Endress+Hauser SpectraSensors OXY5500 User manual

Products Solutions Services
BA02195C/66/EN/01.21
Valid as of version
SSI v1.4.1.0521
(Device firmware)
Operating Instruction
OXY5500 Optical Oxygen Analyzer
ATEX/IECEx/UKEX: Zone 2
cCSAus: Class I, Division 2/Zone 2

Copyright © 2021 Endress+Hauser, Inc. No part of this manual may be reproduced in
whole or in part without the express written permission of Endress+Hauser, Inc.
Endress+Hauser reserves the right to change product design and specifications at any
time without prior notice.

Endress+Hauser i
TABLE OF CONTENTS
1: Introduction
Associated documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Who Should Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Equipment labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Instructional symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Documents Provided with the OXY5500 Analyzer . . . . . . . . . . . . . . . . . . . . . . . 1-4
Manufacturer Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
About the OXY5500 Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cross-sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Getting Familiar with the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Oxygen probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Schematic drawing for the oxygen probe . . . . . . . . . . . . . . . . . . . . . . . . 1-7
How an oxygen sensor works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2: Safety
Potential Risks Affecting Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mitigating risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Electrocution hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Explosion hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Electrostatic discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3: Installation
Shipping Box Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Inspecting the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lifting/carrying the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installing the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Required Basic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hardware and Tools for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Analyzer Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Mounting the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connecting Electrical Power to the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
AC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Protective chassis and ground connections . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Connecting electrical power to the analyzer . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Analyzer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Analog Outputs/Analog Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Connecting the analog outputs/analog inputs . . . . . . . . . . . . . . . . . . . . . . . 3-9
4: Operation
Starting Up the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Measurement Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Measurement Settings (Meas. Settings) Menu . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
To enter editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
To exit editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Device Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

OXY5500 Optical Oxygen Analyzer BA02195C
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Sensor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Digitals Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
To enter editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
To exit the editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Analog Output Settings (Analogues) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
To enter editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
To exit editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Measurement Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Simple screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Details screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Graph screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Measurement Settings (Meas. Settings) Menu Options . . . . . . . . . . . . . . . . . . 4-19
Temperature compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Setting the temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Pressure compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Setting the pressure compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Setting the interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Logging and data management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Device Settings Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Device settings screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Setting the Forced Zero mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Forced Zero mode definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
About screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Sensor details screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Sensor Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Change parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
To enter editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
To exit editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Changing the sensor type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
To manually change the sensor constants values . . . . . . . . . . . . . . . . . . . . 4-32
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Setting calibration pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Setting calibration temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Calibrating the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Equipment and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Calibration gas connections to the OXY5500 analyzer . . . . . . . . . . . . . . 4-38
Connecting the gas inlet for analyzers without the sample conditioning
system (SCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Connecting the gas inlet for analyzers with Endress+Hauser’s sample
conditioning system (SCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Purging the cylinder pressure regulators and analyzer . . . . . . . . . . . . . . . . 4-39
Performing a manual calibration (calibration using sensor values) . . . . . . . . 4-40
Performing a two-point calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
To enter editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
To exit editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Performing pre-calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Setting the first calibration point Cal0. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Setting the second calibration point Cal2nd . . . . . . . . . . . . . . . . . . . . . . . 4-45
Saving the calibration values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Relative accuracy test audit (RATA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Setting RATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
To enter editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
To exit editing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Setting the pressure for RATA calculation . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Setting the temperature for RATA calculation . . . . . . . . . . . . . . . . . . . . . . 4-48
Setting RATA reference values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Setting new RATA mult. manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

