Manual

00809-0100-4925, Rev AB
March 2023

Rosemount™ 925FGD Fixed Gas Detector

Integrated Gas Detection
Safety information

NOTICE

Read this document before working with the product. For personal and system safety, and for optimum product
performance, make sure you thoroughly understand the contents before installing, using, or maintaining this
product. For technical assistance, contacts are listed below:

Customer Central
Technical support, quoting, and order-related questions.
United States - 1-800-999-9307 (7:00 am to 7:00 pm Central Time)
Asia Pacific- 65 777 8211
Europe/Middle East/Africa - 49 (8153) 9390

North American Response Center

Equipment service needs.
1-800-654-7768 (24 hours—includes Canada)
Outside of these areas, contact your local Emerson representative.

WARNING
Explosions
Explosions could result in death or serious injury.
Installation of device in an explosive environment must be in accordance with appropriate local, national, and
international standards, codes, and practices.
Before connecting a handheld communication device in an explosive atmosphere, ensure the instruments are
installed in accordance with Intrinsically Safe or non-incendive field wiring practices.

WARNING
Electrical shock
Electrical shock could cause death or serious injury.
Avoid contact with the leads and terminals. High voltage that may be present on leads can cause electrical shock.

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.

CAUTION
Nuclear applications
The products described in this document are not designed for nuclear qualified applications. Using non-nuclear
qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings.
For information on Rosemount nuclear-qualified products, contact an Emerson sales representative.

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Contents
Chapter 1 Introduction...............................................................................................................................5
1.1 Using this manual........................................................................................................................5
1.2 Definition of models and terms.................................................................................................5
1.3 Device overview........................................................................................................................... 6
Chapter 2 Configuration............................................................................................................................ 7
2.1 Overview....................................................................................................................................... 7
2.2 Configuration options.................................................................................................................7
Chapter 3 Installation.................................................................................................................................9
3.1 Safety messages.......................................................................................................................... 9
3.2 Rosemount 625ND non-dispersive infrared sensor effectiveness........................................9
3.3 Mounting.................................................................................................................................... 10
3.4 Wiring..........................................................................................................................................11
3.5 Local operator interface (LOI)..................................................................................................15
®
3.6 HART communication............................................................................................................. 19
3.7 Power on and start-up.............................................................................................................. 30
Chapter 4 Sensor calibration................................................................................................................... 33
4.1 Factory calibration gases..........................................................................................................33
4.2 Calibration options....................................................................................................................33
4.3 Calibration instructions............................................................................................................ 35
4.4 Calibration diagnostics............................................................................................................. 35
Chapter 5 Operation and maintenance................................................................................................. 37
5.1 Outputs.......................................................................................................................................37
5.2 Proof tests.................................................................................................................................. 39
5.3 Replace sensor...........................................................................................................................40
5.4 Replace complete transmitter electronics assembly............................................................ 41
5.5 Replace transmitter LOI screen and display board...............................................................41
5.6 Event logs................................................................................................................................... 42
5.7 Reset transmitter.......................................................................................................................42
5.8 Service support.......................................................................................................................... 42
5.9 Product recycling/disposal....................................................................................................... 42
Chapter 6 Notifications, faults, and diagnostics...................................................................................43
6.1 Transmitter electronics failure................................................................................................ 43
6.2 Transmitter power supply low.................................................................................................43
6.3 Transmitter analog output failure...........................................................................................43
6.4 Sensor incompatible................................................................................................................. 44
6.5 Transmitter software fault....................................................................................................... 44
6.6 Transmitter temperature high................................................................................................ 44
6.7 Transmitter temperature low.................................................................................................. 44
6.8 Transmitter power supply high............................................................................................... 45
6.9 Transmitter display board failure............................................................................................45

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6.10 Sensor initializing.................................................................................................................... 45

6.11 Sensor not calibrated..............................................................................................................45
6.12 Sensor negative drift.............................................................................................................. 46
6.13 Sensor electronics failure.......................................................................................................46
6.14 Sensor temperature high....................................................................................................... 46
6.15 Sensor temperature low.........................................................................................................47
6.16 Sensor power supply high......................................................................................................47
6.17 Sensor power supply low....................................................................................................... 47
6.18 Sensor environmental fault................................................................................................... 47
6.19 Sensor fault not defined.........................................................................................................48
6.20 Sensor fault.............................................................................................................................. 48
6.21 Sensor weak signal................................................................................................................. 48
6.22 Replace sensor soon............................................................................................................... 49
6.23 Undefined sensor warning.................................................................................................... 49
Appendix A Specifications...........................................................................................................................51
Appendix B Product certifications............................................................................................................. 53
B.1 Reliability.................................................................................................................................... 53
B.2 Global hazardous area and performance.............................................................................. 53
Appendix C Spare parts............................................................................................................................... 55

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1 Introduction
1.1 Using this manual
The sections in this manual provide information on installing, operating, and maintaining
the Rosemount 925FGD Fixed Gas Detector.
The manual sections are organized as follows:
Configuration contains information on the factory default and configurable settings for the
detector.
Installation contains information on the proper installation of the detector.
Sensor calibration provides information on various methods and best practices for
calibrating the Rosemount 625 sensor modules.
Operation and maintenance provides information on the continued use and periodic
maintenance of the detector.
Notifications, faults, and diagnostics provides information on all statuses, notifications,
warnings, faults, and diagnostics provided by the Rosemount 925 transmitter as well as
troubleshooting information.
The appendices contain supplemental information, such as model specifications and
product certifications.

