Emerson Rosemount Xi User manual

Quick Start Guide
00825-0100-4889, Rev AA
July 2018
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. The following instructions must be adhered to and integrated 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 your 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.
•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.
•Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed
by qualified people, to prevent electrical shock and personal injury.
The information contained in this document is subject to change without notice.
NOTICE
The 375 Field Communicator must be upgraded to System Software 2.0 with Graphic License for operation with Xi Electronics. The
AMS software must be upgraded to AMS 8.0 or above.
Contact Emerson's Global Service Center (GSC) at 1-800-833-8314 to upgrade the 375 Field Communicator software to System
Software 2.0 with Graphic License.
Definitions
The following definitions apply to WARNINGS, CAUTIONS, and NOTICES 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.
NOTICE
Highlights an essential operating procedure, condition, or statement.
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.
Technical Support Hotline
For assistance with technical problems, please call the Customer Support Center (CSC).
The CSC is staffed 24 hours a day, 7 days a week.
Phone: [phone]
In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Emerson's field service throughout the U.S. and
abroad.
Phone: [phone]-RSMT (1-800-654-7768)
Emerson may also be reached via the Internet through email and the World Wide Web:
Email: [email protected]
World Wide Web: www.Emerson.com/RosemountGasAnalysis
Warranty
RosemountTM 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,
Rosemount 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
Rosemount 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 purchase'rs sole remedy(ies) for any failure of Rosemount to comply with the warranty
provisions, whether claims by the purchaser are based in contract or in tort (including negligence).
Rosemount 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 Rosemount but not manufactured by it will be subject to the same warranty as is extended to Rosemount 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.

Contents
Chapter 1 Plan ............................................................................................................................... 1
1.1 Unpacking ................................................................................................................................... 1
1.2 System considerations .................................................................................................................3
1.3 Mount ..........................................................................................................................................3
1.4 Specifications .............................................................................................................................. 6
Chapter 2 Wire .............................................................................................................................. 9
2.1 Electrical installation ....................................................................................................................9
2.1.1 Optional flame safety interlock ................................................................................... 11
2.1.2 Wire the traditional architecture cable connections .................................................... 12
Chapter 3 Configure .....................................................................................................................14
3.1 Verify installation .......................................................................................................................14
3.1.1 Xi configuration .......................................................................................................... 14
3.2 Set test gas values ......................................................................................................................15
3.3 Setting test gas values using Field Communicator ..................................................................... 15
3.4 Alarm relay output configuration ...............................................................................................15
3.4.1 Configuring alarm relays with the Xi keypad/display ....................................................16
3.4.2 Configuring autocalibration with the Field Communicator ..........................................16
3.5 Autocalibration setup ................................................................................................................ 17
3.6 Configure analog output ............................................................................................................17
Chapter 4 Startup and operation .................................................................................................. 18
4.1 Startup ...................................................................................................................................... 18
4.1.1 Operation via Xi ...........................................................................................................18
4.1.2 Xi Controls .................................................................................................................. 19
4.1.3 Password protection ................................................................................................... 22
4.2 Operation via HART/AMS ........................................................................................................... 23
4.2.1 Field communicator signal line connections ................................................................23
4.3 Offline and online operations .....................................................................................................24
Appendices and reference
Appendix A Safety instructions for the wiring and installation of this apparatus ..............................25
Appendix B ..................................................................................................................................... 27
Contents
Quick Start Guide i

Contents
ii Rosemount Xi

1 Plan
1.1 Unpacking
1. Inspect the shipping container. If it is damaged, contact the shipper immediately for
instructions. Save the box.
2. If there is no apparent damage, remove the transmitter.
3. Ensure that all items shown on the packing list are present. If items are missing,
notify Rosemount immediately.
See Figure 1-1.
Plan
Quick Start Guide 1

Typical system packageFigure 1-1:
A. Quick Start Guide
B. Weld plate
C. Traditional architecture cable
D. O2 probe
E. Reference air set (not used if SPS 4001B or IMPS 4000 is used)
F. HART® 375/475 Field Communicator package (optional)
G. Optional SPS 4001B or IMPS 4000 Autocalibration Sequencer
H. Xi Advanced Electronics
4. Save the shipping container and packaging.
They can be reused to return the transmitter to the factory in case of damage.
Plan
2Rosemount Xi