BA02195C OXY5500 Optical Oxygen Analyzer
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Digitals Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
RS-232 settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
RS-485 settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
TCP/IP settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Analog Output Settings (Analogues) Menu Options . . . . . . . . . . . . . . . . . . . . . 4-53
4-20mA interface settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
4-20mA values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Concentration alarm relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4-20mA calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Calibrating the output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Calibrating the input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
5: Modbus Communication
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Protocol Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Function codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Data formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Int32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Character . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Boolean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Error response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Different communication channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Holding Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Measurement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Compensation temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Measurement interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Device ID RS-485, RS-232 and Ethernet. . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Measurement values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
4-20mA port1 calibration values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
4-20mA port2 calibration values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
4-20mA input calibration values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Analog input and output value ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Ethernet IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Ethernet subnet mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Configuration of a continuous measurement . . . . . . . . . . . . . . . . . . . . . . . 5-18
Configuration of an analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
1-Point calibration of an OP-9 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Appendix A: Specifications
Technical Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Appendix B: Troubleshooting & Maintenance
Optical Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Cleaning the Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
SMA-fiber connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Oxygen probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Tools and materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Cleaning the oxygen probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Temperature Probe Lifespan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Replacing the fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Replacing the Electro-Optical Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

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Required tools and hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Removing the electro-optical module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Replacing the electro-optical module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Installing/Replacing the Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Removing the pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Installing the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Removing and Replacing the Oxygen Probe . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Tools/parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Removing the oxygen probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Installing the new oxygen probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14
Correcting Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16
High signal strength: Low O2 or no O2 on OP-3, OP-6 or OP-9 probe . . . . . . B-16
Low signal strength: High O2 on OP-3, OP-6 or OP-9 probe . . . . . . . . . . . . B-16
Recommendations for Correct Measurement . . . . . . . . . . . . . . . . . . . . . . . . . B-16
Signal drifts due to oxygen gradients . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17
Signal drifts due to temperature gradients . . . . . . . . . . . . . . . . . . . . . . . . B-17
Signal drift due to photo-decomposition . . . . . . . . . . . . . . . . . . . . . . . . . . B-17
Performance Improvement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19
Before contacting Tech Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19
Service repair order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19
Renewity returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19
Packing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20
Preparing the analyzer for shipment or storage . . . . . . . . . . . . . . . . . . . . . B-20
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Endress+Hauser 1–1
1 - INTRODUCTION
Endress+Hauser’s OXY5500 Optical Oxygen Analyzer is a stand-alone device
designed to detect oxygen in gases such as natural gas and air. Its design is
based on fluorescence quenching technology that creates very stable,
internally referenced measured values.
Associated documents
Enclosed in your analyzer system order is the product Safety Instruction for
your reference. Please review all necessary safety instructions before installing
or operating your analyzer. This document is an integral part of the complete
document package, which is listed in the following table.
For additional instruction manuals, please refer to the following:
• For custom orders:
•Refer to the Endress+Hauser website (https://endress.com/contact)
for the list of local sales channels to request order-specific
documentation.1
• For standard orders:
•Refer to the Endress+Hauser website product page to download the
published manuals for the analyzer: www.endress.com
Part Number Document Type Description
BA02195C Operating Instruction Provides a comprehensive overview of
the analyzer and step-by-step installa-
tion instructions
BA02196C Sample Conditioning
System (SCS) Oper-
ating Instruction
Commission, operation and maintenance
details for the Sample Conditioning Sys-
tem
SD02868C Service Software
Instruction
Instructions for operating the OXY5500
Service software to diagnose and main-
tain OXY5500 Optical Oxygen Analyzer
systems
TI01656C Technical Information Provides technical data on the device
with an overview of associated models
available
XA02754C Safety Instruction Safety Instructions for the OXY5500
Optical Oxygen Analyzer
1. Order-specific documentation is located by analyzer serial number (SN).