1.2 Definition of models and terms

%/volume Percentage concentration per volume
HART ®
Highway addressable remote transducer: a digital communication
protocol
IP filter Ingress protection filter
IR Infrared
LED Light-emitting diode
LEL Lower explosive limit
LOI Local operator interface
PV Primary variable
Rosemount 625 Sensor housing
Rosemount 625ND Non-dispersive infrared sensor module
Rosemount 925 Gas detection universal transmitter
Rosemount 925FGD Fully-assembled gas detector, consisting of transmitter, sensor
housing, and sensor module.

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1.3 Device overview

The Rosemount 925FGD is a fixed gas detector compatible with the Rosemount 625 Sensor
Module.
The Rosemount 925FGD is a fully-assembled unit for only sensor-direct-mount installations.
For this configuration, you can order the Rosemount 925FGD with or without the sensor
module for instances where sensor modules will be installed after the initial transmitter
installation.
The Rosemount 925FGD Transmitter consists of the transmitter electronics, an LOI display,
and infrared touch buttons contained in an explosion-proof housing. The transmitter
provides outputs, including 4-20 mA analog signal, fault relay, alarm relays (2), and HART®
protocol. The transmitter is also equipped with status indication LEDs.
All Rosemount 625 Sensors are smart sensors, meaning all configuration, calibration, and
gas sensing data is stored directly on or generated directly from the sensor. This data is
then communicated to the Rosemount 925 Transmitter, which displays information on the
local operator interface (LOI) and generates outputs for communication with site control
systems.
For combustible hydrocarbon gas detection, the Rosemount 925FGD incorporates the
Rosemount 625ND Sensor Module. The Rosemount 625ND Sensor Module uses non-
dispersive infrared technology to measure combustible hydrocarbon gas using absorption
spectroscopy in the infrared sensor bands.

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2 Configuration
2.1 Overview
Note
Unless otherwise specified, all sensor modules will leave the factory with default
configuration options selected. The operator can change the options in the field using
either the local operator interface (LOI) or HART® communication.

2.2 Configuration options

To order the Rosemount 925FGD or replacement Rosemount 625ND Sensor Modules with
custom configuration, select the C1 optional model code and add it to the configured
model number. Additionally, submit a Configuration Data Sheet specifying the custom
options required. You can also configure settings with HART® communication or the local
operator interface (LOI).
The following are the available configuration options for the Rosemount 925FGD when
ordered as a fully assembled detector:
1. Basic setup
a. Descriptor
b. Message
c. Date
d. HART long tag

2. Display
a. Backlight settings
b. Heater settings

3. Diagnostic alarms and alerts

a. Alarm 1 level
b. Alarm 2 level
c. Alarm latching settings
d. Alarm relays normally open/normally closed

4. Advanced setup
a. Passcode settings

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CAUTION
The Ingress Protection (IP) filter must be installed.
If the IP filter is not installed, damage may occur to the sensor.
Do not operate the transmitter without the correct IP filter installed in the sensor module.
When installing the IP filter, verify that the IP filter gasket is in place, is properly aligned,
and that it does not block the white filter media. When handling the IP filter, avoid contact
with the filter media.
Verify that all three legs are fully latched by pushing upward on each leg of the IP filter.
Avoid getting water inside the IP filter.
Do not attempt to clean the IP filter.
Do not rinse or spray the IP filter with water.
Do not immerse the IP filter in water.
IP ratings does not imply that the equipment will detect gas during and after exposure to
those conditions.

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3 Installation
3.1 Safety messages
Instructions in this section may require special precautions to ensure the safety of
personnel performing the operations.

WARNING
Follow installation guidelines
Failure to follow these installation guidelines could result in death or serious injury.
Ensure that only qualified personnel perform the installation.

WARNING

If the equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.

WARNING
Explosions
Before connecting a handheld communication device in an explosive atmosphere, ensure
that the instruments are installed in accordance with Intrinsically Safe or non-incendive
field wiring practices.
Verify that the operating atmosphere of the transmitter is consistent with the appropriate
hazardous locations certifications.
When connecting an external device to the Rosemount 925FGD's discrete output in a
hazardous area, ensure that the external device is installed in accordance with Intrinsically
Safe or non-incendive field wiring practices.

3.2 Rosemount 625ND non-dispersive infrared

sensor effectiveness
• When installing the Rosemount 925 FGD Gas Detector with a Rosemount 625ND
Non-dispersive Infrared Sensor, it is required the sensor be mounted in a vertical
configuration with the IP filter pointed downward.
• When mapping a gas detection system, it should be understood that gas must
physically pass through the IP filter and the integral sinter to reach the sensor.
Therefore, the “field of view” or detection distance of a non-dispersive infrared sensor is
limited to the immediate vicinity surrounding the sensor.
• The IP filter and sinter should always be kept free of debris and should be subject to
regular scheduled maintenance to clear any obstructions.
• When mounting the sensor, installation height should be determined by considering a
combination of the following: height most suitable to the safety of personnel on site
as well as the correlation of target gas specific gravity compared to the surrounding

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atmosphere (i.e. methane and natural gas are lighter than air and tend to rise, while
propane and butane are heavier than air and tend to sink).
• In order to relay LEL percentage as accurately as possible it is important the correct gas
calibration option be selected that best represents the target gases on site intended to
be detected (i.e. if hoping to detect natural gas leaks, a methane calibration will provide
considerably more accurate percent LEL readings than a propane calibration).
• For optimum accuracy and reliability the calibration schedule should be followed as
mentioned in Sensor calibration. While the minimum recommended calibration interval
is 12 months, if the installation site is subject to more frequent swings in environment
conditions, the calibration interval should be decreased accordingly.

