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Emerson 3081FG User Manual

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Page 1
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
Two-Wire In Situ Oxygen Analyzer (550° to 1600°C)
http://www.processanalytic.com
Page 2

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and mainte-
nance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate In- struction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s per­formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.
The information contained in this document is subject to change without notice.
Rosemount Analytical Inc. Process Analytic Division
1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
Page 3

HIGHLIGHTS OF CHANGES

Effective June, 1998 Rev. 1.0
Page Summary
Page 2-10 Corrected part numbers in Figure 2-9 for Flowmeter and Ref Air Set.
Page 3-4 Modified Figure 3-5 to reflect selection of additional faults.
Page 3-11 Modified paragraph 3-6a to select additional fault screens.
Page 4-4 Updated menus for O
Page 8-1 Added in replacement part numbers for Model 3081 Transmitter.
Effective April, 1999 Rev. 1.1
Page Summary
Cover Added “Model 3081FG” to manual title.
Page 1-2 Deleted 48 in. probe and Mullite probe options from Product Matrix.
Page 1-7 Deleted 48 in. probe and Mullite probe references from specifications.
Page 2-1 through 2-6 Changed probe installation mounting and insertion procedures and
requirements.
Page 5-1 Revised PC board stack replacement procedure.
Throughout Changed all references to “power supply board” to read “analog board”.
Reformatted document in accordance with the latest style guide.
Effective October, 2000 Rev. 1.2
Page Summary
Throughout Changed all references of 38 in. (965 mm) probe to 34.625 in.
(880 mm).
value, SV, TV, and 4V values.
2
Effective April, 2001 Rev. 1.3
Page Summary
Page 2-9 Added 1st WARNING to paragraph 2-3.
Page 10-2 Added drawing 1400184.
Effective January, 2002 Rev. 1.4
Page Summary
Page 8-1 Added part number for PC Board Stack Assembly.
Effective September, 2002 Rev. 1.5
Page Summary
Page 1-7 Updated process temperature limits specification.
Page 4
Page 5
Model 3081FG
PREFACE........................................................................................................................ P-1
Definitions ........................................................................................................................P-1
Safety Instructions .......................................................................................................... P-2
1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1
1-1 Component Checklist Of Typical System (Package Contents) .................................. 1-1
1-2 System Overview............................................................................................................ 1-3
1-3 Specifications................................................................................................................... 1-7
2-0 INSTALLATION .............................................................................................................. 2-1
2-1 Pre-Installation................................................................................................................. 2-1
2-2 Mechanical Installation ................................................................................................... 2-1
2-3 Electrical Installation....................................................................................................... 2-9
2-4 Pneumatic Installation .................................................................................................. 2-11
3-0 STARTUP AND OPERATION ...................................................................................... 3-1
3-1 General ............................................................................................................................ 3-1
3-2 Power Up........................................................................................................................ 3-1
3-3 Reestablishing Proper Calibration Check Gas Flow Rate......................................... 3-2
3-4 Operation ......................................................................................................................... 3-3
3-5 Program Menu ................................................................................................................3-6
3-6 Diagnostics Menu ......................................................................................................... 3-11
3-7 CALCHECK MENU ...................................................................................................... 3-13
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002

