comb manual im 106 6888qs

Quick Start Manual Model 6888IM-106-6888QS March 2012

General InformationThe 6888 is Rosemount Analytical’s latest combustion flue gas oxygen analyzer. This product is intended for measuring the flue gases resulting fromany combustion process. It utilizes the same heatedsensing technology as the O2 sensors found in most automobiles. Contact Rosemount Analytical’s technicalsupport group at 800-433-6076 for any applicationsother than measuring combustion flue (exhaust) gases.

This product utilizes an “in situ” sensor, i.e. the sensor is placed at the end of a probe, and the probe extendsdirectly into the flue gas duct or stack a given length. Thesensor is like a thermocouple, generating it’s own millivoltsignal based on the difference between a reference gas(ambient or instrument air – always 20.95% O2), and theflue gases being measured. The probe has a transmittercircuit card inside that controls an internal cell heater, andalso converts the raw millivolt signal into a linear 4-20mAsignal. This comprises a simple Oxygen analyzing system,and one can set up and operate this system via HART®

communications. If this probe is a “direct replacement”version, and will operate from a pre-existing electronics,go to the traditional architecture link.

An optional Xi electronics provides convenient operatorinterface for set-up , calibration, and diagnostics. HARTcommunications is still present when using the Xi.

System ArchitecturesProbe Only – The 6888 probe has the electronics inthe blue housing that controls the heater temperature,and also amplifies the raw O2 millivolt signal to a linear4-20 mA. The 4-20 mA signal lines can be run directlyto the control room, and also power the transmitterelectronics. There is no O2 display or keypad on theprobe, so set-up must be conducted through HARTcommunications via a 475 handheld communicator, orvia Asset Management Solutions (AMS).

Probe plus Xi electronics – The Xi electronics serve asan operator interface unit, with a back-lit display andkeypad. It is capable of two channels, serving two 6888probes. The Xi also carries these advanced features:

- Fully automatic calibration. Requires XS02Cal Auto calibration system.

- Loss-of flame contact for powering down theheater in the event of a flame-out condition in afurnace.

- Extended process temperature capability. Theprobe heater can be un-powered above 550°Cprocess temperatures, and the O2 will be calculatedbased upon the process temperature, up to 825°C.

- Plugged diffuser diagnostic – part of the calibra-tion procedure, this alarm detects an extended“return to process” response time.

- Stoichiometer – If a furnace goes into a reducingcondition (zero % O2), this feature will determine how far.

- Programmable reference – Permits more accuratereadings at near-ambient O2 levels (20.95% O2).

Traditional Architecture –Here there are no elec-tronics inside the probe head, so the raw sensor signalsfor the heater thermocouple and zirconium oxide O2

sensor are sent to a remote Xi Electronics. The Xi elec-tronics will also directly apply power to the probeheater in order to maintain the correct sensor temper-ature. This arrangement calls for a 7- conductor cableto carry this power and the sensor signals. Maximumlength for this cable is 200 feet.

Wireless Capability – It should be noted that both thetransmitter electronics in the head of the probe andthe Xi electronics communicate over HART communi-cations, and can implement wireless communicationsvia our Smart Wireless THUM adapter.

Combustion O2 AnalyzerFor additional information, please visit RosemountAnalytical.com


Figure 1. Typical System Package

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Technical Support Hotline:For assistance with technical problems, please call the Customer Support Center (CSC).

Phone: 1-800-433-6076 1-440-914-1261

In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Emerson Process Management’sfield service throughout the U.S. and abroad.

Phone: 1-800-654-RSMT (1-800-654-7768)

Emerson Process Management may also be reached via the Internet through e-mail and the World Wide Web:

e-mail: [email protected]

World Wide Web: www.raihome.com

Optional 6888Xi Advanced Electronics

Quick StartManual

Full InstructionManual DVD

6888A Probe

Optional TraditionalArchitecture Cable

Optional Mountingor Adapter Plate

Optional Reference& Calibration GasAccessories


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Model 6888A Product Matrix

Compare the configuration matrix below to the model number on the probe tag to confirm the features present in thisspecific probe.

6888A O2 Transmitter

Code Measurement1OXY Oxygen, Standard Sensing Cell2OXY Oxygen, Acid Resistant Stochiometric Sensing Cell

Code Diffuser1 Snubber (500°C)2 Ceramic (825°C)3 Haselloy (700°C)

Code Housing & Electronics1HT Standard Housing, Transmitter Electronics, HART5DR Standard Housing, Direct Replacement, No Electronics

6DRY Standard Housing, Direct Replacement, YEW Electronics

Code Manual Calibration Accessories00 None01 Calibration & Reference Gas Flowmeters & Reference Regulator/Filter02 Calibration/Reference Panel

Code Probe Length*1 18" Probe, Standard Probe Tube2 18" Probe, Standard Probe Tube with Abrasive Shield3 18" Probe, Abrasion Resistant Probe Tube4 3' Probe, Standard Probe Tube5 3' Probe, Standard Probe Tube with Abrasive Shield6 3' Probe, Abrasion Resistant Probe Tube7 6' Probe, Standard Probe Tube8 6' Probe, Standard Probe Tube with Abrasive Shield9 6' Probe, Abrasion Resistant Probe TubeA 9' Probe, Abrasion Resistant Probe TubeB 12' Probe, Abrasion Resistant Probe Tube

Code Mounting Plate00 None04 New Installation - Square Weld Plate with ANSI 2" - 150# Studs & Flange05 New Installation - Square Weld Plate with DIN Studs & Flange06 New Installation - Variable Insertion Mount; Abrasion Resistant Probe Only

07 New Installation - Variable Insertion Mount; Mounted to Existing OXT/WC Abrasive ShieldMounts; Abrasion Resistant Probe Only

08 Adapter to Existing ANSI 3", 150# Flange09 Adapter to Existing ANSI 4", 150# Flange10 Adapter to Existing ANSI 6", 150# Flange11 Adapter to Existing ANSI 3", 300# Flange12 Adapter to Existing ANSI 4", 300# Flange99 Special Adapter

* Probes supplied with flanges with dual ANSI/DIN hole pattern. See Figure 3 for details.