3.3 Mounting
The Rosemount 925FGD Gas Transmitter must be mounted with the sensor directly
attached to the transmitter as in Figure 3-1. You can also mount the transmitter either
on the surface or on a pole.
For the surface mounting with direct-mount sensors, refer to Figure 3-1.

Figure 3-1: Surface Mount with Direct-Mount Sensor

For pole mounting with direct-mount sensors, select the BP optional model code, which
includes the necessary pole mount bolts in the box with the transmitter. Refer to Figure
3-2.

Figure 3-2: Pole Mount with Direct-Mount Sensor

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3.4 Wiring

3.4.1 Analog output, isolated supply, non-isolated supply, and

jumper configuration
The analog output may be powered from the main instrument power supply or a separate,
isolated power supply, in which case an isolated wiring configuration is necessary.
An isolated loop uses 4-wires, 2 to power the device, and 2 for the analog output. A
non-isolated loop uses 3-wires, as the analog output is tied into the power supply loop.
Ensure the loop jumper is correctly set for the wiring configuration you are using. See
Figure 3-3

Figure 3-3: 925 Transmitter Terminal Block

3.4.2 Field wiring

The power to the transmitter is supplied over the signal wiring. Signal wiring must be
shielded, twisted pair. Do not run unshielded signal wiring in conduit or open trays with
power wiring or near heavy electrical equipment because high voltage may be present on
the leads and may cause an electrical shock.
To meet EMC requirements, for the transmitter power wiring (V+ and COM) and signal
wiring (mA+ and mA-) it is required to use twisted shielded pair wires between the user
power supply and the 925 transmitter. All flameproof entry devices, including plugs, must
be rated to a pressure greater than 2450 kPa (356 psi).
Seal all threads with an approved thread sealant, such as silicone or PTFE tape (if required).
When attaching the cover; tighten at least one-third turn after the O-ring contacts the
transmitter housing. The transmitter cover must be fully engaged to meet explosion proof
requirements
Note
Do not apply high voltage (e.g., AC line voltage) to the power or sensor terminals, since
high voltage can damage the unit

To wire the transmitter:

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Table 3-1: Sensor terminals

Sensor terminals

Sensor wires Transmitter sensor board terminal designation

Red +Vdc (from transmitter)

Blue Signal A

White Signal B

Black Communication

Green Earth ground

Table 3-2: Transmitter power terminals

Transmitter power terminals

Transmitter terminal designation Function

V+ 18-30Vdc Power (+)

COM Power (-)

RST Remote reset

mA+ Current loop output

mA- Current loop output

Figure 3-4: Direct mount wiring diagram

Note
Ground wire from 625 sensor must be connected to ground inside of 925 transmitter
housing.

Isolated 4-wire loop wiring

For a 4-wire loop setup, ensure the loop jumper is set to the ISOLATE position and that
shielded, twisted pairs are used.

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Figure 3-5: Isolated 4-wire wiring diagram

A. Power supply (18-30 Vdc)

B. 200 ≤ RL ≤ 800
C. Power/4-20 mA analog loop terminals
D. HART modem

Non-isolated 3-wire loop wiring

For a 3-wire loop setup, ensure the loop jumper is set to the NON ISO position and that
shielded, twisted pairs are used.

Figure 3-6: Non-isolated 3-wire wiring diagram

A. Power supply (18-30 Vdc)

B. 200 ≤ RL ≤ 800
C. Power/4-20 mA analog loop terminals
D. HART modem

Wiring to Emerson Wireless 775 THUM adapter

Refer to Figure 3-7 for wiring instructions.

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Figure 3-7: THUM wiring

A. Power supply (18-30 Vdc)

B. 200 ≤ RL ≤ 800
C. Power/4-20 mA analog loop terminals
D. Emerson Wireless 775 THUM adapter

3.4.3 Remote reset

If the alarm relays are configured for latching operation, you may want to reset latched
alarms from a remote location. In this case, you can connect a normally open, momentary
push-button switch across terminals RST and COM.

3.4.4 Relays
Electromechanical relays have Form-C SPDT contacts rated 5 amps at 30 Vdc. There are
three physical relays; one fault and two alarm relays. These relays have normally open and
normally closed contacts at the output terminals.

Alarm relay(s)
The transmitter comes with two programmable alarm relays. These relays will change state
from their non-alarm state to an alarm state when gas concentrations, as read by the
sensor, reach the programmed alarm points set in the transmitter.
The alarm relays change states at the configured alarm 1 and alarm 2 set points (where
alarm 2 is greater than alarm 1). The relays can be programmed to be energized or
de-energized under normal conditions. They are also configurable to be either latching or
non-latching in alarm.