TABLE OF CONTENTS

4-0 HART/AMS...................................................................................................................... 4-1
4-1 Overview.......................................................................................................................... 4-1
4-2 HART Communicator Signal Line Connections ........................................................... 4-1
4-3 HART Communicator PC Connections ........................................................................ 4-3
4-4 Off-Line and On-Line Operations ................................................................................. 4-3
4-5 Menu Tree for HART Communicator/
Two-Wire In Situ Oxygen Analyzer Applications...................................................... 4-3
4-6 HART Communicator Start CALCHECK Method ........................................................ 4-7
5-0 MAINTENANCE AND SERVICE .................................................................................. 5-1
5-1 Model 3081 Electronics Replacement ......................................................................... 5-1
5-2 Oxygen Probe Replacement ......................................................................................... 5-3
6-0 TROUBLESHOOTING .................................................................................................... 6-1
6-1 General ............................................................................................................................ 6-1
6-2 Probe Life ....................................................................................................................... 6-1
6-3 Fault Indications.............................................................................................................. 6-2
6-4 Identifying and Correcting Fault Indications ................................................................. 6-3
7-0 RETURN OF MATERIAL .............................................................................................. 7-1
8-0 REPLACEMENT PARTS ............................................................................................... 8-1
9-0 INDEX.............................................................................................................................. 9-1
10-0 DRAWINGS AND SCHEMATICS ............................................................................... 10-1
Rosemount Analytical Inc. A Division of Emerson Process Management i
Page 6
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Figure 1-1. Typical System Package ....................................................................................... 1-1
Figure 1-2. Two-Wire In Situ Oxygen Analyzer HART Connections and AMS Application ..... 1-5
Figure 1-3. Typical System Installation .................................................................................... 1-6
Figure 1-4. Power Supply and Load Requirements ................................................................. 1-8
Figure 2-1. Probe Installation Details ....................................................................................... 2-2
Figure 2-2. Optional Adapter Plate........................................................................................... 2-3
Figure 2-3. Optional Probe Mounting Flange ........................................................................... 2-3
Figure 2-4. Horizontal Probe Installation .................................................................................. 2-4
Figure 2-5. Adjusting Probe Insertion Depth ............................................................................ 2-5
Figure 2-6. Flat Surface Mounting Dimensional Information.................................................... 2-7
Figure 2-7. Pipe Mounting Dimensional Information ................................................................ 2-8
Figure 2-8. Display Positioning Assembly................................................................................ 2-9
Figure 2-9. Oxygen Probe Terminal Block ............................................................................. 2-10
Figure 2-10. Model 3081 Transmitter Terminal Block .............................................................. 2-11
Figure 2-11. Oxygen Probe Gas Connections ......................................................................... 2-11
Figure 2-12. Air Set, Plant Air Connection ............................................................................... 2-12
Figure 3-1. Normal Operation Display...................................................................................... 3-1
Figure 3-2. Faulted Operation Display ..................................................................................... 3-1
Figure 3-3. Proper Calibration Check Gas Flow Rate.............................................................. 3-2
Figure 3-4. Normal Operation Display...................................................................................... 3-3
Figure 3-5. Model 3081 Transmitter Menu Tree ...................................................................... 3-4
Figure 3-6. Infrared Remote Control (IRC)............................................................................... 3-5
Figure 3-7. CODE..................................................................................................................... 3-6
Figure 3-8. DISPLAY CODE ................................................................................................... 3-6
Figure 3-9. FAULT VAL........................................................................................................... 3-7
Figure 3-10. UPPER RANGE VAL ........................................................................................... 3-7
Figure 3-11. CELL T HI ............................................................................................................ 3-7
Figure 3-12. RESET MAX CELL T ........................................................................................... 3-8
Figure 3-13. SET O
Figure 3-14. TRIM 4 mA?........................................................................................................... 3-8
Figure 3-15. TRIM 20 mA?......................................................................................................... 3-9
Figure 3-16. SET HI BOTTLE O Figure 3-17. SET LO BOTTLE O Figure 3-18. SET O
Figure 3-19. SET CODE.......................................................................................................... 3-10
Figure 3-20. SHOW FAULT .................................................................................................... 3-11
Figure 3-21. T/C mV................................................................................................................. 3-11
Figure 3-22. O
Figure 3-23. CELL IMPEDANCE............................................................................................. 3-12
Figure 3-24. PREVIOUS SLOPE ............................................................................................ 3-12
Figure 3-25. PREVIOUS CONSTANT .................................................................................... 3-12
Figure 3-26. MAX CELL T ......................................................................................................3-13
Figure 3-27. IN MANUAL? ...................................................................................................... 3-14
Figure 3-28. ACCEPT HIGH O Figure 3-29. ACCEPT LOW O
Figure 3-30. SLOPE ................................................................................................................. 3-15
Figure 3-31. CONSTANT ......................................................................................................... 3-15
Figure 4-1. Signal Line Connections, > 250 Ohms Lead Resistance ...................................... 4-2
Figure 4-2. Signal Line Connections, < 250 Ohms Lead Resistance ...................................... 4-3
Model 3081FG
LIST OF ILLUSTRATIONS
FILTER TIME.......................................................................................... 3-8
2
............................................................................................. 3-9
2
............................................................................................ 3-9
TRACKING ............................................................................................ 3-10
2
CELL mV ....................................................................................................... 3-11
2
2
.............................................................................................. 3-14
2
............................................................................................... 3-15
2
ii Rosemount Analytical Inc. A Division of Emerson Process Management
Page 7
Model 3081FG
Figure 4-3. Menu Tree for HART/AMS on the Two-Wire In Situ
Oxygen Analyzer (Sheet 1 of 3)............................................................................. 4-4
Figure 5-1. Two-Wire In Situ Oxygen Analyzer Exploded View............................................... 5-2
Figure 5-2. Oxygen Probe Terminal Block ............................................................................... 5-4
Figure 6-1. Slope vs. Impedance ............................................................................................. 6-1
Figure 6-2. Speed of Response ............................................................................................... 6-2
Figure 6-3. Faulted Operation Display ..................................................................................... 6-2
Figure 6-4. Model 3081 Transmitter Terminal Block................................................................ 6-3
Figure 6-5. Fault 1, Open Thermocouple ................................................................................. 6-4
Figure 6-6. Fault 2, Reversed Thermocouple .......................................................................... 6-4
Figure 6-7. Fault 3, Shorted Thermocouple ............................................................................. 6-5
Figure 6-8. Fault 4, High Probe Temperature .......................................................................... 6-5
Figure 6-9. Fault 5, O
Figure 6-10. Fault 6, Cell Impedance Too High ......................................................................... 6-6
Figure 6-11. Fault 7, Reversed O
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
Cell Open............................................................................................. 6-6
2
Cell ...................................................................................... 6-7
2

LIST OF TABLES

Table 1-1. Product Matrix........................................................................................................ 1-2
Table 3-1. Model 3081 Transmitter Parameters ................................................................... 3-10
Table 8-1. Replacement Parts List.......................................................................................... 8-1
Rosemount Analytical Inc. A Division of Emerson Process Management iii
Page 8
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
iv Rosemount Analytical Inc. A Division of Emerson Process Management
Page 9
Model 3081FG
The purpose of this manual is to provide information concerning the components, func­tions, installation and maintenance of the Model 3081FG Two-Wire In Situ Oxygen Ana­lyzer (550° to 1600°C).
Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
PREFACE

DEFINITIONS

Highlights an operation or maintenance procedure, practice, condition, state­ment, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an essential operating procedure, condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