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Model 6888Xi Product Matrix6888Xi Advanced Electronics

Code Remote Type1OXY Single Channel O2

2OXY Single Channel O2 with Flame Safety Interlock for Heater3OXY Dual Channel O2

4OXY Single Channel O2, Traditional Architecture for 120V Probes

Code Cable00 No Cable10 20' (6m) Cable11 40' (12m) Cable12 60' (18m) Cable13 80' (24m) Cable14 100' (30m) Cable15 150' (45m) Cable16 200' (60m) Cable

Code Stoichiometer Function00 No01 Single Channel02 Dual Channel

Code Extended Temperature Function00 None01 Single Channel02 Dual Channel

Code Plugged Diffuser Diagnostic Function00 None01 Single Channel02 Dual Channel

Code Mounting00 No Hardware01 Panel Mount Kit with Gasket02 2" Pipe / Wall Mount Kit

Code Programmable Reference Function00 None01 Single Channel02 Dual Channel


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SpecificationsTransmitter/DR Probe Measurement SpecificationsNet O2 Range: 0 to 50% O2 user scalable, -2 to 50% O2

user scalable with stoichiometer

Accuracy in Oxidizing Conditions: ±0.75% of readingor 0.05% O2 whichever is greater

Lowest Detectable Limit: 0.01% O2

Signal Stability: ±0.03% O2

Process Temperature Effect: less than 0.05% O2 from100° to 700°C (212° to 1292°F)

System Speed of Response to Calibration Gas: Initialresponse in less than 3 seconds T∞ in less than 8 secondsResponse to process gas changes will vary depending onvelocity and particulate loading of the diffuser

Calibration Validity: Presentation of calibration gasesmatches the normal process to within ±0.02% O2

Accuracy in Reducing Conditions: ±10% of reading or0.1% O2

System Response in Reducing Conditions:going from oxidizing to reducing -T90 in 120 secondsgoing from reducing to oxidizing -T90 in 30 seconds

Ambient Temperature Effect on Transmitter 4-20mA Signal: less than 0.005% O2 per degree Celsius

Environmental SpecificationsTransmitter Probe: Process-wetted materials are 316Lor 304 Stainless

Process Temperature Limits: 0° to 800°C (32° to1472°F), 0° to 705°C (32° to 1300°F)550° to 825°C (1022° to 1517°F)* with Xi “heaterlessoperation” feature*Reduced cell life can be expected if operatedcontinuously at temperatures above 705°C (1300°F)[optional bypass and jacket accessories permitoperation to 1050°C (1922°F)]

Transmitter Electronics Housing: Low copperaluminum Type 4X/IP66, with reference air exhaustport piped to clean, dry area

Ambient Temperature Limits:-40° to 70°C (-40° to 158°F), Transmitter-40° to 85°C (-40° to 185°F) as measured by electronics-40° to 90°C (-40° to 194°F), DR Probe

Process Mounting Temperature:200°C (392°F)Maximum

General Purpose Certifications:

Installation SpecificationsProbe Mounting: Flanged, ANSI/DIN, Non-PressureRatedVertical or Horizontal

Probe Lengths and Approximate Shipping Weights:

18 in (457 mm) 25 lbs. (11,3 Kg)3 ft (0,91 m) 27 lbs. (12,2 Kg)6 ft (1,83 m) 38 lbs. (17,2 Kg)9 ft (2,74 m) 70 lbs. (31,8 kg)12 ft (3,66 m) 91 lbs. (41,3 kg)15 ft (4,57 m) 111 lbs. (50,3 kg)18 ft (5,49 m) 132 lbs. (59,9 kg)

Reference Air: 2 scfh (1 l/min), clean, dry, instrument-quality air (20.95% O2), regulated to 5 psi (34 kPa) optional but recommended 9ft and longer

Calibration: Semi-automatic or automatic

Cal Gases: 0.4% O2 and 8% O2, balance N2

Calibration Gas Line: 300ft. (91 m) maximum length

Calibration Gas Flow: 5 scfh (2.5l/min) @ 25 psi (172.4 kPa).

Heater Electrical Power: 120/240 VAC ±10%, 50/60Hz, 260/1020 VA max, 1/2 in. - 14NPT conduit ports

4-20mA/HART Loop Power: 12-30 VDC (Loop powerfrom control room or 6888Xi)


Specifications 6888XiMeasurement SpecificationsNet 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 or0.1% O2

System Response in Reducing Conditions goingfrom oxidizing to reducing -T90 in 120 seconds, goingfrom 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 SpecificationsXi Advanced Electronics: Type 4X/IP66, Polycar-bonate Material

Ambient Temperature Limits: -20°C to 50°C (-4°F to122°F), -20°C to 70°C (-4°F to 158°F) as measured byelectronics

Xi LCD display:Ambient Temperature Limits: -20°C to 55°C (-4°F to 131°F)

General Purpose Certifications:

Installation SpecificationsMounting: Panel, wall, or pipe.

Reference Air: 2 scfh (1 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

4-20mA/HART Loop Power: 12 - 36 VDC (internal nominal 24 VDC or external from control room.)

Electrical Power for Xi: 120/240VAC ±10%, 50/60 Hz

Power Consumption of Xi: 12 VA maximum or 1020VA maximum with Traditional Architecture, 120VProbes

Alarm Relay Outputs: Two provided - 2 Amperes, 30VDC, Form-C

Optional Loss of Flame Input: Internally poweredinput to remove heater power actuated via dry contactoutput from user’s burner management system.

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Installation

Mechanical installationNote that most combustion processes run only slightly negative or positive in pressure, so this flange is for mechanicalmounting, only. The probe is not rated for high pressures. If this is a new installation, a “weld plate” for welding to theflue gas duct can be supplied.

If an existing flange mount exists, the probe can mount to this. Many mounting adaptors are available for use withother existing flanges that may be larger.

