Emerson Rosemount 6888A User manual

Quick Start Guide
00825-0100-4890, Rev AB
October 2019
Rosemount™ 6888A
O2 Combustion Flue Gas Transmitter

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 Reference 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 or unauthorized substitution of
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™ 6888A 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
Refer to reference manual.
The following definitions apply to Warnings, Cautions, and Notes 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.
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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.
Note
Highlights an essential operating procedure, condition, or statement.
WARNING
Explosions
Do not open when an explosive atmosphere may be present.
WARNING
Electrical shock
Do not open while energized.
CAUTION
Equipment damage
For the standard housing probe and direct replacement probe, only use supply cables & certified
cable glands rated > 221 °F (105 °C).
For the autocal housing, only use supply cables and certified cable glands rated > 185 °F (85 °C).
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.
Contents
Install........................................................................................................................................... 5
Configuration, startup, and operation........................................................................................ 27
Product certifications................................................................................................................. 33
Declaration of Conformity..........................................................................................................36
China RoHS Table....................................................................................................................... 38
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1 Install
WARNING
Failure to follow safety instructions could result in serious injury or death.
Before installing this equipment, read the Essential Instructions at the front
of this document.
WARNING
Electrical shock
Failure to install covers and ground leads could result in serious injury or
death.
Install all protective covers and ground leads after installation.
WARNING
Hazardous areas
The transmitter can be installed in general purpose areas only.
Do not install the transmitter in hazardous areas or in the vicinity of
flammable liquids.
CAUTION
Equipment damage
If external loop power is used, the power supply must be a safety extra low
voltage (SELV) type.
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1.1 Install probe
Most combustion processes run only slightly negative or positive in pressure,
so that the probe flange is for mechanical mounting only. The probe is not
rated for high pressures. If this is a new installation, a weld plate for welding
to the flue gas duct can be supplied.
WARNING
Electrical shock
Failure to install covers and ground leads could result in serious injury or
death.
Install all protective covers and ground leads after installation.
WARNING
Hazardous areas
The transmitter can be installed in general purpose areas only.
Do not install the transmitter in hazardous areas or in the vicinity of
flammable liquids.
Procedure
1. Ensure all components are available to install the probe.
If using the optional ceramic or Hastelloy diffusion element, make
sure to orient the vee deflector correctly.
2. Before inserting the probe, check the direction of gas flow in the
duct. Orient the vee deflector so the apex points upstream toward
the flow.
See Figure 1-1.
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Figure 1-1: Orienting the Optional Vee Deflector
A. Gas flow direction
B. Vee deflector
C. Diffusion element
D. Setscrew
E. Vee deflector
F. Filter
G. Apex
3. If using the standard square weld plate or an optional flange
mounting plate, weld or bolt the plate onto the duct.
The through hole diameter in the stack or duct wall and refractory
material must be at least 2½-in. (63.5 mm).
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Figure 1-2: Rosemount 6888A Probe with Standard
Terminations/Electronic Housing
Note
All dimensions are in inches with millimeters in parentheses.
Figure 1-3: Rosemount 6888A Integral Autocal Housing
A. Dimension (see Table 1-1)
B. Dimension (see Table 1-1)
C. Hastelloy diffuser
D. Ceramic diffuser
Note
All dimensions are in inches with millimeters in parentheses.
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Figure 1-4: Rosemount 6888A Integral Autocal Housing Close-up
A. Dimension (see Table 1-1)
B. Dimension (see Table 1-1)
C. Calibration gas ¼ tube fittings 5.0 SCFH (2.4 L/min) 20 psi (138
kPa)
D. #10 socket head cap screw (external ground)
E. ½ NPT conduit connection (power, signal)
F. Reference gas ¼ tube fitting 2.0 SCFH (1.0 L/min) 20 psi (138
kPa)
G. Reference air vents
Note
All dimensions are in inches with millimeters in parentheses.