Highlights an operation or maintenance procedure, practice, condition, state­ment, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
The number in the lower right corner of each illustration in this publication is a manual illus­tration number. It is not a part number, and is not related to the illustration in any technical manner.
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
Page 10
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
FOR THE WIRING AND INSTALLATION
The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non­EU states should also comply with the following unless superseded by local or National Standards.
1. Adequate earth connections should be made to all earthing points, internal and external, where provided.
2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times.
3. Mains supply cords should comply with the requirements of IEC227 or IEC245.
Model 3081FG
IMPORTANT

SAFETY INSTRUCTIONS

OF THIS APPARATUS
4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.
5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.
6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.
7. Where equipment or covers are marked with the symbol to the right, hazard­ous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then only by trained service personnel.
8. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Cer­tain surfaces may remain hot to the touch.
9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions.
10. All graphical symbols used in this product are from one or more of the follow­ing standards: EN61010-1, IEC417, and ISO3864.
P-2 Rosemount Analytical Inc. A Division of Emerson Process Management
Page 11
Model 3081FG
1

DESCRIPTION AND SPECIFICATIONS

Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
SECTION 1
1-1 COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
A typical Rosemount Two-Wire In Situ Oxygen Analyzer should contain the items shown in Figure 1-1. Record the part number, serial num­ber, and order number for each component of your system in the table located on the first
8
MAN4275A00
English
October1994
HART Communicator
o
page of this manual. Also, use the product ma­trix in Table 1-1 to compare your order number against your unit. The first part of the matrix de­fines the model. The last part defines the vari­ous options and features of the analyzer. Ensure the features and options specified by your order number are on or included with the unit.
1
2
3
TM
FISHER-ROSEMOUNT
6
1. Instruction Bulletin
2. Model 3081 Transmitter
3. Oxygen Probe
4. Adapter Plate with mounting hardware and gasket (Optional)
Figure 1-1. Typical System Package
7
5
4
5. Infrared Remote Control (IRC) (Optional)
6. Reference Air Set (Optional)
7. HART
®
Communicator Package (Optional)
8. Pipe Mounting Kit (Optional)
26020036
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Page 12
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Table 1-1. Product Matrix
3081FG High Temperature Oxygen Flue Gas Analyzer
High Temperature Analyzer - Instruction Book
Code Sensing Probe Length
1 20 in. (508 mm) probe, 1/4 in. tube fittings
2 26 in. (660 mm) probe, 1/4 in. tube fittings
3 34.625 in. (880 mm) probe, 1/4 in. tube fittings
Code Probe Outer Tube Material - Maximum Operating Temperature
1 Alumina - 2912°F (1600°C) maximum - 1.25 NPT mounting
2 Inconel 600 - 1832°F (1000°C) maximum - 1.25 NPT mounting
Code Mounting Adapter - Stack Side
0 No adapter plate required uses 1.25 NPT
("0" must also be chosen under "Mounting Adapter" below)
1 New flanged installation - Square weld plate with studs (matches "Mounting Adapter" below)
2 Model 450 mounting ("4" must also be chosen under "Mounting Adapter" below)
3 Competitor's Mount ("5" must also be chosen under "Mounting Adapter" below)
Code Mounting Adapter - Probe Side
0 No adapter plate
1 ANSI 2 in. 150 lb flange to 1.25 NPT adapter
(6 in. dia. flange, 4.75 in. BC with 4 x 0.75 in. dia. holes)
2 DIN to 1.25 NPT adapter (184 mm flange, 145 mm BC with 4 x 18 mm dia. holes)
3 JIS to 1.25 NPT adapter (155 mm flange, 130 mm BC with 4 x 13 mm dia. holes)
4 Model 450 to 1.25 NPT adapter
5 Competitor's mounting flange
Code Electronics & Housing - Intrinsically Safe, NEMA 4X, IP65
1 3081 Electronics (Hart-compatible) - CENELEC EEx ia IIC T5
2 3081 Electronics (Hart-compatible) - CSA pending
3 3081 Electronics (Hart-compatible) - FM Class I, Div. I, Groups B,C,D
Code Housing Mounting
0 Surface or wall mounting
1 1/2 to 2 in. pipe mounting
Code Communications
0 No remote control
1 Infrared Remote Control (IRC)
(LCD display through cover window)
Code Calibration Accessories
1 No hardware
2 Calibration and reference air flowmeters and refer-
ence air pressure regulator
Code Armored Cable Length
00 No cable
11 20 ft (6 m)
12 40 ft (12 m)
13 60 ft (18 m)
14 80 ft (24 m)
15 100 ft (30 m)
16 150 ft (45 m)
17 200 ft (61 m)
18 300 ft (91 m)
19 400 ft (122 m)
20 500 ft (152 m)
3081FG2100111211 Example
Model 3081FG
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Page 13
Model 3081FG
1
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002