Fault relay
The fault relay is normally energized (normally open) when no fault conditions are present
and is set up for non-latching. The operation of the fault relay is not configurable.
The transmitter indicates various fault conditions when the transmitter or connected
sensor(s) are not operating as expected. These fault conditions will override any alarm
conditions because the sensor may be unable to reliably detect a gas exposure. Examples
of fault conditions can include no gas detection due to memory corruption, communication
errors, or sensor failure. Other faults can provide unreliable detection due to sensor drift

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or sensor nearing the end of its life. When a transmitter is in fault mode, take immediate
action to determine the source and correct the fault condition.
Emerson 925 transmitters and 625 sensors continually check for situations that may
prevent the transmitter and sensor from providing an expected response to ambient
conditions and records these as a fault condition in the event log and the output(s) of
the transmitter. When the transmitter detects a system fault, the amber Status LED will
flash fast (250 milliseconds on, 250 milliseconds off), the analog output will output a 2.5
mA signal, and the fault relay will change states from normally open to normally closed
(de-energize to indicate a fault condition).
Note
The fault relay output is not commonly used to imitate an automatic shutdown. The fault
output indicates a potential problem with the transmitter not an alarm condition.

3.5 Local operator interface (LOI)

The Rosemount 925 Transmitter uses through-the-glass infrared (IR) touch buttons to
navigate the LOI display.
Figure 3-8 shows the location of the IR buttons on the left, right, and bottom of the LOI.

Figure 3-8: Front view of LOI

For best results when activating the IR touch buttons, ensure that your finger covers the
complete surface of the glass above the button.
The IR buttons have automatically adjusting sensitivity, meaning that they will adjust to
installation conditions, such as the cover being removed.

3.5.1 Unlock local operator interface (LOI)

The Rosemount 925 Transmitter comes with a screen lock feature as a default to inhibit
accidental operation and potential environmental stimulus that might activate the infrared
(IR) touch buttons.
For added safety, you can enable a four-digit passcode instead of the following standard
unlock sequence. You can do this through the LOI or via HART®.
Refer to LOI menu tree and HART® communication.

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For more information on this safety feature, refer to the Rosemount 925FGD Safety Manual.

Procedure
1. Press any IR button to initiate the unlock sequence.
2. Press the check mark.
3. Press the up arrow.
4. Press the check mark.
5. Press the down arrow.

3.5.2 LOI menu tree

Figure 3-9, Figure 3-10, and Figure 3-11 show the navigation and menu options of the
Rosemount 925FGD display.

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Figure 3-9: LOI Menu Tree Sheet 1

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Figure 3-10: LOI Menu Tree Sheet 2

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Figure 3-11: LOI Menu Tree, Sheet 3

3.6 HART® communication

Figure 3-12 through Figure 3-21 show the navigation paths for Field Communicator
commands and options. A Rosemount 925FGD device description (DD) is required for HART
transmitter communication. To obtain the latest Emerson DD, visit the System Software
and Device Description web page for your handheld communicator. Refer to your handheld
communicator's reference manual for a menu structure with descriptions of each option.
Prior to making any changes to the Rosemount 925FGD Fixed Gas Detector, such as
changing the configuration or replacing the sensor, take appropriate action to avoid a
false trip by electronically bypassing the safety Programmable Logic Controller (PLC).
Prior to placing the transmitter online and removing the bypass from the safety PLC, verify
the transmitter configuration and all safety parameters.

WARNING

If the transmitter is in a classified area, do not open the wiring compartment unless the
power to the transmitter has been removed or unless the area has been declassified.
Contact customer support for further information.

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Figure 3-12: HART Menu Tree, Sheet 1

A. If there are no alerts active, then Device Status is Good. Otherwise, the Device Status is
one of the following: Failure, Function Check, Out of Specification, or Maintenance
Required.
B. Communication Status is Polled initially. If Burst Message is enabled, Communication
Status will show Burst.

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Figure 3-13: HART Menu Tree, Sheet 2

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Figure 3-14: HART Menu Tree, Sheet 3

A. Selected Gas and Sensor Upper Range are only writable if an infrared (IR) or
electrochemical sensor is selected.

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Figure 3-15: HART Menu Tree, Sheet 4

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Figure 3-16: HART Menu Tree, Sheet 5

A. View Message 1 Configuration menu will be visible only when Message 1 is Enabled.
B. Trigger Level will not be visible of the Trigger Mode is Continuous or On-Change.
C. Default Update Rate will not be visible if Trigger Mode is Continuous.

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Figure 3-17: HART Menu Tree, Sheet 6

A. View Message 2 Configuration menu will be visible only when Message 2 is Enabled.
B. Trigger Level will not be visible of the Trigger Mode is Continuous or On-Change.
C. Default Update Rate will not be visible if Trigger Mode is Continuous.
D. View Message 3 Configuration menu will be visible only when Message 3 is Enabled.
E. Trigger Level will not be visible of the Trigger Mode is Continuous or On-Change.
F. Default Update Rate will not be visible if Trigger Mode is Continuous.

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Figure 3-18: HART Menu Tree, Sheet 7

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Figure 3-19: HART Menu Tree, Sheet 8

A. Relay Board is always present. Fault Relay is always disabled.

B. This method sends command 48 to refresh alert status.
C. If there are no alerts active, No Active Alerts is shown. Otherwise, a combination of the
Failure, Function Check, Out of specification, or Maintenance Required alerts are shown
depending on the active alerts.
D. Methods are used to display the text related to the alert if it is longer than 19 characters.