1.2 System considerations
A typical system installation for an Xi or O2 probe is shown in Figure 1-2.
Typical system installationFigure 1-2:
A. Gases
B. Duct
C. Adapter plate and flange
D. Instrument air supply (reference air)
E. Pressure regulator
F. Flowmeter
G. Calibration gas
H. Line voltage
I. 4 to 20 mA signal
J. Rosemount 6888Xi Advanced Electronics (optional)
K. Stack
1.3 Mount
The Xi Advanced Electronics is available in a panel mounting, wall mounting, or pipe
mounting configuration.
Refer to Figure 1-3 or Figure 1-4 for the panel, wall, or pipe mounting details.
Plan
Quick Start Guide 3

Procedure
1. Ensure all components are available to install the Xi.
2. Select a mounting location near or removed from the O2 probe.
Consider the temperature limitations of the Xi (see Section 1.4) when selecting the
mounting location.
3. Mount the 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 Xi may have interior and exterior protective membranes.
Remove the protective membranes prior to use of the 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.
Plan
4Rosemount Xi

Xi Advanced Electronics - panel mounting detailsFigure 1-3:
Plan
Quick Start Guide 5

Xi Advanced Electronics - wall/surface and pipe mounting detailsFigure 1-4:
1.4 Specifications
SpecificationsTable 1-1:
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
Plan
6Rosemount Xi

Specifications (continued)Table 1-1:
Signal stability ±0.03% O2
Accuracy in reducing conditions ±10% of reading or 0.1% O2
System responses in reducing conditions Going from oxidizing to reducing -T90 in 120 seconds
Going from reducing to oxidizing -T90 in 30 seconds
Ambient temperature effect on Xi 4-20 mA signal Less than 0.0025% O2 per degree Celsius
Environmental specifications
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
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 Xi)
Electrical power for Xi 100 - 240 Vac ±10%, 50/60 Hz
Power consumption of Xi 12 VA maximum or 776 VA maximum with traditional arch-
tecture, 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 leg-
islation to harmonize the product requirements in Europe.
All static performance characteristics are with operating
variables constant. Specifications subject to change with-
out notice.
Product matrix, Xi advanced electronicsTable 1-2:
Xi Xi Advanced Electronics
Code Remote type
01 Single channel(1)
Plan
Quick Start Guide 7

Product matrix, Xi advanced electronics (continued)Table 1-2:
02 Single channel, accepting a loss-of-flame input to remove heater power with flame
status relay(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 (stoichiometer cell also required in probe)
02 Dual channel (stoichiometer cell also required in probe)
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
Note
All static performance characteristics are with operating variables constant. Specifications subject to
change without notice.
Plan
8Rosemount Xi

2 Wire
2.1 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.
WARNING!
ELECTRIC SHOCK
To meet the safety requirements of IEC 1010 (EC requirement) and ensure safe operation of this
equipment, connection to the main electrical power supply must be made through a circuit
breaker (min 10 A) which will disconnect all current-carrying conductors during a fault
situation. This circuit breaker should also include a mechanically operated isolating switch. If it
does not, locate another external means of disconnecting the power supply close by. Circuit
breakers or switches must comply with a recognized standard such as IEC 947.
Note
Line, voltage, signal, and relay wiring must be rated for at least 105 °C (221 °F).
NOTICE
If a metal conduit is used with the Xi, the conduit should be reliably bonded to protective earth.
The grounding plate inside the Xi is not bounded to PE and does not provide adequate
grounding.
1. Remove cover screws from the front cover of the Xi. Swing down the front cover of
the interface box.
2. Pull out the I/O board on the right-hand side of the card rack inside the Xi. If your
system is configured to operate two transmitter probes, there are two I/O interface
boards.
3. See Figure 2-1. Connect the 4-20 mA signal wires at J4 of the I/O board. Attach the
supplied ferrite clamp over the 4-20 mA OUT wires that extend past the shield.
Wire
Quick Start Guide 9

NOTICE
Installation of the ferrite clamp over the 4-20 mA OUT wires is required for compliance
with the European EMC directive.
Signal connections at I/O boardFigure 2-1:
Alarm indicator relay terminalsFigure 2-2:
4. Terminate the shield of the 4-20 mA signal wires at the designated ground terminal
of the Xi. Do not allow bare shield wires to contact the circuit boards. Insulate the
shield wires prior to termination.
5. Connect the signal wires from the SPS or IMPS (if used) to the applicable terminals of
J3. Refer to the SPS or IMPS instruction manual for wiring details.
6. Connect the signal wires for the flame status input (if used) to the applicable
terminals of J2. The flame status sensing device is supplied by the customer. Refer to
the applicable OEM documents for signal wiring details.
Wire
10 Rosemount Xi