1-2 SYSTEM OVERVIEW

a. Scope
This Instruction Bulletin is designed to sup­ply details needed to install, start up, oper­ate, and maintain the Rosemount Two-Wire In Situ Oxygen Analyzer. The analyzer con­sists of an oxygen probe and Model 3081 Transmitter. The signal conditioning elec­tronics of the Model 3081 Transmitter out­puts a 4-20 mA signal representing an O value. An infrared remote control (IRC) al­lows access to setup, calibration, and diag­nostics. This same information, plus additional details, can be accessed with the HART Model 275 handheld communicator or Asset Management Solutions (AMS) software.
b. System Description
The Rosemount Two-Wire In Situ Oxygen Analyzer is designed to measure the net concentration of oxygen in an industrial pro­cess; i.e., the oxygen remaining after all fu­els have been oxidized. The oxygen probe is permanently positioned within an exhaust duct or stack and performs its task without the use of a sampling system. The Model 3081 Transmitter is mounted remotely and conditions the oxygen probe outputs.
The equipment measures oxygen percent­age by reading the voltage developed across an electrochemical cell, which con­sists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. The millivolt output voltage of the cell is given by the following Nernst equation:
EMF = KT log10(P1/P2) + C
Where:
1. P
is the partial pressure of the oxygen
2
in the measured gas on one side of the cell.
2. P
is the partial pressure of the oxygen
1
in the reference air on the opposite side of the cell.
3. T is the absolute temperature.
4. C is the cell constant.
5. K is an arithmetic constant.
NOTE
For best results, use clean, dry, in­strument air (20.95% oxygen) as the reference air.
NOTE
The probe uses a Type B thermocou­ple to measure the cell temperature.
When the cell is at 550°C to 1600°C
2
(1022°F to 2912°F) and there are unequal oxygen concentrations across the cell, oxy­gen ions will travel from the high oxygen partial pressure side to the low oxygen par­tial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade.
The output is proportional to the inverse logarithm of the oxygen concentration. Therefore, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the Rosemount Two-Wire In Situ Oxygen Ana­lyzer to provide exceptional sensitivity and accuracy at low oxygen concentrations.
Oxygen analyzer equipment measures net oxygen concentration in the presence of all the products of combustion, including water vapor. Therefore, it may be considered an analysis on a "wet" basis. In comparison with older methods, such as the portable apparatus, which provides an analysis on a "dry" gas basis, the "wet" analysis will, in general, indicate a lower percentage of oxy­gen. The difference will be proportional to the water content of the sampled gas stream.
c. System Configuration
The equipment discussed in this manual consists of two major components: the oxy­gen probe and the Model 3081 Transmitter.
Oxygen probes are available in three length options, providing in situ penetration appro­priate to the size of the stack or duct. The options on length are 20 in. (508 mm), 26 in. (660 mm), or 34.625 in. (880 mm).
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Page 14
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
The Model 3081 Transmitter is a two-wire transmitter providing an isolated output, 4­20 mA, that is proportional to the measured oxygen concentration. A customer-supplied 24 VDC power source is required to simul­taneously provide power to the electronics and a 4-20 mA signal loop. The transmitter accepts millivolt signals generated by the probe and produces the outputs to be used by other remotely connected devices. The output is an isolated 4-20 mA linearized current.
d. System Features
1. The cell output voltage and sensitivity increase as the oxygen concentration decreases.
2. High process temperatures eliminate the need for external cell heating and increase cell accuracy.
3. HART communication is standard. To use the HART capability, you must have either:
(a) HART Model 275 Communicator
(b) Asset Management Solutions
(AMS) software for the PC
(a) Infrared Remote Control. The IRC
allows access to fault indication menus on the Model 3081 Trans­mitter LCD display. Calibration can be performed from the IRC keypad.
(b) Optional HART Interface. The
Two-Wire In Situ Oxygen Ana­lyzer’s 4-20 mA output line trans­mits an analog signal proportional to the oxygen level. The HART output is superimposed on the 4-20 mA output line. This information can be accessed through the following:
1 Rosemount Model 275 Hand-
held Communicator - The handheld communicator re­quires Device Description (DD) software specific to the Two-Wire In Situ Oxygen Analyzer. The DD software will be supplied with many Model 275 units but can also be programmed into existing units at most Fisher­Rosemount service offices. See Section 4, HART/AMS, for additional HART information.
4. Easy probe replacement due to the light-weight, compact probe design.
5. Remote location of the Model 3081 Transmitter removes the electronics from high temperature or corrosive environments.
6. Power is supplied to the electronics through the 4-20 mA line for intrinsic safety (IS) purposes.
7. Infrared remote control (IRC) allows interfacing without exposing the electronics.
8. An operator can operate and diagnos­tically troubleshoot the Two-Wire In Situ Oxygen Analyzer in one of two ways:
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
9. Selected Distributed Control Systems -
10. A calibration check procedure is pro-
2 Personal Computer (PC) -
The use of a personal com­puter requires AMS software available from Fisher­Rosemount.
The use of distributed control systems requires input/output (I/O) hardware and AMS Security codes are provided to (by infrared remote control) prevent unintended changes to analyzers adja­cent to the one being accessed.
vided to determine if the Rosemount Two-Wire In Situ Oxygen Analyzer is correctly measuring the net oxygen concentration in the industrial process.
Page 15
Model 3081FG
1
TWO-WIRE IN SITU
OXYGEN ANALYZER
CALIBRATION CHECK
GAS LINE
REFERENCE
Figure 1-2. Two-Wire In Situ Oxygen Analyzer HART Connections and AMS Application
AIR LINE
OmV
2
SIGNAL
MODEL 3081
TRANSMITTER
TEMPERATURE
mV SIGNAL
4-20 mA OUTPUT (TWISTED PAIR)
TERMINATION IN
CONTROL ROOM
+
24 VDC POWER SUPPLY
Instruction Manual
HART MODEL 275
HAND HELD
INTERFACE
INTRINSIC
SAFETY
BARRIER
(OPTIONAL)
ASSET MANAGEMENT
IB-106-3081 Rev. 1.5
September 2002
SOLUTIONS
26020037
e. Handling the Analyzer
The probe was specially packaged to pre­vent breakage due to handling. Do not re­move the padding material from the probe until immediately before installation.