OXY5500 Optical Oxygen Analyzer BA02195C
1–2 Endress+Hauser
Who Should Read This Manual
This manual should be read and referenced by anyone installing, operating or
having direct contact with the analyzer.
How to Use This Manual
Take a moment to familiarize yourself with the content included in this
Operating Instruction by reviewing the "Table of Contents".
There are a number of options and accessories available for the OXY5500
analyzers. This manual has been written to address the most common options
and accessories. Images, tables and charts have been included to provide a
visual understanding of the analyzer and its functions. Special symbols are also
shown to provide the user with key information regarding the system
configuration and/or operation. Pay close attention to this information.
Conventions used in this manual
In addition to the symbols and instructional information, this manual is created
with “hot links” to enable the user to quickly navigate between different
sections within the manual. These links include table, figure and section
references and are identified by a pointing finger cursor when rolling
over the text. Simply click on the link to navigate to the associated reference.
General warnings and cautions
Instructional icons are provided in this manual to alert the user of potential
hazards, important information and valuable tips. Following are the symbols
and associated warning and caution types to observe when servicing the
analyzer.
Equipment labels
Failure to follow all directions may result in damage or
malfunction of the analyzer.
Follow instructions to avoid
possible explosion.
Follow instructions to avoid
electrostatic discharge.
WARNING - DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE
MAY BE PRESENT.
______________________________________________________
AVERTISSEMENT - NE PAS OUVRIR SI UNE ATMOSPHERE
EXPLOSIVE PEUT ETRE PRESENTE
WARNING - POTENTIAL ELECTROSTATIC CHARGING HAZARD –
SEE INSTRUCTIONS
______________________________________________________
AVERTISSEMENT - DANGER DE CHARGE ELECTROSTATIQUE
POTENTIELS - VOIR LES INSTRUCTIONS

BA02195C OXY5500 Optical Oxygen Analyzer
Endress+Hauser 1–3
Use appropriate tools to avoid
electrostatic discharge.
Substitution of components may
void certification.
Switch off power before replacing
components to avoid explosion
risk.
Switch off power before
disconnecting system to avoid
explosion risk.
Ensure grounding wire is
connected at all times during
operation.
WARNING - USE DAMP CLOTH TO CLEAN DISPLAY AND KEYPAD
TO AVOID STATIC ELECTRICITY DISCHARGE.
______________________________________________________
AVERTISSEMENT - AUX CHARGES ELECTROSTATIQUES.
UTILISER UN CHIFFON HUMIDE POUR NETTOYER L’AFFICHEUR
ET LE CLAVIER.
WARNING - EXPLOSION HAZARD – SUBSTITUTION OF COMPO-
NENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2 OR
ZONE 2
______________________________________________________
AVERTISSEMENT - RISQUE D'EXPLOSION – LA SUBSTITUTIOND
E COMPOSANTSP EUTR ENDRE CE MATERIEL INACCEPTABLE
POUR LES EMPLACEMENTS DE CLASSE I, DIVISION 2 ou ZONE 2
WARNING - EXPLOSION HAZARD - DO NOT REPLACE ________
UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS
KNOWN TO BE NON-HAZARDOUS
______________________________________________________
AVERTISSEMENT - RISQUE D'EXPLOSION - COUPER LE
COURANT OU S'ASSURER QUE L'EMPLACEMENT EST DESIGNE
NON DANGEREUX AVANT DE REMPLACER LE ______
WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIP-
MENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE
AREA IS KNOWN TO BE NON-HAZARDOUS
______________________________________________________
AVERTISSEMENT - RISQUE D'EXPLOSION - AVANT DE
DECONNECTER L'EQUIPEMENT, COUPER LE COURANT OU
S'ASSURER QUE L'EMPLACEMENT EST DESIGNE NON
DANGEREUX
CAUTION: DO NOT OPERATE MACHINE WITH GROUNDING WIRE
DISCONNECTED
_______________________________________________________
ATTENTION: NE PAS METTRE L'APPAREIL EN MARCHE QUAND
LE CON DUCTEUR DE MISE A LA TERRE EST DEBRANCHE.

OXY5500 Optical Oxygen Analyzer BA02195C
1–4 Endress+Hauser
Instructional symbols
Documents Provided with the OXY5500 Analyzer
Each OXY5500 analyzer shipped from the factory is packaged with documents
and software that are to be used for system operation, as applicable to the
system configuration. Typically, each shipment includes the following
documents:
•Operating Instruction (electronic copy)
•Sample Conditioning System (SCS) Operating Instruction
(electronic copy)
•OXY5500 Service Software Operating Instruction (electronic copy)
(and software)
•OXY5500 Safety Instruction (paper copy)
•Calibration Certificate (paper copy)
Manufacturer Address
Endress+Hauser
11027 Arrow Route
Rancho Cucamonga, CA 91730
United States
www.endress.com
General notes and important information concerning the
installation and operation of the analyzer.
Failure to follow all directions may result in damage or
malfunction of the analyzer.
Warning statement for hazardous voltage. Contact may cause
electric shock or burn. Turn off and lock out system before
servicing.
Maximum voltage and current specifications for fuses.