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Figure 3-20: HART Menu Tree, Sheet 9

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Figure 3-21: HART Menu Tree, Sheet 10

The following parameters can be modified via the LOI or HART communicator menu trees,
within the range limits shown below.

LOI/HART parameter Valid range

Alarm 1 level 1% to 100%

Alarm 2 level 1% to 100% (must be higher than Alarm 1 level)

Alarm latching mode Yes/No

Inhibit mode Off/On

Alarm 1 relay activation mode Normally closed/Normally open

Alarm 2 relay activation mode Normally closed/Normally open

Gas type Methane, Propane, Butane, Ethane, Ethylene

Range 1(0-100)

LEL standard ISO/IEC, NFPA

Passcode 0000 to 9999

Heater setting Disabled, Automatic

Backlight setting Disabled, Enabled, Automatic

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3.7 Power on and start-up

Once you have made all necessary wiring connections and applied power, the transmitter
will power on.
During this start-up process, the display will show a progress bar as well as the firmware
versions for all components of the Rosemount 925FGD system. The status indicator LEDs
will cycle through all colors: green, amber, and red.

Figure 3-22: Local operator interface (LOI) at start-up

When a new sensor module is detected, either upon initial installation or replacement of a
sensor module, the configuration settings are shown on the LOI. At this point, you have the
option of accepting configuration settings or selecting new settings.

Figure 3-23: New Sensor Detected Screen

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Following the configuration prompt, an additional prompt appears stating that a field
calibration is recommended. Refer to Calibration options.

Figure 3-24: Field Calibration Recommended screen

Unless one or more faults are present, the LOI will go to the Primary Variable screen,
displaying the gas type and current concentration being measured by the sensor.

Figure 3-25: Primary Variable Screen Using Methane

Note
If the operator removes and reapplies power to the transmitter without replacing the
sensor module, and no faults are present upon start-up, the display will go directly to the
Primary Variable screen following the Start-up screen.

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Note
If the 4-20 mA analog output has not been connected, a current loop failure fault will
be present after the other prompts have been cleared. You can clear this fault either by
terminating the 4-20 mA output to the appropriate control system input or by placing a 250
Ω resistor between the analog output terminals.

Figure 3-26: Current Loop Fault Screen

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4 Sensor calibration
Note
All sensor modules for the Rosemount 925FGD will arrive with factory calibration
information stored in the sensor memory. While field calibration following initial
installation is not required, it is best practice to calibrate sensors according to the
specific environmental conditions present to achieve highest levels of accuracy. After initial
installation it is recommended to perform complete zero and span calibration every 12
months.
For more information on Installation, Use And Maintenance Of Detectors For Flammable
Gases, refer to IEC 60079-292-2.

4.1 Factory calibration gases

Table 4-1: Rosemount 625ND Non-Dispersive Infrared Combustible Gas Sensor Module

Gas type Range Default 50% lower Optional 50%LEL

explosive limit (LEL) calibration gas per
calibration gas per International Organization
National Fire Protection for Standardization
Association (NFPA) (ISO)/IEC standards
standards

Methane (default) 0-100% LEL 2.50%/volume 2.20%/volume

Propane 0-100% LEL 1.05%/volume 0.85%/volume

Butane 0-100% LEL 0.95%/volume 0.70%/volume

Ethane 0-100% LEL 1.50%/volume 1.20%/volume

Ethylene 0-100% LEL 1.35%/volume 1.15%/volume

Note
To order a Rosemount 925FGD with the optional ISO/IEC gas concentrations used for
factory calibration, you must add the optional IEC model code to the configured model
number. You can also change this in the field by selecting sensor settings in the local
operator interface (LOI) menu or via HART® communication.

Note
To ensure proper calibration, verify that the correct concentration of calibration gas is used
in correlation with the concentration settings selected in the transmitter.

4.2 Calibration options

The calibration cup (part number 00625-2012-0001) is the preferred method for sensor
calibration.
The calibration cup attaches to the sensor by fitting over the pre-installed IP filter on the
Rosemount 625ND Infrared Sensor. Refer to Figure 4-1 to see how to attach ¼-in inner
diameter (ID) (⅜-in outer diameter [OD]) plastic gas tubing.

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Figure 4-1: Attaching Calibration Cup to Sensor

The calibration cup creates a mostly sealed environment for the sensor, mitigating
environmental effects such as wind and humidity. Leaving the calibration cup attached
would render the sensor inoperable for detecting hazardous gases.

NOTICE
Remove the calibration cup after calibration.

If a calibration cup isn't used, the IP filter is designed with an attachment point for ¼-in ID
(⅜-in OP) plastic gas tubing. This design feature allows for permanent attachment of plastic
gas tubing.

NOTICE
As the IP filter does not provide for physical containment of the gas supply leaving the
tubing, it is subject to dispersion from environmental effects. This may affect the accuracy
of calibration. Calibration using the IP filter may require higher volumes, pressures, and/or
flow rates of calibration gas.