It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to pre­vent possible equipment damage.
The oxygen probe is designed for in­dustrial applications. Treat with care to avoid physical damage. The probe contains components made from ce­ramic, which are susceptible to shock when mishandled. THE WARRANTY DOES NOT COVER DAMAGE FROM MISHANDLING.
f. System Considerations
Prior to installing your Rosemount Two-Wire In Situ Oxygen Analyzer, make sure you have all the components necessary to make the system installation. Ensure all the com­ponents are properly integrated to make the system functional.
After verifying that you have all the compo­nents, select mounting locations and deter­mine how each component will be placed in terms of available line voltage, ambient temperatures, environmental considera­tions, convenience, and serviceability. Fig­ure 1-2 shows a typical system wiring. A typical system installation is illustrated in Figure 1-3.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
Page 16
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
GASES
DUCT
STACK
OXYGEN
PROBE
MODEL 3081
TRANSMITTER
4-20 mA SIGNAL
Figure 1-3. Typical System Installation
A source of instrument air is required at the oxygen probe for reference air use. Since the Two-Wire In Situ Oxygen Analyzer is equipped with an in-place calibration fea­ture, provisions should be made for con­necting calibration check gas tanks to the oxygen probe during calibration.
If the calibration check gas bottles are to be permanently connected, a check valve is required next to the calibration fittings on the integral electronics.
This check valve is to prevent breathing of calibration check gas line and subsequent flue gas condensation and corrosion. The
OPTIONAL ADAPTER PLATE
FLOWMETER
INSTRUMENT AIR SUPPLY (REFERENCE AIR)
PRESSURE
REGULATOR
26020038
check valve is in addition to the stop valve in the calibration check gas kit.
NOTE
The electronics of the Model 3081 Transmitter is rated NEMA 4X (IP65) and is capable of operating at tem­peratures up to 65°C (149°F).
Retain the packaging in which the Rosemount Two-Wire In Situ Oxygen Analyzer arrived from the factory in case any components are to be shipped to another site. This packag­ing has been designed to protect the product.
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Page 17
Instruction Manual
1
IB-106-3081 Rev. 1.5
Model 3081FG
1-3 SPECIFICATIONS
Range....................................................................... 0 to 25% O
Net O
2
Fully Field Selectable via the HART Interface
Lowest Limit................................................................. 0.05% O
Highest Limit ................................................................ 25.00% O
Accuracy .............................................................................. ±1.5% of reading or 0.05% O2, whichever is greater
System Response to Calibration Check Gas ...................... Initial response in less than 3 seconds
T90 in less than 10 seconds PROBE
Lengths ................................................................................ 20 in. (508 mm)
26 in. (660 mm)
34.625 in. (880 mm)
Temperature Limits
Process Temperature Limits........................................ 550° to 1400°C (1022° to 2552°F)
Operation to 1600°C (2912°F) with reduced cell life.
Ambient........................................................................ -40° to 149°C (-40° to 300°F) Ambient
Mounting and Mounting Position ......................................... Vertical or Horizontal
Materials of Construction
Process Wetted Parts
Inner Probe .................................................................. Zirconia
Outer Protection Tube ................................................. Alumina [1600°C (2912°F) limit]
Inconel 600 [1000°C (1832°F) limit]
Probe Junction Box ..................................................... Cast aluminum
Speed of Installation/Withdrawal ......................................... 1 in. (25.4 mm) per minute
Hazardous Area Certification............................................... Intrinsically safe per EN50 014 (1977), clause 1.3(1)
Reference Air Requirement ................................................. 100 ml per minute (0.2 scfh) of clean, dry instrument
air; 1/4 in. tube fittings
Calibration Check Gas Fittings ............................................ 1/4 in. tube fittings
Cabling................................................................................. Two twisted pairs, shielded
(1)
Thermocouple and O2 probe cell are both unpowered, developing a millivolt emf, and are considered a “simple apparatus” by certifying agencies.
2
2
2
September 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7
Page 18
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
ELECTRONICS
Enclosure ....................................................................... IP65 (NEMA 4X), weatherproof, and corrosion-resistant
Materials of Construction ............................................... Low copper aluminum
Ambient Temperature Limits ......................................... -20° to 65°C (-4° to 149°F)
Relative Humidity ........................................................... 95% with covers sealed
Power Supply and Load Requirements ......................... See Figure 1-4
Inputs (from O
Probe)................................................... Two wires - O2 signal
2
Two wires - type B thermocouple
Output ............................................................................ One 4-20 mA signal with superimposed digital HART
signal
Hazardous Area Certification......................................... Cenelec EEx ia IIC T4 or T5(2)
NEC Class I Div. I Group B,C,D
Fisher-Rosemount has satisfied all obliga­tions coming from the European legislation to harmonize the product requirements in Europe.
Power Transient Protection ........................................... IEC 801-4
Shipping Weight............................................................. 10 lbs (4.5 kg)
INFRARED REMOTE CONTROL
Power Requirements .....................................................Three AAA batteries
Hazardous Area Certification......................................... Cenelec EEx ia IIC Class I, Div. I, Group A, B, C, D
(2)
Dependent on ambient temperature limits.
Model 3081FG
1848 1800
1500
1000
LOAD (OHMS)
500
250
0
12.0 VDC 18 VDC 40 VDC @ ZERO LOAD 42.4 VDC LIFT OFF
WITHOUT HART COMMUNICATOR
POWER SUPPLY VOLTAGE
OPERATING
REGION
MAXIMUM
Figure 1-4. Power Supply and Load Requirements
1848 OHMS @ 42.4 VDC
600 OHMS @ 42.4 VDC
29750007
1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Page 19
Model 3081FG
2
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
SECTION 2