Installation may be either horizontal or vertical.

6888A Probe Installation1. Ensure all components are available to install the 6888A O2 probe. Refer to Figure 1.

2. If using the optional ceramic diffusion element, the vee deflector must be correctly oriented. Before inserting the 6888A probe, check the direction of gas flow in the duct. Orient the vee deflector so the apex points upstreamtoward the flow. See Figure 2.

3. If using the standard square weld plate or an optional flange mounting plate (Figure 3) weld or bolt the plate onto theduct. The through hole diameter in the stack or duct wall and refractory material must be at least 2-1/2 in. (63.5 mm).

4. Insert probe through the opening in the mounting flange and bolt the unit to the flange.

CAUTION

If the ducts will be washed down during outage MAKE SURE to power down the probes and remove them from the wash area.

Figure 2. Orienting the Optional Vee Deflector

WARNINGInstall all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads couldresult in serious injury or death.

WARNINGThe X-STREAM O2 Transmitter can be installed in general purpose areas only. Do not install the transmitter or Xi in hazardousareas or in the vicinity of flammable liquids.


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spa on

D

Adapte and 12

Installatio

Adapter platefor Oxymitter 4000Installation. SeeFigure 2-1.

4 studs,lockwashers andnuts equallyspaced onC Dia B.C.

A

A

2.500 Dia(63,5)

45o

C

B

Note: Dimensions arein inches withmillimeters inparentheses.

38890071

Table 3. Installation Weld Plate Outline

ANSI DIN

“A”6.00(153)

7.5(191)

“B”Thread

.625(11)

(M-16x2)

“C”Dia

4.75(121)

5.708(145)

Table 1. Mounting Flange

ANSI DIN

Flange Dia7.28(185)

Hold Dia.75(20)

(4) Holes Eq Spon BC

4.75(121)

5.71(145)

Figure 3. 6888A Probe Installation

Table 2. Removal/ Installation*

Probe LengthDIM “A” Insertion

DepthDIM “B” Removal

Envelope

18 IN. (457 mm)Probe 16.10 (409) 15.77 (401)

3 FT. (0.91 m) Probe 32.52 (826) 46.6 (1182)

6 FT. (1.83 m) Probe 68.52 (1740) 82.6 (2097)

9 FT. (2.74 m) Probe 104.52 (2655) 118.6 (3011)

12 FT. (3.66 m)Probe 140.52 (3569) 154.6 (3926)

* Add 3.80 (96) to DIM “A” and DIM “B” for probe with ceramicor Hastelloy� diffuser.


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Figure 4. Installation with Drip Loop and Insulation Removal


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6888Xi Advanced Electronics InstallationThe Xi Advanced Electronics is available in a panel mounting, wall mounting, or pipe mounting configuration. Refer toFigure 5 or Figure 6 for the panel, wall, or pipe mounting details.

1. Ensure all components are available to install the 6888Xi.

2. Select a mounting location near or removed from the O2 Probe. Consider the temperature limitations of the6888Xi (see "Specifications") when selecting the mounting location.

3. Mount the 6888Xi at a height convenient for viewing and operating the interface. Approximately 5 ft (1,5 m) isrecommended.

4. The keypad window on the 6888Xi may have interior and exterior protective membranes. Remove the protectivemembranes prior to use of the 6888Xi enclosure. Failure to remove the protective membranes may cause thedisplay to appear distorted. The membrane may be difficult or impossible to remove after extended use atelevated temperatures.


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Figure 5. Wall/Surface and Pipe Mount


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Figure 6. Panel Mount


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Electrical installationAll wiring must conform to local and national codes. Multiple wiring diagrams are shown in this section. Always refer tothe diagrams that apply to your transmitter configuration and disregard all other wiring diagrams.

WARNINGDisconnect and lock out power before connecting the power supply.

WARNINGInstall all protective covers and safety ground leads after installation. Failure to install covers and ground leads could resultin serious injury or death.

WARNINGTo meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, connection tothe main electrical power supply must be made through a circuit breaker (min 10A) which will disconnect all current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolatingswitch. If not, then another external means of disconnecting the supply from the equipment should be located close by.Circuit breakers or switches must comply with a recognized standard such as IEC 947.

Note:To maintain proper earth grounding ensure a positive connection exists between the transmitter housing and earth. The connectingground wire must be 14 AWG minimum..

Note:Line voltage, signal, and relay wiring must be rated for at least 105°C (221°F).

Note:If metal conduit is used with the 6888Xi the conduit should be reliably bonded to protective earth. The grounding plate inside the6888Xi is not bonded to PE and does not provide adequate grounding.

6888A Transmitter1. Remove the cover from transmitter.

2. Refer to Figures 8 and 9. Connect the line (L1 wire) to the L1 terminal, the neutral (L2 wire) to the L2/N terminal, and theground wire to the ground lug. The 6888A accepts 120/240 VAC ±10% line voltage and 50/60 Hz. No setup is required.

3. Connect the 4-20 mA signal wires at the transmitter. Use a shielded twisted wire pair. Do not allow bare shield wiresto contact the circuit boards. Insulate the shield wires prior to termination.

4. Terminate the shield only at the transmitter electronics housing unless using a 6888Xi. When using the 6888XiEnhanced Interface, terminate the shield at both ends.

NOTEThe 4-20 mA signal represents the O2 value and also powers the probe-mounted electronics. Superimposed on the 4-20 mA signalis HART information accessible through a Field Communicator or AMS software.

5. Reinstall cover on transmitter.

6. Follow the remaining electrical installation instructions only if the 6888Xi is included with your system configuration.


6888A Direct Replacement (DR) Probe A direct replacement probe is available for connection to an existing electronics package. Use the following procedureto connect a DR probe to the transmitter electronics.

1. Remove cover from probe.

2. Feed all DR probe wiring through the conduit port of probe.

3. Refer to figure 10. Connect DR probe heater power leads to DR probe connector.

4. Connect O2 signal and thermocouple wires to DR probe connector.

6888 Xi Advanced Electronics1.Remove cover screws from the front cover of the 6888Xi. 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 6888Xi. If your system is configured to operatetwo transmitter probes there are two I/O interface boards.