Table 1-1: Removal/Installation
Probe length(1) Dim A insertion
depth
Dim B removal
envelope standard
housing
Dim B removal
envelope accessory
housing
18 in. (457 mm)
probe
16.1 in. (409 mm) 15.77 in. (401 mm) 19.26 in. (490 mm)
3 ft. (0.91 m) probe 33.52 in. (826 mm) 46.6 in. (1182 mm) 50.1 in. (1271 mm)
6 ft. (1.83 m) probe 68.52 in. (1740 mm) 82.6 in. (2097 mm) 86.1 in. (2186 mm)
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Table 1-1: Removal/Installation (continued)
Probe length(1) Dim A insertion
depth
Dim B removal
envelope standard
housing
Dim B removal
envelope accessory
housing
9 ft. (2.74 m) probe 104.52 in. (2655 mm) 118.6 in. (3011 mm) 122.1 in. (3100 mm)
12 ft. (3.66 m) probe 140.52 in. (3569 mm) 154.6 in. (3926 mm) 158.1 in. (4015 mm)
(1) Add 3.8 in. (96 mm) to Dim A and Dim B for probe with ceramic or Hastelloy diffuser.
The through hole diameter in the stack or duct wall and refractory
material must be at least 63.5 mm (2½ in.)
4. Insert probe through the opening in the mounting flange and bolt
the unit to the flange.
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Figure 1-5: Probe Installation
A. Dimension (see Table 1-3)
B. Dimension (see Table 1-3)
C. Dimension (see Table 1-3)
D. Four studs, lockwashers, and nuts equally spaced on C dia. B C
Table 1-2: Mounting flange
ANSI DIN
Flange diameter 7.28 in. (185 mm)
Hole diameter .75 in. (20 mm)
(4) holes eq sp on BC 4.75 in. (121 mm) 5.71 in. (145 mm)
Table 1-3: Installation Weld Plate Outline
Dimension ANSI DIN
A 152 in. (600 mm) 191 in. (750 mm)
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Table 1-3: Installation Weld Plate Outline (continued)
Dimension ANSI DIN
B thread 11 in. (62.5 mm) M16x2
C diameter 121 in. (475 mm) 145 in. (579 mm)
Figure 1-6: Drip Loop and Insulation Removal
A. Line voltage
B. Logic I/O, 4-20 mA signal
C. Stack or duct metal wall
D. Adapter plate
E. Insulation
F. Note
Replace insulation after installing Rosemount 6888A
Note
Standard housing probe shown. Accessory housing is similar. Probe
installation may be vertical or horizontal.
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1.2 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
Electrical shock
Failure to install covers and ground leads could result in serious injury or
death.
Disconnect and lock out power before connecting the power supply.
Install all protective covers and ground leads after installation.
To meet the safety requirements of IEC 61010-1 (EC requirement) and
ensure safe operation of this equipment, connect the main electrical
power supply 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, keep another external means of disconnecting the
power supply from the equipment located close by. Circuit breaks or
switches must complay with a recognized standard such as IEC 947.
To maintain proper earth grounding, ensure a positive connection exists
between the transmitter housing and earth. The connecting ground wire
must be 14 AWG minimum.
Line voltage, signal, and relay wiring should be rated for at least 221 °F
(105 °C).
1.2.1 Wire Rosemount 6888 Transmitter probe only (no Rosemount 6888
Xi Electronics)
The Rosemount 6888 transmitter probe has electronics in the blue housing
that controls the heater temperature and also amplifies the raw O2 millivolt
signal to a linear 4-20 mA. You can run the 4-20 mA signal lines directly to
the control room and also power the transmitter electronics. There is no O2
display or keypad on the probe, so you must set up the transmitter through
HART® communications via a handheld communicator or via Asset
Management Solutions (AMS).
Procedure
1. Remove the cover from the probe.
2. Connect the line (L1 wire) to the L1 terminal, the netural (L2 wire) to
the L2/N terminal, and the ground wire to the ground lug.
The transmitter accepts 120/240 Vac ±10% line voltage and 50/60
Hz. No setup is required.
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Figure 1-7: Rosemount 6888A Standard Probe Housing
3. Connect the 4-20 mA signal wires at the transmitter. Use a shielded
twisted wire pair.
Do not allow bare shield wires to contact the circuit boards. Insulate
the shield wires prior to termination. The transmitter electronics are
loop-powered, i.e., the 4-20 mA signal wires supply 24 Vdc from the
DCS or an external power supply.
4. Terminate the shield only at the transmitter electronics housing
unless using a Rosemount 6888 Xi. When using the Rosemount 6888
Xi Advanced Electronics, terminate the shield at both ends.
NOTICE
The 4-20 mA signal represents the O2 value and also powers the
probe-mounted electronics. Superimposed on the 4-20 mA signal is
HART information accessible through a Field Communicator or AMS
software.