INSTALLATION

2-1 PRE-INSTALLATION
a. Inspect
Carefully inspect the shipping container for any evidence of damage. If the container is damaged, notify the carrier immediately.
b. Packing List
Confirm that all items shown on the packing list are present. Notify Rosemount Analytical immediately if items are missing.
Before installing this equipment, read the “Safety instructions for the wiring and installation of this apparatus” at the front of this Instruction Bulletin. Failure to follow the safety instruc­tions could result in serious injury or death.
2-2 MECHANICAL INSTALLATION
Avoid installation locations near steam soot blowers.
sensing point should be selected so the process gas temperature falls within a range of 550° to 1600°C (1022° to 2912°F). Figure 2-1 provides mechanical installation references.
2. Check the flue or stack for holes and air leakage. The presence of this con­dition will substantially affect the accu­racy of the oxygen reading. Therefore, either make the necessary repairs or install the probe upstream of any leakage.
3. Ensure the area is clear of internal and external obstructions that will interfere with installation and maintenance ac­cess to the probe. Allow adequate clearance for probe removal (Figure 2-1).
b. Installing Oxygen Probe
The probe was specially packaged to prevent breakage due to handling. Do not remove the padding material from the probe until immediately before installation.
a. Locating Oxygen Probe
1. The location of the oxygen probe in the stack or flue is important for maxi­mum accuracy in the oxygen analyzing process. The probe must be positioned so the gas it measures is representa­tive of the process. Best results are normally obtained if the probe is posi­tioned near the center of the duct (40­60% insertion). Longer ducts may re­quire several analyzers since the O can vary due to stratification. A point too near the wall of the duct, or the in­side radius of a bend, may not provide a representative sample because of the very low flow conditions. The
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
2
Leave the probe inner protective cover in place until installation. This is re­quired to protect the ceramic cell dur­ing movement.
1. Ensure all components are available to install the probe.
NOTE
2. If using an optional adapter plate (Figure 2-2) or an optional mounting flange (Figure 2-3), weld or bolt the component onto the duct. The through hole in the stack or duct wall and re­fractory material must be 2 in. (50.8 mm) diameter, minimum.
Page 20
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
1/4 TUBE FITTING (REFERENCE AIR PORT)
1/4 TUBE FITTING
(CALIBRATION
CHECK GAS PORT)
REFERENCE AIR VENT
FRONT VIEW
(REMOVAL ENVELOPE)
1.1
O
(29)
DIM “A”
1.25 NPT PROCESS CONNECTION
7.1 (180)
DIM “B”
O
4.1
(109)
SIDE VIEW
1.8
(49)
TABLE 1. INSTALLATION (REMOVAL)
PROBE
20 IN.
26 IN.
34.625 IN.
DIM “A”
20 (508)
26 (660)
34.625 (880)
DIM “B”
31 (787)
37 (940)
46 (1170)
Figure 2-1. Probe Installation Details
BOTTOM VIEW
INSTALL WITH PORT AT
THE BOTTOM
3.0
(77)
NOTE: DIMENSIONS ARE IN INCHES WITH
MILLIMETERS IN PARENTHESES.
3/4 NPT
CONDUIT
PORT
29750001
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
2
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
A
B
C
NOTE: DIMENSIONS ARE
IN INCHES WITH MILLIMETERS IN PARENTHESES.
DIMENSION
“B” THREAD 0.625-11 M-16x2 M-12x1.75
“C” DIA. 4.75 (121) 5.71 (145) 5.12 (130)
METAL WALL
STACK OR DUCT
A
WELD OR BOLT ADAPTER PLATE TO STACK OR DUCT. JOINT MUST BE AIR TIGHT.
ANSI
4512C34G01
“A” 6.00 (153) 7.5 (191) 6.50 (165)
2.50 (63.5) MIN. DIA.
JOINT MUST
BE AIR TIGHT
PLATE DIMENSIONS
DIN
4512C36G01
MASONRY WALL
STACK
3.00 SCHEDULE 40 PIPE SLEEVE
SUPPLIED BY CUSTOMER
JIS
4512C35G01
WELD PIPE TO
ADAPTER PLATE
3.50 (89)
O.D. REF
29750002
Figure 2-2. Optional Adapter Plate
TAP 1.25 NPT
B
A
C
FLANGE DIMENSIONS
ANSI
DIMENSION
“A” DIA. 6.00 (153) 7.28 (185) 6.10 (155) 9.00 (229)
“B” DIA. 0.75 (20) 0.71 (18) 0.59 (15) 0.50 (13)
“C” DIA. 4.75 (121) 5.71 (145) 5.12 (130) 7.68 (195)
5R10158H01
DIN
5R10158H02
0.50 (12.7)
NOTE: DIMENSIONS ARE IN
INCHES WITH MILLIMETERS IN PARENTHESES.
JIS
5R10158H03
MODEL 450
5R10158H04
29750003
Figure 2-3. Optional Probe Mounting Flange
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
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Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
STACK OR DUCT
METAL WALL
WELD PIPE TO
METAL WALL
2.0 IN. (51 mm) MIN. DIA.
REFRACTORY
SCHEDULE 40
STACK OR DUCT METAL WALL
ADAPTER
2 IN. NPT
PIPE
1.25 NPT
CUSTOMER
SUPPLIED ADAPTER
INSULATE IF EXPOSED
TO AMBIENT WEATHER
CONDITIONS
2 IN. NPT
SCHEDULE 40
PIPE
CALIBRATION
CHECK
GAS LINE
REFERENCE
AIR LINE
SYSTEM
CABLE
29750004
Figure 2-4. Horizontal Probe Installation
3. If the optional adapter plates are not used, a 2 in. NPT, schedule 40, pipe nipple (Figure 2-4) should be welded to the stack or duct wall.
the adapter provides the pipe threads needed for the probe’s process fitting.
4. Where high particulate or slag is in the flue gas stream, it may be desirable to inset the probe in the refractory as
When a 2 in. NPT to 1.25 NPT adapter is threaded to the welded pipe nipple,
shown in Figure 2-5. Use pipe cou­plings and nipples to adjust the probe insertion depth.