3.See Figures 8,9, and 10. Connect the 4-20 mA signal wires at J4 of the I/O board. Attach the supplied ferrite clampover the 4-20 mA OUT wires that extend past the shield.

NOTEInstallation of the ferrite clamp over the 4-20 mA OUT wires is required for compliance with the European EMC Directive.

4.Terminate the shield of the 4-20 mA signal wires at the designated ground terminal of the 6888Xi. Do not allow bareshield 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 customer’s alarm indicator devices to the alarm indicator relay terminals.

7.Reinstall the I/O board in the card rack of the 6888Xi.

8.If your system is configured for two channel operation, repeat steps 2 through 7 to connect the other signal wires.

9.Remove the connector from the power supply board located on the left-hand side of the card rack inside the 6888Xi.

10. Connect the line, or L1 wire to the L1 terminal and the neutral, or L2 wire, to the N terminal.

11. Reinstall the power supply connector in the power supply board.

Flame Safety InterlockA flame safety interlock by Emerson Process Management is available for heater power disconnect whenever there is aloss of the process flame or a heater runaway condition (heater over-temperature) in the O2 Probe. This input is internallypowered by the Xi and is actuated via a dry contact output from the user’s flame scanner. A closed contact indicates aflame is present. An open contact indicates a loss of flame.

1.Connect the signal wires from the burner management system flame status output to the flame status input terminalsof J2. The flame status sensing device is supplied by the customer. Refer to the applicable OEM documents for signalwiring details.

2. Remove the J1 and J2 connectors from the AC relay board.

3. Connect the AC line input to the J1 connector.

4. Connect the AC power to the 6888A probe to the J2 connector.

5. Reinstall connector J1 and J2 to the AC relay board.

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Traditional Architecture Cable ConnectionsA traditional architecture configuration is used to provide for remote location of the transmitter electronics. All electronics are housed inside the Xi. A multi-conductor power/signal cable connects between the probe and the Xi.Use the following procedure to connect the traditional architecture probe to the Xi.

NOTEThe Traditional Architecture cable is provided at the specified length and is ready for installation. The cable glands must be properlyterminated to maintain EMC/EMI noise protection.

1. Run the 7-conductor cable between the traditional architecture probe and the installation site for 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 6888Xi enclosure according to the following procedure:

a. Unscrew locking nut from gland assembly, Figure 7, and slide locking nut back along cable.

b. Pull the gland body away from the plastic insert. Use care not to damage the cable shield braid.

c.Insert the cable wires into the proper entry port in either the probe housing or the 6888Xi enclosure.

d. At the probe housing, apply Teflon tape or similar sealing compound to the tapered pipe threads. Thread the glandbody into the probe housing until properly seated.

e. At the 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 beevenly 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 insidethe plastic insert compresses against the cable wall to provide an environmental seal.

4. At the 6888Xi, connect the cable leads to the connectors on the transmitter I/O board as indicated in Figure 10.

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Figure 7. Traditional Architecture Cable Gland Assembly


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Figure 8. Single/Dual Channel Wiring Diagram


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Figure 8 cont. Single/Dual Channel Wiring Diagram

120/240 VAC


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Figure 9. Single Channel with Flame Safety Wiring Diagram


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Figure 9 cont. Single Channel with Flame Safety Wiring Diagram

120/240 VAC


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Figure 10. Traditional Architecture Wiring Diagram


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Figure 10 cont. Traditional Architecture Wiring Diagram

120/240/ VAC


Pneumatic InstallationReference Air PackageAfter the 6888 is installed, connect the reference air set to the 6888 unit. Refer to the schematic diagram and themounting dimensions in Figure 11 for a locally assembled reference air supply.

Instrument Air (Reference Air): 5 psi (34 kPa) minimum, 8 psi (54 kPa) maximum at 2.0 scfh (1.0 /min) maximum; lessthan 40 parts per million total hydrocarbons. Regulator outlet pressure should be set at 5 psi (34 kPa). Reference aircan be supplied by the reference air set or the optional SPS 4001B or IMPS 4000.

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Figure 11. Plant Air Schematic Diagram


Power Up ProcedureThe 6888 O2 System is provided with certain preconfigured parameters as follows. Refer to full instruction manual forprocedures for changing these parameters.

•O2 Range 0-10%

•Calibration

o Manual calibration

o Hi gas 8.0%

o Lo gas 0.4%

o Test gas flow time 300 seconds

o Purge time 300 seconds

•Alarms (6888XI only)

o Alarm 1 – Cal Recommended / Unit Alarm

o Alarm 2 – No Alarm (except for Single Channel with Flame Safety Interlock configuration)

•4-20 mA/HART Loop Power

o Alarm Level – 3.5 mA

o Standalone 6888 Transmitter – Requires external power

o 6888Xi to 6888 Transmitter – Internal Power from 6888Xi

o 6888XI to DCS – Internal Power from 6888Xi

6888 Transmitter Without 6888XI1. Apply AC line power to the Transmitter.

2.Apply 24 VDC loop power to the Transmitter.

3.Using either the DCS control or a Field Transmitter, verify communications to the Transmitter.

4.The transmitter probe will take approximately 45 minutes to warm up to the 736°C heater setpoint. The 4-20 mA signalwill remain at a default value of 3.5 mA and the O2 reading will remain at 0% through this warm-up period. After warmup, the probe will begin reading oxygen and the 4-20 mA output will be based on the default range of 0-10% O2.

5.If there is an error condition at startup, an alarm message will be displayed. Refer to full instruction manual for troubleshooting alarms.

6888 Transmitter With Single/Dual Channel or Single Channel & FlameSafety Interlock 6888XI1.Apply AC line power to the Transmitter.

2.Apply AC line power to the 6888XI.

3.Verify communications between the Transmitter and the 6888XI. The 6888XI display is preconfigured to display O2 &cell temperature for single channel configurations and both O2 readings for dual channel configurations.