NOTICE
A new calibration is required following changes to any of the below settings:
1. Gas type
2. LEL standard
3. Span gas concentration

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4.3 Calibration instructions

4.3.1 Zero calibrate only

Procedure
1. Go to Menu → *Unlock sequence* → Sensor Calibration → Calibrate Zero.
2. Attach the calibration cup to the Rosemount 625ND Sensor, leaving the IP filter in
place.
3. Connect the appropriate zero gas concentration cylinder to the sensor, attaching the
tubing to the IP filter.
4. Confirm Yes on the local operator interface (LOI) to begin the zero calibration
process.
5. Open the regulator and allow zero-gas to flow until prompted with the message Zero
calibration is a success.
6. Select OK to return to the Primary Variable screen.

4.3.2 Zero and span calibrate

Procedure
1. Go to Menu → *Unlock sequence* → Sensor Calibration → Calibrate Zero.
2. Attach the calibration cup to the Rosemount 625ND Sensor, leaving the IP filter in
place.
3. Connect the appropriate zero gas concentration cylinder to the sensor, attaching the
tubing to the IP filter.
4. Confirm Yes on the local operator interface (LOI) to begin zero calibration.
5. Open the regulator and allow zero-gas to flow until prompted to stop.
6. Select Next on the LOI while applying zero gas to the sensor.
7. Once zero calibration is complete, disconnect the zero gas and attach the
appropriate concentration of span gas.
8. Select Next on the LOI to begin span calibration.
9. Open the regulator and allow span-gas to flow until prompted to stop.
10. Remove span gas when prompted on the LOI.
After calibration is completed, the LOI shows Zero && Span Calibration Success.
11. Select OK and return to the Primary Variable screen.

4.4 Calibration diagnostics

Stability requirements
If inconsistent calibration gas concentrations are measured during calibration, or if the
calibration gas flow is sporadically stopped, the calibration attempt will fail and be rejected.
Note
Calibration attempts using the IP filter attachment in high wind environments may not
create the required stability and may be rejected.

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Note
If any calibration attempt is rejected or aborted, the sensor will defer to to the most recent
calibration information stored in memory.

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5 Operation and maintenance

5.1 Outputs
The outputs from the Rosemount 925 Transmitter include the current loop, HART signal,
and relay outputs. The current loop and relay outputs are updated every 200 milliseconds.
The 4-20 mA analog output is capable of both sink or source configuration.
The HART® protocol is accessible over the 4-20 mA analog wiring or through the HART
specific connection points found on the front of the transmitter electronics, as shown in
Figure 5-1.

Figure 5-1: HART Connection Points

Status indication LEDs are installed on the local operator interface (LOI), located behind the
check mark, up arrow, and down arrow characters.
Table 5-1: Status Indication LEDs

Color Style Detector operation mode

Green Alternating 3 seconds On, 1 Normal mode

second Off

Amber Solid On Warning or Fault mode

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Table 5-1: Status Indication LEDs (continued)

Color Style Detector operation mode

Red Solid On Gas concentrations have

reached Alarm 1 and/or Alarm 2
values.

Table 5-2: Device outputs status conditions

Status Current loop Fault relay Alarm 1 Alarm 2 Display Button LED Event
level output relay output relay output color logged

Startup Less than 0.5 De-energized De-energized De-energized 925 Red, Yes
mA Amber,
Green,
Startup
sequence

Sensor 2.5 mA Fault Not changed Not changed Icons: Sensor Amber Yes
initialization fault icon
Fault message
text: "Sensor
Initializing"

Signal range 4.0 to 20.0 Not changed Not changed Not changed PV screen Green No
mA,
reflecting the
gas value

Hardware 0 mA Fault Not changed Not changed Icons: Sensor Amber Yes
failure fault icon
Fault message
text: "Transmitter
electronic failure"
Required user
action text:
"Replace module"

Diagnostic 2.0 mA Fault Not changed Not changed Icons: Sensor Amber Yes
faults fault icon
Fault message
text: "varies base
on fault"
Required user
action text:
"varies base on
fault"

Diagnostic If no alarm is Fault Alarm Alarm Icons: Fault icon Red No

faults with active then condition condition Fault message
active alarm 2.5 mA, 4-20 text: "varies base
mA if alarm is on fault"
active Required user
action text:
"varies base on
fault"

Sensor 3.0 mA Not changed Not changed Not changed Message text: Amber No
calibration "varies based on
calibration status"

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Table 5-2: Device outputs status conditions (continued)

Status Current loop Fault relay Alarm 1 Alarm 2 Display Button LED Event
level output relay output relay output color logged

Under range 2.0 mA Fault Not changed Not changed Icons: Sensor Amber Yes
fault icon
Fault message
text: "Sensor
negative drift"
Required user
action text:
"Calibrate sensor"

Over range 20.5 mA Not changed Not changed Not changed Icons: Sensor Amber Yes
warning:
Active alert text:
"Sensor over
range"

Inhibit 4 mA No fault No fault No fault Icon: Fixed Amber No

current mode condition condition condition current

Fixed current 4.20 mA,as Not changed Not changed Not changed Icon: Fixed Amber No
mode set by user current

Transmitter Not changed Not changed Not changed Not changed Icon: Transmitter Amber Yes
warning warning
Active alert
message text:
varies based
on the specific
warning"

Sensor Not changed Not changed Not changed Not changed Icon: Sensor Amber Yes
warning warning
Active alert
message text:
varies based
on the specific
warning"

5.2 Proof tests

Conduct proof tests, otherwise known as bump tests, of sensor modules using one of the
gas delivery options described in Calibration options.
To conduct proof testing without changing any detector outputs, enable the Inhibit output
feature. This feature can be found in the Transmitter Settings section of the LOI menu or via
HART® communication.
Provide calibration gas to the sensor for approximately two seconds or until the primary
variable displays a gas concentration equal to concentration of the calibration gas, within
the acceptable accuracy tolerances.