BA02195C OXY5500 Optical Oxygen Analyzer
Endress+Hauser 1–5
About the OXY5500 Analyzer
The OXY5500 is a stand-alone precision oxygen analyzer enclosed in an ingress
protected stainless steel case. The rugged design and low power consumption
makes the OXY5500 ready for an indoor or outdoor application in Class I,
Division 2, Groups A, B, C and D, T4. In addition, the analyzer is also marked
as II 3 G Ex nA IIC T3 Gc IP64.
The OXY5500 is designed for three types of measurement ranges: 0 to 300
ppmv, 0 to 5% O2 and 0 to 50% O2. This analyzer was specifically designed for
gas measurements using a flow through fiber-optic oxygen sensor mounted in
a 1/4 in. compression tee. The instrument LCD and data-logger are integrated
into the system. The analog outputs are programmable to provide data for
oxygen and temperature. The digital interface and PC software (included) are
used for internal data storage and external data logging. Complete control,
including all calibration and adjustments, can be completed through the PC.
Temperature
Endress+Hauser’s optical oxygen sensors must be used with an RTD probe
(Pt100 temperature sensor) in the temperature ranges shown in Table A–1 on
page A–1. Each instrument is supplied with the RTD probe for compensation
and to record temperature variations.
Cross-sensitivity
The sensors can be used in methanol- and ethanol-water mixtures, as well as
in pure methanol and ethanol.
Endress+Hauser recommends avoiding other organic solvents, such as
acetone, chloroform or methylene chloride, which may swell the sensor matrix,
rendering it unusable.
There are no cross-sensitivity issues with CO2, H2S or SO2 (iconic species)
pertaining to any of the three probe types.
Getting Familiar with the Analyzer
Figure 1–1 shows a sample OXY5500 analyzer. Signal wiring and analyzer
power are connected from the right side of the analyzer (facing the unit). On
the front panel of the analyzer, the LCD serves as the user interface to the
analyzer. The analyzer control electronics drive the sensor, collect the signal
and provide measurement output signals.
Inside the cabinet is the electro-optical module that provides power and other
connections to the analyzer. Refer to Figure 1–2 for an internal view of the
analyzer.
The optional sample conditioning system (SCS) contains flow devices for the
bypass loop and to control the flow to the oxygen sensor. A pressure reducing
device is also installed to reduce and control the pressure of the sample going

OXY5500 Optical Oxygen Analyzer BA02195C
1–6 Endress+Hauser
to the oxygen sensor. Depending on the application and/or ambient conditions,
the SCS may also contain a heater and thermostat to maintain the interior of
an optional enclosure at a constant temperature. Refer to the Sample
Conditioning System (SCS) Operating Instruction for more information.
Oxygen probe
The oxygen sensor consists of a polymer optical fiber (POF) with a polished
distal tip that is coated with a planar oxygen-sensitive foil. The end of the
polymer optical fiber is covered with a high-grade steel tube to protect both the
sensor material and the POF. Refer to Figure 1–3. Typically, the fiber is coated
with an optical isolated sensor material in order to exclude ambient light from
the fiber sensor spot.
Schematic drawing for the oxygen probe
Refer to Figure 1–4 for a schematic of the trace oxygen probe.
Figure 1–1 OXY5500 analyzer
KEYPAD
RTD PROBE (pt100)
CHASSIS GROUND STUD
GRAPHIC DISPLAY
ANALYZER POWER PORT
SIGNAL WIRING
PORT
PRESSURE SENSOR (OPTIONAL)
OXYGEN PROBE
Figure 1–4 Trace oxygen probe schematic
SENSOR SPOT OXYGEN FIBER ASSEMBLY SMA CONNECTOR
STEEL TUBE