4.The transmitter probes will take approximately 45 minutes to warm up to the 736°C heater setpoint. The 4-20 mAsignal will remain at a default value of 3.5 mA and the O2 reading will remain at 0% through this warm-up period.After warm up, the probe will begin reading oxygen and the 4-20 mA output will be based on the default range of 0-10% O2.

5.If there is an error condition at startup, an alarm message will be displayed on the 6888Xi. Refer to full instructionmanual for troubleshooting alarms.

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6888 Transmitter With Traditional Architecture 6888XI1. Apply AC line power to the 6888XI.

2. Verify communications between the Transmitter and the 6888XI. The 6888XI display is preconfigured to display O2 &cell temperature.

3. The transmitter probe will take approximately 45 minutes to warm up to the 736°C heater setpoint. The 4-20 mA signalwill remain at a default value of 3.5 mA and the O2 reading will remain at 0% through this warm-up period. After warmup, the probe will begin reading oxygen and the 4-20 mA output will be based on the default range of 0-10% O2.

4. If there is an error condition at startup, an alarm message will be displayed on the 6888Xi. Refer to full instructionmanual for troubleshooting alarms.

CalibrationThe 6888 O2 analyzer system can be calibrated in the installed condition without removing the instrument, and alsowhile the combustion process is on-line. A stainless steel tube runs the length of the probe, and delivers the calibrationgasses into the cell area. Factory calibration will usually be satisfactory for initial start-up and operation, but most accu-rate measurement is gained by executing a calibration after the combustion process is up and operating.

Recommended calibration gases are .4 % O2 and 8 % O2, with the balance of nitrogen in the gas bottles, but other valuescan be used as long as the electronics are configured identically. Instrument air or pure nitrogen are not recommended ascalibration gas values.

A two-stage pressure regulator should be used to establish a pressure of 20 PSI, from the bottles, and the flowmetershould be set to 5 SCFM flow rate. Calibration is semi-automatic, with the electronics prompting the technician to introduce the two calibration gases in sequence. All adjustments to the electronics are made automatically. Refer tothe menu maps under the “detailed setup” / “cal setup”, and make sure that the gas values in the cal bottles are setproperly in the electronics. A 300 second flow time is the default set for each gas, as well a purge time to permit theflue gases to displace the cal gases completely. Once the set-up is complete, go to the “calibration”/”start cal” menu,and follow the prompts to execute the calibration. The calibration will be noted as successful or failed. If successful,note the calibration slope, constant, and impedance on the calibration log. If the process flue gases have high levels ofparticulate in it, also note the Tinitial and Tfinal return to process time in this log. If the cal was unsuccessful, try again,making sure that the gas flows are correct, and the procedure followed correctly.

Make sure that the calibration port at the probe is capped tightly after calibration, or elevated O2 readings can resultfrom fresh air being drawn into the cal gas line traveling down to the cell.

Troubleshooting, Maintenance, and Spare Parts information is included in the full manual on CD supplied with each shipment.

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Menu Trees - The following menu trees will assist in navigating the electronics for configuration and troubleshooting.

6888Xi Menu- This is the most typical arrangement, and provides direction for the main display on the 6888Xi. Thisinterface addresses the electronic inside the 6888Xi, and also for the electronic in the probe head. This menu is alsoapplicable for “traditional architecture” systems, where there is no electronics in the probe head.

1.1 6888Xi Menu Tree

Note: The “Menu” button toggles between the “system”, “probe #1”, and “probe #2” (if a second probe is in place). Keep pushing themenu button to get to the menu you desire.

1.1.1 System Menu TreeSystem: TAGSystem Menu

1 Diagnostics1 Active Alarms2 Status

1 SystemCOM 1 DisconnectCOM 2 DisconnectNV Memory FailFAC Memory FailIOB 1 Type MismatchIOB 2 Type MismatchIOB 1 Bad ChecksumIOB 2 Bad Checksum

3 Acknowledge Alarms1 Ack IOB1 Bad Cksum2 Ack IOB2 Bad Cksum (Note 1)

4 Maintenance1 Revisions

1 Version2 Build Num

2 Reset1 Restart Count2 Reset Restart Count3 Reset System Params4 Reset Xi

1 Reset Xi2 Reset UI Board

2 Configure UIB1 Tag*2 Num I/O Board*3 Menu

1 I/O Board 11 Probe Count2 Dev Type 1

2 I/O Board 2 (Note 1)1 Probe Count2 Dev Type 1

4 Main Display 1 One-Probe /Two-Probe Format (Note 2)

1 LINE 11 Center*

2 LINE 21 Center*

3 LINE 31 Left*2 Right*

4 LINE 41 Left*2 Right*

2 Revert Time*3 Language*4 Contrast*5 Reset Contrast6 Flash Alarm*

5 Security1 Password*2 Enable Password*

3 Configure IOB1 I/O Board 1

1 Revisions1 Version2 Checksum

2IOB SN3 Features*

StoichiometerProg ReferenceExtended Temp

Diffuser Warning4 Factory Mode5 Reset Xi6 Reset I/O Board

2 I/O Board 2 (Note 1)1 Revisions

1 Version2 Checksum

2IOB SN


26

3 Features*StoichiometerProg ReferenceExtended TempDiffuser Warning

4 Factory Mode5 Reset Xi6 Reset I/O Board

* = R/W parameters

Note 1:Visible if the device is configured for 2 I/O Boards.

Note 2:Label differently based on one or two I/O Board.

Note 3:Visible if the Password is enabled.