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Page 23
Model 3081FG
2
REFRACTORY
STACK OR
DUCT METAL
PROBE LENGTH
A
WAL L
1.5 + A
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
DIMENSION A -- 1-5/8, 2-1/2, 3, OR 4 IN. 1.25 NPT SCHEDULE 40 PIPE NIPPLE
2 IN., 1.25 NPT
PIPE COUPLING
29750005
Figure 2-5. Adjusting Probe Insertion Depth
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
Page 24
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
5. Use high temperature material (alu­mina wool) to seal around the probe during insertion. This prevents hot gases from escaping or cold air from entering the stack or duct.
6. Initially insert the probe to a depth of 3 in. (76.2 mm) or 1/2 the depth of the stack or duct refractory, whichever is greater.
After initial insertion, do not insert the probe at a rate exceeding 1 in. per mi­nute (25.4 mm per minute) or damage to the probe may result due to thermal shock.
7. After initial insertion, insert the probe at a rate of 1 in. (25.4 mm) per minute until the probe is fully inserted.
8. Install anti-seize compound on the pipe threads and screw the probe into the process flange or adapter.
9. If insulation was removed to access the duct work for probe mounting, make sure the insulation is replaced after­ward. See Figure 2-4.
If the ducts will be washed down dur­ing outage, MAKE SURE to power down the probes and remove them from the wash area.
c. Locating Model 3081 Transmitter
1. Ensure the Model 3081 Transmitter is easily accessible for maintenance and service and for using the infrared re­mote control (if applicable).
Do not allow the temperature of the Model 3081 Transmitter exceed 65°C (149°F) or damage to the unit may result.
NOTE
Use anti-seize compound on threads to ease future removal of probe.
The electrical conduit port should be facing down for a horizontal probe in­stallation. See Figure 2-4. In vertical probe installations, orient the probe so the system cable drops vertically from the probe. Ensure the electrical conduit is routed below the level of the terminal block housing. This drip loop minimizes the possibility that moisture will accu­mulate in the housing.
2. The ambient temperature of the trans­mitter housing must not exceed 65°C (149°F). Locate the electronics in an area where temperature extremes, vi­bration, and electromagnetic and radio frequency interference are minimal.
3. Locate the Model 3081 Transmitter within 150 ft (45.7 m) of the oxygen probe due to wiring and signal considerations.
2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Page 25
Model 3081FG
2
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
d. Installing Model 3081 Transmitter
1. Ensure all components are available to install the Model 3081 Transmitter.
2. Choose a method or location to mount the transmitter.
(a) Flat Surface Mounting. The trans-
mitter may be mounted on a flat
COVER
LOCK
CIRCUIT
END
6.32
(160.5)
6.35
(161.3)
TERMINAL END
THREADED CAP (2 PLACES)
surface using the threaded mount­ing holes located on the bottom of the transmitter housing. Refer to Figure 2-6 for installation references.
(b) Pipe Mounting. An optional pipe
mounting bracket is available for this type of installation. Refer to Figure 2-7 for installation references.
TERMINAL BLOCK (TB)
TERMINAL END
CAP OMITTED
FOR CLARITY
(THIS VIEW)
1.32
(33.5)
O-RING
(2 PLACES)
NOTE: DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN PARENTHESES.
3.68
(93.5)
Figure 2-6. Flat Surface Mounting Dimensional Information
3/4-14 NPT (2 PLACES)
SURFACE
BY OTHERS
0.839
(21.31)
FLAT SURFACE MOUNTING
PAD HOLE PATTERN
1/4-20 THREADS (4 PLACES)
0.839 (21.31)
26020003
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7
Page 26
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
6.35
(161.3)
COVER LOCK
6.9
(175.3)
Model 3081FG
TERMINAL BLOCK (TB)
CIRCUIT
6.32
(160.5)
9.63
(244.6)
1.00
(25.4)
0.375 (9.525) DIA. (4 MOUNTING
HOLES)
1.405
(35.687)
2.81
(71.374)
END
1.32 (33.5)
C
L
3.87
(98.3)
3.25
(82.55)
7.5
(190.5)
6.5
(165.1)
C
L
TERMINAL END
3/4 -14 NPT 2 PLACES
3/4-14 FNPT
(2 PLACES)
5/16-18 NUT
4.00
(101.6)
TERMINAL END CAP OMITTED FOR CLARITY IN THIS VIEW.
2 IN. PIPE/WALL MOUNTING BRACKET (OPTION)
U-BOLT (2 PLACES)
%
mAmA
1/4-20 THREADS
BRACKET HOLE PATTERN
FOR WALL MOUNTING
NOTE:
DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.
*SCREWS FURNISHED WITH
Figure 2-7. Pipe Mounting Dimensional Information
5/16 WASHER
U-BOLT
MOUNTING KIT ONLY. NOT FURNISHED WITH ANALYZER/TRANSMITTER.
BOTTOM VIEW
1/4-20 SCREW*
26020042
2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Page 27
Model 3081FG
2
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
3. For correct viewing orientation, the dis­play may be changed 90 degrees, us­ing the following procedure:
(a) Refer to Figure 2-8. Loosen the
cover lock screw until the cover lock is disengaged from the knurled surface on the threaded circuit end cap.
(b) Remove the circuit end cap.
(c) Remove the three screws retaining
the display board in place.
(d) Lift and rotate the display board 90
degrees either way.
(e) Reposition the display board on the
standoffs. Install and tighten all three screws.
CIRCUIT END CAP
(f) Install the circuit end cap and
tighten the cover lock screw to se­cure the cover lock in place.