BA02195C OXY5500 Optical Oxygen Analyzer
Endress+Hauser 1–7
Figure 1–2 Inside cabinet view (AC version)
PROTECTIVE EARTH
GROUND
ELECTRO-OPTICAL
MODULE RJ-45 AND USB
CONNECTORS
OPTICAL MODULE
WITH SMA CONNECTOR
RELAYS
AC/DC POWER
CONNECTION
FUSE ENCLOSURE
Figure 1–3 OXY5500 probe sensor spot
OP-3
OP-6
OP-9

OXY5500 Optical Oxygen Analyzer BA02195C
1–8 Endress+Hauser
Endress+Hauser’s fiber-optic oxygen sensors are made with 2 mm polymer
optical fibers. The sensing portion is a 4 mm stainless steel probe. As a
standard, the probe is mounted in a 1/4 in. Swagelok Union Tee using a 1/4 in.
x 4 mm adapter as shown in Figure 1–5. Please contact your sales
representative for more information.
How an oxygen sensor works
The principle of measurement is based on the effect of fluorescence quenching
by molecular oxygen.
Principle of fluorescence quenching by molecular oxygen (refer to Figure 1–6):
(1) Fluorescence process in absence of oxygen
– Absorption of light: Excitation energy from the analyzer to the
sensor spot.
– Excited state: Sensor spot becomes excited.
– Emission of light: In the absence of oxygen, the sensor spot
decays to original energy state. The light emitted during decay is
quantified by the analyzer.
(2) Fluorescence process in the presence of oxygen
– Absorption of light: The light from an LED is absorbed by the
sensor spot.
1/4 in. compression “tee” flow-
through fitting
4 mm oxygen dipping probe mounts in
the compression “tee”
Figure 1–5 Standard fiber-optic oxygen sensors
fittings

BA02195C OXY5500 Optical Oxygen Analyzer
Endress+Hauser 1–9
– Excited state: Sensor spot becomes excited.
– Emission of light: If the sensor encounters oxygen molecules, the
excess energy is transferred to the molecule, decreasing or
“quenching” the fluorescence signal. The degree of quenching
correlates to the oxygen partial pressure.
Safety Guidelines
All functions of this device has been carefully tested and comply with safety
requirements, prior to leaving the factory. The correct functional and
operational safety of this instrument can only be ensured if the user observes
the necessary safety precautions and specific guidelines presented in this
manual. Refer to Appendix A, Specifications, and the list outlined below.
•Before connecting the device to the electrical supply network, ensure
that the operating voltage stated on the power supply corresponds to
the main voltage input as described in Table A–1.
•If the instrument is moved from cold to warm surroundings,
condensation may form and interfere with the functioning of the
system. In this event, wait until the instrument temperature reaches
room temperature before putting the analyzer back into operation.
Please read these instructions and the OXY5500 Safety Manual
(P/N XA02754C) carefully before working with this instrument.
Figure 1–6 Principle of dynamic quenching of
luminescence by molecular oxygen
no emission of light
Energy transfer by collision
(1)
excited state emission of light
(2)
absorption of light

OXY5500 Optical Oxygen Analyzer BA02195C
1–10 Endress+Hauser
•Calibration, maintenance and repair work must only be completed by
qualified trained personnel.
•If there is any doubt as to the working condition of the analyzer,
return the instrument for repair and maintenance. Consult with
“Service” on page B-19.