1.1.2 6888-O2 Probe Menu Tree IOB 1 Probe1: TAG6888-O2 Probe Menu

1 Process Variables1 Process Variables

1 O2

2 O2 Temp 3 Cell Imp 4 O2 Cell

2 Temperatures1 O2 Temp2 CJC Temp3 Board Temp4 OP Mode

3 Raw Values1 O2 Cell 2 Cell Imp3 T/C Volt4 Heater5 Update Cell Imp

4 Analog Output1 O2 AO 2 O2 AO% 3 O2 LRV 4 O2 URV

5 Maximums1 Temperature

1 O2 Temp Max2 O2 Temp Max Time3 CJC Temp Max 4 CJC Temp Max Time 5 Board Temp Max 6 Board Temp Max Time

2 Voltage 1 Heater Max2 Heater Max Time 3 Cell Max 4 Cell Max Time

3 Ramp Rate 1 Heater Max2 Heater Max Time

6 Heater1 Duty Cycle2 O2 Temp SP3 O2 Temp4 Heater Ramp Rate

2 Diagnostics1 Active Alarms2 Status

1 Current1 Device

PV Out of LimitNPV Out of LimitAO SaturatedAO FixedMore StatusCold StartCfg ChangedDev Failure

2 FailedNV Memory FailBoard Temp HighFactory ModeHeater Ramp Rate

3 Maintenance 1 O2 Sensor OpenO2 T/C OpenO2 Temp LowO2 Temp HighO2 T/C ShortedO2 T/C ReversedHeater FailureBurner Flameout

4 Maintenance 2Xmtr DisconnectCal RecommendCal FailedCell Imp HighProbe Mismatch

5 AdvisoryCal ChangedHeater Volt LowProbe ChangedLow O2

Diffuser Warning


27

2 Previous1 Previous Alarms2 Ack Alarm Time

3 Acknowledge Alarms1 Ack Calibration2 Ack Cal Failed3 Ack Probe Changed

1 Get from Probe2 Send to Probe

4 Ack Diff Warn4 Maintenance

1 Revision1 HART

1 Device Rev 1 Transmitter

1 Version 2 I/O Board

1 Version 2 Analog Output

1 Trim mA Output3 Operating Status

Factory ModeFlame StatusAutoCal DeviceRelay 1 DeviceRelay 2 DeviceAO Device

4 I/O States1 I/O States 1

Gas 1 SolenoidGas 2 Solenoid

2 I/O States 2Flame Status InFactory ModeRelay 1 OutRelay 2 OutSPS/IMPS InSPS/IMPS Out

5 EE Status 1 Xmtr EE Value 2 IOB EE Value

6 Reset 1 Xmtr Restart 2 IOB Restart 3 Reset Restart Count4 Reset Device

3 Basic Setup 1 Identification

1 Tag* 2 Serial Number*3 Device ID

2 Communication1 Poll Address

2 Xmtr Address3 Variable Mapping

1 PV 2 SV 3 TV 4 4V

4 Detailed Setup 1 Sensor

1 T90 Filter*2 Low O2 Alm SP* 3 O2 Cell Ref (Note 2)*4 High Temp Alm SP (Note 3)*5 Heater SP (Note 3)*6 Heater Latch Off (Note 3)*7 Features

StoichiometerProg ReferenceExtended TempDiffuser Warning

2 Analog Output 1 O2 LRV* 2 O2 URV* 3 AO Range*4 Alarm Level*

3 Relay 1 Relay 1*

Unit AlarmLow O2

Cal RecommendedIn Calibration

2 Relay 2*Unit AlarmLow O2

Cal RecommendedIn CalibrationHeater Relay

4 Calibration 1 AO Track* 2 Tol Check*3 Cal Recommend*4 Cal Acknowledge*5 Cal Gas 1*6 Cal Gas 2*7 Gas Time* 8 Purge Time* 9 Diffuser (Note 4)

1 Plugged Diffuser*2 Auto Advance Cal*

5 Auto Calibration1 Enable Auto Cal*2 Start On Cal Rec* 3 Cal Interval*4 Next Cal Time


28

6 Resource1 Analog Output2 Auto Cal3 Relay 14 Relay 2

5 Calibration 1 O2 Calibration2 Abort Calibration3 Cal State4 Cal Constants

1 Current Cal1 Slope 2 Constant3 Impedence4 Time 5 Reset Cal 6 Change Cal

2 Cal Logs3 Failed Cal

1 Bad Slope 2 Bad Constant

5 Cal Result 1 Cal Result 2 Delta Imp

6 Diffuser (Note 4)1 Diff Diagnostics

1 Process2 O2

3 Step4 Step Time5 Diag State6 Init Resp7 Process Resp8 Rtn Process9 O2 Rate Change

2 Diff T903 Purge Time %4 Diff Warn

7 Pressures (Note 1)1 Bottle Pressure 12 Bottle Pressure 23 Cell Pressure 14 Cell Pressure 2

* = R/W parameters

Note 1:Visible if the device is configured for HSPS Autocal.

Note 2:Visible if the Programmable Reference software feature is enabled.

Note 3:Visible if the Extended Temperature software feature is enabled.

Note 4:Visible if the Diffuser Warning software feature is enabled.


29

1OVERVIEW1 Device Status:

1 Refresh Alerts2 No Active Alerts {No Alarm}2 F:Alert {Failed Alarms}2 M:Alert {Maintenance Alarms}2 A:Alert {Advisory Alarms}

2 O23 O2 Analog Output4 O2 URV5 O2 LRV6 VARIABLES

1 Operating Mode2 PROCESS VARIABLES

1 Oxygen Concentration2 O2 Temperature3 Cell Impedance4 O2 Cell

3 NON PRIMARY VALUES1 O2 Temperature2 CJC Temperature3 Board Temperature

4 RAW VALUES1 O2 Cell2 Cell Impedance3 T/C Volt4 Heater Volt5 Update Cell Imp

7 DEVICE INFORMATION1 IDENTIFICATION

1 Tag2 Model3 Serial Number4 Date5 Descriptor6 Message7 Device ID

2 REVISIONS1 HART REVISION

1 Universal2 Field Device3 Hardware4 Software5 DD

2 SOFTWARE VERSION1 Transmitter2 Input/Output Board

2 CONFIGURE1 GUIDED SETUP

1 Configure Sensor2 Configure Analog Output3 Configure Relay4 Configure Calibration5 Configure Auto Calibration

2 MANUAL SETUP1 IDENTIFICATION

1 Tag*2 Serial Number*3 Final Assembly Num*4 Date*5 Descriptor*6 Message*

2 COMMUNICATION1 Poll Address*2 Num Req Preambles3 Physical Signal Code

3 SENSOR1 T90 Filter*2 Low O2 Alarm SP*3 O2 Cell Reference* (Note 2)4 High Temp Alarm SP* (Note 3)5 Heater Set Point* (Note 3)6 Heater Latch Off* (Note 3)7 Features*8 Slope*9 Constant*