7. Connect the customer's alarm indicator devices to the alarm indicator relay
terminals. See Figure 2-2 for the alarm indicator relay terminals.
8. Reinstall the I/O board in the card rack of the Xi.
Power connections - Xi Advanced ElectronicsFigure 2-3:
9. If your system is configured for two channel operation, repeat steps 2 through 7 to
connect the other signal wires.
10. Remove the connector from the power supply board located on the left-hand side of
the card rack inside the Xi.
11. See Figure 2-3. Connect the line, or L1, wire to the L1 terminal and the neutral, or L2,
wire to the N terminal.
12. Reinstall the power supply connector in the power supply board.
13. Close and fasten the Xi cover.
2.1.1 Optional flame safety interlock
A flame safety interlock by Emerson is available for the heater power disconnect whenever
there is a loss of the process flame or a heater runaway condition (heater over-
temperature) in the O2 probe. A simplified wiring diagram for the flame safety interlock is
shown in Figure 2-4. The input is internally powered by the Xi and is actuated via a dry
contact output from the user's flame scanner. A closed contact indicates a flame is
present. An open contact indicates a loss of flame.
Wire
Quick Start Guide 11

Flame safety interlock - wiring diagramFigure 2-4:
2.1.2 Wire the traditional architecture cable connections
A traditional architecture configuration is used to provide for remote location of the
transmitter electronics. All electronics are housed inside the Rosemount 6888Xi. A multi-
conductor power/signal cable connects between the probe and the Rosemount 6888Xi.
Use the following procedure to connect the traditional architecture probe to the
Rosemount 6888Xi.
NOTICE
The traditional architecture cable is provided at the specified length and is ready for
installation. The cable glands must be properly terminated to maintain EMC/EMI noise
protection.
Procedure
1. Run the 7-conductor cable between the traditional architecture probe and the
installation site for the Rosemount 6888Xi. Use new cable conduit or trough as
needed.
2. Install the cable and lead wires to the probe per manufacturer's instructions.
3. Install the cable at the probe housing and at the Rosemount 6888Xi enclosure
according to the following procedure:
a. Unscrew the locking nut from the gland assembly and slide the locking nut back
along the cable.
b. Pull the gland body away from the plastic insert.
Use care not to damage the cable shield braid.
Wire
12 Rosemount Xi

c. Insert the cable wires into the proper entry port in either the probe housing or
the Rosemount 6888Xi enclosure.
d. At the probe housing, apply Teflon® tape or similar sealing compound to the
tapered pipe threads. Thread the gland body into the probe housing until
properly seated.
e. At the Rosemount 6888Xi enclosure, insert the gland body into the left front
cable port from the inside of the enclosure. Use the rubber O-ring provided to
seal the cable port.
f. Ensure the cable shield braid is evenly formed over the gray insert.
When properly formed, the braid should be evenly spaced around the
circumference of the insert and not extend beyond the narrow diameter portion.
g. Carefully press the gray insert into the gland body. The grooves on the insert
should align with similar grooves inside the gland body. Press the insert in until it
bottoms out in the gland body.
h. Slide the locking nut up and thread it onto the gland body. Tighten the locking
nut so the rubber grommet inside the plastic insert compresses against the cable
wall to provide an environmental seal.
4. At the Rosemount 6888Xi, connect the cable leads to the connectors on the
transmitter I/O board.
Wire
Quick Start Guide 13

3 Configure
3.1 Verify installation
WARNING!
ELECTRIC SHOCK
Install all protective equipment covers and safety ground leads before equipment startup.
Failure to install covers and ground leads could result in serious injury or death.
WARNING!
ELECTRIC SHOCK
If external loop power is used, the power supply must be a safety extra low voltage (SELV)
type.
3.1.1 Xi configuration
Refer to Figure 3-1 for the configuration of jumpers JP1 through JP8. The jumper
configuration for your I/O board depends on the system design and system components
used in your installation.
The setting of switch SW4 and the configuration of jumpers JP1 through JP8 must be
verified on the I/O board in the Xi. All four dip switches on switch SW4 must be set to the
Off position, as shown.
I/O board jumper configurationFigure 3-1:
Configure
14 Rosemount Xi