
this section. Always refer to the diagrams that apply to your transmitter configuration and
disregard all other wiring diagrams.
WARNING
ELECTRIC SHOCK
Disconnect and lock out power before connecting the power supply. Failure to lock out
power could result in serious injury or death.
WARNING
ELECTRIC SHOCK
Install all protective covers and safety ground leads after installation. Failure to install
covers and ground leads could result in serious injury or death.
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