4 ANALOG OUTPUT1 O2 LRV*2 O2 URV*3 Output Range*4 Alarm Level*

5 Relay1 Relay 1*

1 Unit Alarm2 Low O2

3 Cal Recommended4 In Calibration

2 Relay 2*1 Unit Alarm2 Low O2

3 Cal Recommended4 In Calibration5 Heater Relay

HART Communications with the 6888Xi- Menu tree for communicating to the 6888Xi via HART communicationswith a 475 handheld communicator. (this includes interface with the 6888A probe electronics through the 6888Xi).

1.2 475 Menu Tree for 6888Xi


30

6 CALIBRATION1 Analog Output Track*2 Tolerance Check*3 Cal Recommended*4 Cal Acknowledge*5 Gas 1*6 Gas 2*7 Gas Time*8 Purge Time*9 Diffuser

1 Plugged Diffuser*2 Auto Advance Cal*

7 AUTO CALIBRATION1 Enable Auto Cal*2 Start On Cal Rec*3 Calibration Interval*4 Next Cal Time*

8 RESOURCE1 Analog Output2 Auto Calibration3 Relay 14 Relay 2

9 SCAN DEVICE3 CALIBRATION

1 CALIBRATION1 O2 Calibration2 Start/Stop Calibration3 Abort Calibration4 State

1 Calibration Setup2 Time Remain3 O2

4 O2 Cell5 Result

1 Calibration Result2 Delta Impedance

6 Diffuser (Note 4)1 Diffuser T902 Purge Time %3 Diffuser Warn

2 CALIBRATION CONSTANTS1 CURRENT CALIBRATION

1 Slope2 Constant3 Impedance4 Time

2 Calibration Logs3 Failed Calibration

1 Bad Slope2 Bad Constant

4 Reset Calibration Constants

3 SERVICE TOOLS1 ALERTS

1 ACTIVE ALERTS1 Refresh Alerts2 No Active Alerts {No Alarm}2 F:Alert {Failed Alarms}2 M:Alert {Maintenance Alarms}2 A:Alert {Advisory Alarms}

2 DEVICE STATUS1 CURRENT

1 DEVICE2 FAILED

NV Memory FailedBoard Temp HighFactory ModeHeater Ramp Rate

3 MAINTENANCE 1O2 Sensor OpenO2 T/C OpenO2 Temperature LowO2 Temperature HighO2 T/C ShortedO2 T/C ReversedHeater FailureBurner Flameout

4 MAINTENANCE 2Transmitter DisconnectCalibration RecommendedCalibration FailedCell Impedance HighProbe MismatchXi Disconnected

5 ADVISORYCalibration ChangedHeater Voltage LowProbe ChangedLow O2

Diffuser Warning2 PREVIOUS

1 Process Alarm2 Ack Alarm Time

3 ACKNOWLEDGE1 Ack Calibration 2 Ack Calibration Failed3 Ack Diffuser Warning4 Ack Probe Changed

2 VARIABLES1 PROCESS VARIABLES

1 PV2 SV3 TV4 4V5 Primary Variable


31

6 Secondary Variable7 Tertiary Variable8 Fourth Variable

2 NON PRIMARY VALUES1 O2 Temperature2 CJC Temperature3 BoardTemperature

3 RAW VALUES1 O2 Cell2 Cell Impedance3 T/C Volt4 Heater Volt5 Update Cell Imp

4 ANALOG OUTPUT1 O2

2 O2 Analog Output3 O2 Analog Output %

5 MAXIMUMS1 TEMPERATURE

1 O2 Maximum2 O2 Maximum Time3 CJC Maximum4 CJC Maximum Time5 Board Maximum6 Board Max Time

2 VOLTAGE1 Heater Maximum2 Heater Max Time3 Cell Maximum4 Cell Maximum Time

3 RAMP RATE1 Heater Maximum2 Heater Max Time

6 HEATER1 Duty Cycle2 O2 Temperature SP3 O2 Temperature4 Heater Ramp Rate

3 TRENDS1 Oxygen Concentration2 O2 Temperature3 Analog Output

4 MAINTENANCE1 CALIBRATION

1 O2 Calibration2 Start/Stop Calibration3 Abort Calibration4 State

1 Calibration Step2 Time Remain3 O2

4 O2 Cell

5 RESULT1 Calibration Result2 Delta Impedance

6 DIFFUSER (Note 4)1 Diffuser T902 Purge Time %3 Diffuser Warn

2 ANALOG OUTPUT1 Trim mA Output2 Loop Test

3 OPERATING STATUS1 Factory Mode2 Flame Status3 Auto Cal Device4 Relay 1 Device5 Relay 2 Device6 Analog Output device

4 INPUT/OUTPUT STATES1 I/O States 1

1 Gas 1 Solenoid2 Gas 2 Solenoid

1 I/O States1 Flame Status In2 Factory Mode3 Relay 1 Out4 Relay 2 Out5 SPS/IMPS In6 SPS/IMPS Out

5 EE STATUS1 Transmitter EE Value2 I/O Board EE Value

6 RESET/RESTORE1 Transmitter Restart2 I/O Board Restart3 Reset Restart Count4 Reset Device

* = R/W parameters** = Alarm supported by 6888Xi only and will always be off

Note 1:Visible if the device is configured for HSPS Autocal.

Note 2:Visible if the Programmable Reference software featureis enabled.

Note 3:Visible if the Extended Temperature software feature isenabled.

Note 4:Visible if the Diffuser Warning software feature isenabled.