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5.3 Replace sensor

To replace the Rosemount 625ND Non-dispersive Infrared Combustible Module, refer to
the latest Rosemount 925FGD Product Data Sheet for configured model number and
ordering information.

5.3.1 Replace Rosemount 625ND Non-dispersive Infrared

Combustible Gas Sensor Module
Prerequisites
Remove power from the Rosemount 925FGD and open the Rosemount 625ND sensor
housing. Ensure all appropriate permits are gathered and all actions are taken to declassify
the installation area.

Procedure
1. Loosen the set screw locking the sensor retaining ring; then screw off the retaining
ring by rotating it counterclockwise.
2. Pull the sensor module straight down to remove it.
3. Insert the new sensor module using the alignment guides, ensuring the sensor is
properly seated and the electronic connection has been made.
4. Replace the sensor retaining ring, rotating clockwise.
5. Tighten the set screw to complete the sensor replacement.
As stated in Power on and start-up, the transmitter display will show prompts for sensor
configuration information and calibration after detecting a new sensor.

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5.4 Replace complete transmitter electronics

assembly
The transmitter electronics assembly part number is 92511E4TE.

Figure 5-2: Rosemount 92511E4TE

5.5 Replace transmitter LOI screen and display

board
The part number of the Rosemount 925 transmitter display board, which includes the LOI
screen and IR buttons, is 00925-3201-0001.

Figure 5-3: 00925-3201-0001

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5.6 Event logs

The transmitter maintains an event log which is accessible through both the LOI display
and HART® communication. There are two types of events which are logged, calibration
events and operational events.

Calibration events Record of all field calibrations, both zero only and zero and span
calibrations. Zero and span events are recorded as separate events.
Operational events These are any changes in status or mode except for calibration
events.

5.7 Reset transmitter

This function restarts the transmitter. This function does not reset the transmitter or
sensor to factory configurations if they have been changed.

5.8 Service support

For technical support, contact your Emerson representative or email
[email protected].
The Response Center will ask for product model and serial numbers and will provide a
Return Material Authorization (RMA) number.
The Response Center will also ask for the process materials to which the product was last
exposed.

WARNING
Hazardous substances
Individuals who handle products exposed to a hazardous substance can avoid injury if they
are informed of and understand the hazard. If the product being returned was exposed to
a hazardous substance as defined by the Occupational Safety and Health Administration
(OSHA), a copy of the required Safety Data Sheet (SDS) for each hazardous substance
identified must be included with the returned goods.

5.9 Product recycling/disposal

Consider recycling equipment and packaging. Dispose of the product and packaging in
accordance with local and national legislations and regulations.

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6 Notifications, faults, and diagnostics

6.1 Transmitter electronics failure
Icon Transmitter fault
Fault message text Transmitter electronics failure
Required user action text Replace module.

Potential cause
A failure has been detected in the transmitter electronics circuit board.

Recommended actions
1. Power cycle.
2. If issue persists, replace transmitter module.

6.2 Transmitter power supply low

Icon Transmitter fault
Fault message text Transmitter power supply low
Required user action text Verify operation range.

Potential cause
Supply voltage is lower than 15.5 V.

Recommended actions
1. Raise power supply voltage.
2. If issue persists, replace transmitter module.

6.3 Transmitter analog output failure

Icon Transmitter fault
Fault message text Transmitter analog output failure
Required user action text Verify output connection.

Potential cause
The current loop readback error is larger than two percent of span.

Recommended actions
1. Power cycle.
2. Verify analog output connection and 3-wire or 4-wire jumper position.
3. If issue persists, replace transmitter module.

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6.4 Sensor incompatible

Icon Transmitter fault
Fault message text Sensor incompatible
Required user action text Refer to manual.

Potential cause
Transmitter is not compatible with sensor.

Recommended action
Update transmitter firmware or install compatible sensor.

6.5 Transmitter software fault

Icon Transmitter fault
Fault message text Transmitter software fault
Required user action text Reset device.

Potential cause
Software has detected an unexpected software condition or parameter that may be
impairing device operation.

Recommended actions
1. Power cycle.
2. If issue persists, replace transmitter module.

6.6 Transmitter temperature high

Icon Transmitter warning
Active alert message text Transmitter temperature high

Potential cause
Temperature is above the device maximum operating temperature.

Recommended actions
1. Lower ambient temperature.
2. If the condition persists, replace the transmitter module.

6.7 Transmitter temperature low

Icon Transmitter warning
Active alert message text Transmitter temperature low

Potential cause
Temperature is below the device minimum operating temperature.

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Recommended actions
1. Raise ambient temperature.
2. If the condition persists, replace the transmitter module.

6.8 Transmitter power supply high

Icon Transmitter warning
Active alert message text Transmitter power supply high

Potential cause
The supply voltage is higher than 29.75 V.

Recommended actions
1. Lower power supply voltage.
2. If the condition persists, replace the transmitter module.

6.9 Transmitter display board failure

Icon Transmitter warning
Active alert message text Transmitter display board failure

Potential cause
Software unable to communicate with LOI display buttons.