Endress+Hauser 2–1
2 - SAFETY
Potential Risks Affecting Personnel
This section addresses the appropriate actions to undertake when faced with
hazardous situations before or during service of the analyzer. It is not possible
to list all potential hazards within this document. The user is responsible for
identifying and mitigating any potential hazards present when servicing the
analyzer.
Mitigating risks
Refer to the instructions for each situation listed below to mitigate associated
risks.
Electrocution hazard
1. Shut off power at the main disconnect external to the analyzer and
open the enclosure.
2. Open enclosure door.
Explosion hazard
Any work in a hazardous area must be carefully controlled to avoid creating any
possible ignition sources (e.g., heat, arcing, sparking, etc.). All tools must be
appropriate for the area and hazards present. Electrical connections must not
be made or broken with power on (to avoid arcing).
Electrostatic discharge
Use a damp cloth to clean the display and keypad to avoid static electricity
discharge.
Technicians are expected to follow all safety protocols established
by the customer that are necessary for servicing the analyzer.
These may include, but are not limited to, lockout/tag-out
procedures, toxic gas monitoring protocols, personal protective
equipment (PPE) requirements, hot work permits and other
precautions that address safety concerns related to performing
service on process equipment located in hazardous areas.
Complete this action before performing any service that requires
working near the main input power or disconnecting any wiring or
other electrical components.

OXY5500 Optical Oxygen Analyzer BA02163C
2–2 Endress+Hauser
Adhere to all warning labels to prevent damage to the unit. Refer to “General
warnings and cautions” on page 1-2.

Endress+Hauser 3–1
3 - INSTALLATION
This section describes the processes used to install and setup your OXY5500
analyzer. Once the analyzer arrives, fully examine the contents before installing
the unit.
Shipping Box Contents
The contents of the crates should include:
•The Endress+Hauser OXY5500 analyzer
•Optional Sample Conditioning System (SCS), if applicable
•A USB flash drive or CD, which includes this manual and other system
manuals, calibration certificate and software. Refer to “Documents
Provided with the OXY5500 Analyzer” on page 1-4.
•One USB cable (for Service purposes)
If any of these contents are missing, refer to “Service” on page B-19.
Inspecting the Analyzer
Unpack and place the unit on a flat surface. Carefully inspect all enclosures for
dents, dings, or general damage. Inspect the supply and return connections for
damage, such as bent tubing. Report any damage to the carrier.
Each analyzer is custom configured with various accessories and options. If
there is any discrepancy with your order, please contact your local sales
channel. Refer to “Service” on page B-19.
Endress+Hauser Class I Division 2 analyzers use a non-incendive
protection method and Zone 2 uses a non-arcing protection method; as
such, all portions of the local electrical installation codes apply. The
maximum allowed inductance to resistance ratio (L/R ratio) for the field
wiring interface must be less than 25 μH/Ω.
The safety of the analyzer is the responsibility of the installer and
the organization he/she represents.
Avoid jolting the instrument by dropping it or banging it against a
hard surface.

OXY5500 Optical Oxygen Analyzer BA02195C
3–2 Endress+Hauser
Lifting/carrying the analyzer
At approximately 5.44 Kg (12 lbs) without the sample conditioning system, the
OXY5500 can easily be lifted from the packaging and moved to the installation
location. Take care to lift or carry the analyzer by the enclosure and not by any
ancillary probes or cables or damage may occur.
If the analyzer is configured with an optional integrated sample conditioning
system (SCS), two individuals may be required to lift and move the analyzer
system. Refer to the OXY5500 SCS Operating Instruction (P/N BA02196C) for
more information.
Installing the Analyzer
Installing the analyzer is relatively easy requiring only a few steps that, when
carefully followed, will ensure proper mounting and connection. This section
includes information regarding:
•Hardware and Tools for Installation
•Analyzer Mounting
•Connecting Electrical Power to the Analyzer
•Analog Outputs/Analog Input Connections
Required Basic Equipment
The following components are shipped with the OXY5500 analyzer from the
factory for installation and operation:
•Flow-through Tee fitting with probe
•Flow-through Tee fitting for temperature probe and pressure sensor
(pressure sensor is optional)
Hardware and Tools for Installation
Depending on the particular configuration of accessories and options ordered,
you may need the following hardware and tools to complete the installation
process.
Hardware:
•1/4 in. (~6 mm) thickness Unistrut® (or equivalent) bolts and spring
nuts
•Stainless steel tubing (using 1/4 in. [~6 mm] O.D. x 0.035 in. wall
thickness, seamless stainless steel tubing is recommended)
•3/4 in. conduit or appropriate Ex e M20 cable gland
•1/4 in. (M6) screws with an appropriate screw length for wall
material, e.g., concrete, drywall, etc.