32

1 OVERVIEW1 Device Status {Good/Fail/Maint/Advise}

1 Refresh Alerts2 No Active Alerts {No Alarm}2 F:Alert {Failed Alarms}2 M:Alert {Maintenance Alarms}2 A:Alert {Advisory Alarms}

2 O2

3 O2 Analog Output4 O2 URV5 O2 LRV6 VARIABLES

1 Operating Mode2 PROCESS VARIABLES

1 Oxygen Concentration2 O2 Temperature3 Cell Impedance4 O2 Cell

3 NON PRIMARY VALUES1 O2 Temperature2 CJC Temperature

4 RAW VALUES1 O2 Cell2 Cell Impedance3 Heater Volt4 Update Cell Imp

7 DEVICE INFORMATION1 IDENTIFICATION

1 Tag2 Model3 Serial Number4 Date5 Descriptor6 Message7 Device ID

2 REVISIONS1 HART REVISION

1 Universal 2 Field Device3 Hardware4 Software5 DD

2 SOFTWARE VERSION1 Transmitter

2 CONFIGURE1 GUIDED SETUP

1 Configure Analog Output2 Configure Calibration

2 MANUAL SETUP1 IDENTIFICATION

1 Tag*2 Serial Number*3 Final Assembly Num*4 Date*5 Descriptor*6 Message*

2 COMMUNICATION1 Poll Address*2 Num Req Preambles3 Physical Signal Code

3 SENSOR1 Slope*2 Constant*

4 ANALOG OUTPUT1 O2 LRV*2 O2 URV*3 Output Range4 Alarm Level*5 Xi Mode*

5 CALIBRATION1 Analog Output Track*2 Gas 1*3 Gas 2*4 Gas Time*5 Purge Time*

6 Scan Device3 CALIBRATION

1 CALIBRATION1 O2 Calibration2 RESULT

1 Calibration Result2 CALIBRATION CONSTANTS

1 CURRENT CALIBRATION 1 Slope2 Constant3 Impedance4 Time

2 Calibration Logs3 Reset Calibration Constants

3 SERVICE TOOLS1 ALERTS

1 ACTIVE ALERTS1 Refresh Alerts2 No Active Alerts {No Alarm}2 F:Alert {Failed Alarms}2 M:Alert {Maintenance Alarms}2 A:Alert {Advisory Alarms}

Transmitter Electronics- If not using the 6888Xi electronics, one can access the electronics inside the probe via HART communications with a 475 handheld communicator.

1.3 475 Menu Tree for 6888-O2 Transmitter


33

2 DEVICE STATUS1 CURRENT

1 DEVICE2 FAILED

NV Memory FailedBoard Temp HighFactory ModeHeater Ramp Rate**

3 MAINTENANCE 1O2 Sensor OpenO2 T/C OpenO2 Temperature LowO2 Temperature HighO2 T/C ShortedO2 T/C ReversedHeater Failure**Burner Flameout**

4 MAINTENANCE 2Transmitter Disconnect**Calibration Recommended**Calibration FailedCell Impedance High**Probe Mismatch**Xi Disconnected

5 ADVISORYCalibration Changed**Heater Voltage LowProbe Changed**Low O2**Diffuser Warning**

2 ACKNOWLEDGE1 Ack Calibration Failed

2 VARIABLES1 PROCESS VARIABLES

1 PV2 SV3 TV4 4V5 Primary Variable6 Secondary Variable7 Tertiary Variable8 Fourth Variable

2 NON PRIMARY VALUES1 O2 Temperature2 CJC Temperature

3 RAW VALUES1 O2 Cell2 Cell Impedance3 Heater Volt4 Update Cell Imp

4 ANALOG OUTPUT1 O2

2 O2 Analog Output5 MAXIMUMS

1 TEMPERATURE1 O2 Maximum2 O2 Maximum Time3 CJC Maximum4 CJC Maximum Time

2 VOLTAGE1 Heater Maximum2 Heater Max Time3 Cell Maximum4 Cell Maximum Time

6 HEATER1 Duty Cycle2 O2 Temperature SP3 O2 Temperature

3 TRENDS1 Oxygen Concentration2 O2 Temperature3 Analog Output

4 MAINTENANCE1 CALIBRATION

1 O2 Calibration2 RESULT

1 Calibration Result2 ANALOG OUTPUT

1 Trim mA Output2 Loop Test

3 OPERATING STATUSFactory ModeFlame StatusAuto Cal DeviceRelay 1 DeviceRelay 2 DeviceAnalog Output device

4 EE STATUS1 Transmitter EE Value

5 RESET/RESTORE1 Transmitter Restart2 Reset Restart Count3 Reset Device

* = R/W parameters** = Alarm supported by 6888Xi only and will always be off

Return of MaterialIf factory repair of defective equipment is required, proceed as follows:

1. Secure a return authorization number from a Emerson Process Management Sales Office or representative beforereturning the equipment. Equipment must be returned with complete identification in accordance with EmersonProcess Management instructions or it will not be accepted.

In no event will Emerson Process Management be responsible for equipment returned without proper authorizationand identification.

CAUTIONObserve proper ESD handling and packaging precautions when returning individual circuit boards.

2. Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to ensure that no additionaldamage will occur during shipping. When returning individual circuit boards, observe proper ESD precautions.

3. In a cover letter, describe completely:

a. The symptoms from which it was determined that the equipment is faulty.

b. The environment in which the equipment has been operating (housing, weather, vibration, dust, etc.).

c. Site from which equipment was removed.

d. Whether warranty or nonwarranty service is requested.

e. Complete shipping instructions for return of equipment.

f. Reference the return authorization number.

4. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided inEmerson Process Management Return Authorization, prepaid, to:

Emerson Process ManagementRosemount AnalyticalRMR Department10241 West Little YorkSuite 200Houston TX 77040 USA

34


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comb manual im 106 6888qs

Documents

o2 display

optional xi electronics

remote xi electronics

o2 sensors

probe head

raw o2 millivolt signal

xi electronics

preexisting electronics