5. Reinstall cover on transmitter.
6. Follow the remaining electrical instructions only if the Rosemount
6888 Xi is included with your system configuration.
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1.2.2 Wire standard housing transmitter probe plus Rosemount™ 6888 Xi
Electronics
The Rosemount 6888 Xi Electronics serve as an operator interface unit with a
back-lit display and keypad. It is capable of two channels, serving two
Rosemount 6888 probes.
Procedure
1. Remove cover screws from the front cover of the Rosemount 6888
Xi. Swing down the front cover of the interface box.
2. Pull out the I/O board on the right side of the card rack inside the
Rosemount 6888Xi.
If your system is configured to operate two transmitter probes, there
are two I/O interface boards. See Figure 1-8.
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Figure 1-8: Wiring Diagrams - Single/Dual Channel Wiring
Diagram
Note
A. Except for JP5, JP2, and JP8 on IO board, jumper and switch
settings are factory set and are shown for reference only.
B. IO board 4-20 mA/HART loop power settings:
JP5: Pins 1-2 internal power Rosemount 6888Xi to Rosemount
6888 transmitter, pins 2-3 external power Rosemount 6888Xi to
Rosemount 6888 transmitter (requires 2500 resistor across J4, PR
+ to PR-)
JP7/JP8: Pins 1-2 internal power Rosemount 6888Xi to DCS, pins
2-3 external power Rosemount 6888Xi to DCS.
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Figure 1-9: Rosemount 6888 Xi Front and Bottom View
A. Power supply board
B. Channel #2 IO board
C. Shield ground
D. Channel #1 IO board
E. AC input to P/S
F. Plug
G. Channel #2 alarm relay, SPS/IMPS
H. Channel #2 4-20 mA/HART® output
I. Channel #1 alarm relay SPS/IMPS
J. Channel #1 4-20 mA/HART output
3. 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.
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NOTICE
Installation of the ferrite clamp over the 4-20 mA out wires is
required for the compliance with the European EMC directive.
4. Terminate the shield of the 4-20 mA signal wires at the designated
ground terminal of the Rosemount 6888 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 Rosemount SPS or Rosemount
IMPS (if used) to the applicable terminals of J3.
Refer to the Rosemount SPS 4001B or Rosemount IMPS 4000
reference manual for wiring details.
6. Reinstall the I/O board in the card rack of the Rosemount 6888 Xi.
7. If your system is configured or two channel operation, repeat Step 2
through Step 6 to connect the other probe's signal wires.
8. Remove the probe's connector from the power supply board located
on the left side of the card rack inside the Rosemount 6888Xi.
9. Connect the line, or L1, wire to the L1 terminal and the neutral, or L2,
wire to the N terminal.
10. Reinstall the power supply connector in the power supply board.
1.2.3 Wire transmitter probe with integral autocal and HART®
communications
You can initiate calibration 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. You can only implement the integral autocal feature when using the
probe with the Rosemount 6888 Xi.
Procedure
1. Remove the two covers from the transmitter.
2. Connect the line (L1 wire) to the L1 terminal, the neutral (L2) wire to
the L2/N terminal, and the ground wire to the ground lug.
The Rosemount 6888A accepts line voltage at 120/240 Vac ±10%,
50/60 Hz. No setup is required.
3. Connect the 4-20 mA signal wires form the Rosemount 6888 Xi to
the connections in the side chamber of the transmitter.
Do not connect the signal wires to the terminals in the main chamber
where the AC input wires are connected. Use a shielded twisted wire
pair. Do not allow bare shield wires to contact the circuit boards.
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Insulate the shield wires prior to termination. The 24 Vdc loop power
is sourced from the Rosemount 6888 Xi.
4. Terminate the shield at both the probe and the Rosemount 6888 Xi
Advanced Electronics.
NOTICE
The 4-20 mA signal represents the O2 value and also powers the
probe-mounted electronics. Superimposed on the 4-20 mA signal is
HART information accessible through a Field Communicator or AMS
software.
5. Reinstall both covers on transmitter.
6. Follow the remaining electrical installation instructions for the
Rosemount 6888 Xi included with your system configuration.
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Figure 1-10: Integral Autocal and HART Communications
A. Ferrite clamp
B. Signal
C. Test points
D. #8 pan htd scr (internal ground)
E. Power
F. Test point group
Note
A. Except for JP5, JP7, and JP8 on IO board, jumper and switch settings are factory set and are
shown for reference only.
B. IO board: 4-20 mA/HART loop power settings
•JP5
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