Recommended actions
1. Cycle power to the transmitter.
2. If the condition persists, replace the transmitter module.

6.10 Sensor initializing

Icon Sensor fault
Fault message text Sensor initializing

Potential cause
The sensor is initializing.

Recommended action
Allow sensor to finish performing its initialization sequence.

6.11 Sensor not calibrated

Icon Sensor fault
Fault message text Sensor not calibrated
Required user action text Calibrate sensor.

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Potential cause
The sensor has not been calibrated.

Recommended action
Perform a zero and span calibration of the sensor.

6.12 Sensor negative drift

Icon Sensor fault
Fault message text Sensor negative drift
Required user action text Calibrate sensor.

Potential cause
Sensor is detecting a negative reading.

Recommended action
Perform a zero calibration on the sensor.

6.13 Sensor electronics failure

Icon Sensor fault
Fault message text Sensor electronics failure
Required user action text Replace module.

Potential cause
A failure has been detected in the sensor electronics.

Recommended action
Replace sensor hardware.

6.14 Sensor temperature high

Icon Sensor fault
Fault message text Sensor temperature high
Required user action text Verify operation range.

Potential cause
Temperature is above the sensor's maximum operating temperature.

Recommended actions
1. Lower ambient temperature for sensor.
2. If the condition persists, replace the sensor electronics.

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6.15 Sensor temperature low

Icon Sensor fault
Fault message text Sensor temperature low
Required user action text Verify Operation Range.

Potential cause
Temperature is below the sensor's minimum operating temperture.

Recommended actions
1. Raise ambient temperature for sensor.
2. If the condition persists, replace the sensor electronics.

6.16 Sensor power supply high

Icon Sensor fault
Fault message text Sensor power supply high
Required user action text Verify operation range.

Potential cause
Supply voltage to the sensor is higher than the sensor's maximum operating voltage.

Recommended actions
1. Verify supply voltage to sensor.
2. If the condition persists, replace the sensor electronics.

6.17 Sensor power supply low

Icon Sensor fault
Fault message text Sensor power supply low
Required user action text Verify operation range.

Potential cause
Supply voltage to the sensor is lower than the sensor's minimum operating voltage.

Recommended actions
1. Verify supply voltage to sensor.
2. If the condition persists, replace the sensor electronics.

6.18 Sensor environmental fault

Icon Sensor fault
Fault message text Sensor environmental fault
Required user action text Verify operation range.

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Potential cause
Environmental conditions exceed the operating limits of the sensor.

Recommended actions
1. Verify all environmental conditions (pressure, humidity, etc.).
2. If issue persists, replace sensor module.

6.19 Sensor fault not defined

Icon Sensor fault
Fault message text Sensor fault not defined
Required user action text Refer to manual.

Potential cause
Undefined sensor status detected.

Recommended actions
1. Power cycle.
2. If issue persists, replace sensor module.

6.20 Sensor fault

Icon Sensor Fault
Text --- (instead of showing gas concentration)
Fault message Sensor Communication Fault
Required user action text Verify Sensor Connection.

Potential cause
Software unable to communicate with sensor.

Recommended actions
1. Verify sensor is properly connected to transmitter.
2. If the condition persists, replace the transmitter module.

6.21 Sensor weak signal

Icon Sensor warning
Active alert text Sensor weak signal

Potential cause
Sensor signal is weak.

Recommended actions
1. Verify calibration gas and re-calibrate sensor.
2. If issue persists, replace sensor module.

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6.22 Replace sensor soon

Icon Sensor warning
Active alert text Replace sensor soon.

Potential cause
Sensor is nearing end of life.

Recommended action
Replace the sensor in the near future.

6.23 Undefined sensor warning

Icon Sensor warning
Active alert text Undefined sensor warning

Potential cause
Undefined sensor status detected.

Recommended actions
1. Power cycle.
2. If issue persists, replace sensor module.

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A Specifications
For the most recent specifications, refer to the Rosemount 925FGD Product Data Sheet.

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B Product certifications
B.1 Reliability
Certified SIL2 per IEC 61508.

B.2 Global hazardous area and performance

For the most recent information, please refer to the Rosemount 925FGD Quick Start Guide.

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54 Emerson.com/Rosemount
Manual Spare parts
00809-0100-4925 March 2023

C Spare parts
Part number Description

00925-9100-0001 625ND and 628 Calibration Cup (Individual)

00925-9100-0006 Replacement 925 Transmitter Display Assembly

00925-9100-0008 U-Bolt for 925 Transmitter Pole Mount (Set of 2)

00925-9100-0015 Gas Calibration Kit, 0.5 LPM SST Regulator, with Cal Cup

00628-9000-0001 Spare, ingress protection filter assembly for 625ND and 628

SSK-51 Sunshade assembly, 1-in. pipe

SSK-52 Sunshade assembly, 2-in. pipe

SSK-53 Sunshade assembly, 3-in. pipe

Rosemount 925FGD 55
 00809-0100-4925
Rev. AB
2023

For more information: Emerson.com

©2023 Emerson. All rights reserved.

Emerson Terms and Conditions of Sale are available

upon request. The Emerson logo is a trademark and
service mark of Emerson Electric Co. Rosemount is a
mark of one of the Emerson family of companies. All
other marks are the property of their respective owners.