2-3 ELECTRICAL INSTALLATION

All wiring must conform to local and national codes.
For intrinsically safe applications, re­fer to drawing 1400184, page 10-2 of this Instruction Bulletin.
Disconnect and lock out power before connecting the unit to the power supply.
Install all protective equipment covers and safety ground leads after installa­tion. Failure to install covers and ground leads could result in serious injury or death.
SCREW
DISPLAY
BOARD
90
O
90
O
HOUSING
Figure 2-8. Display Positioning Assembly
26020061
To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, con­nection to the main electrical power supply must be made through a circuit breaker (min 10 A) which will discon­nect all current-carrying conductors during a fault situation. This circuit breaker should also include a me­chanically operated isolating switch. If 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.
a. General
The power supply and signal wiring should be shielded. Also, make sure the signal wiring is grounded at the Model 3081 Transmitter end only. Do not ground the signal loop at more than one point. Twisted
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9
Page 28
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
pairs are recommended. Ground the trans­mitter housing to an earth ground to prevent unwanted electromagnetic interference (EMI) or radio frequency interference (RFI).
NOTE
For optimum EMI/RFI immunity, shield the 4-20 mA current loop cable and enclose in an earth grounded metal conduit.
NOTE
Never run signal or sensor wiring in the same conduit, or open tray, with power cables. Keep signal or sensor wiring at least 12 in. (0.3 m) away from other electrical equipment and 6.5 ft (2 m) from heavy electrical equipment.
It is necessary to prevent moisture from entering the Model 3081 Transmitter hous­ing. The use of weather-tight cable glands is required. If conduit is used, plug and seal connections on the transmitter housing to prevent moisture accumulation in the termi­nal side of the housing.
signal is HART information that is ac­cessible through a Model 275 Hand­held Communicator or AMS software.
2. Two signals representing the O and the cell temperature are supplied to the Model 3081 Transmitter from the oxygen probe.
3. Wiring connections for the Model 3081 Transmitter are shown in Figure 2-10.
NOTE
The ground arrangement shown in Figure 2-10 limits the amount of noise introduced into the electronics.
4. Connect wire shields to terminal 1. Connect earth ground as shown.
value
2
Moisture accumulation in the transmit­ter housing can affect its performance and may void its warranty.
b. Oxygen Probe Signal Connections
1. Two signals represent the O
value and
2
the cell temperature. The probe pro­vides these values to the Model 3081 Transmitter for processing and signal conditioning.
2. Wiring connections for the probe are shown in Figure 2-9.
c. Model 3081 Transmitter 4-20 mA and
Signal Connections
1. A 4-20 mA signal represents the O value. Superimposed on the 4-20 mA
TERMINAL BLOCK
CONDUIT
THERMOCOUPLE + (GY)
2
Figure 2-9. Oxygen Probe Terminal Block
THERMOCOUPLE - (RD)
CELL - (WH)
CELL + (BK)
26020004
2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Page 29
Model 3081FG
2
3
12
CELL + (BK)
6
5
4
FACTORY-INSTALLED
JUMPER
TERMINAL
BLOCK (TB1)
PROBE CABLE
SHIELD
GROUND
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
b. Reference Air Package
After the oxygen probe is installed, connect the reference air set. Install the reference air set according to Figure 2-12.
c. Instrument Air (Reference Air)
CELL - (WH)
THERMOCOUPLE - (RD)
THERMOCOUPLE + (GY)
8
9
7
10
11
12
13
14
15
16
EARTH GROUND TERMINALS
4-20 mA (-) 4-20 mA (+)
Instrument air is required for reference. Use 10 psig (68.95 kPa gage) minimum, 225 psig (1551.38 kPa gage) at 0.2 scfh (100 ml/min.); less than 40 parts-per-million total hydrocarbons. Regulator outlet pressure should be set at 5 psi (35 kPa).
d. Calibration Check Gas
CELL AND THERMOCOUPLE
CONDUITS
NOTE:
RUN CELL AND THERMOCOUPLE SIGNALS IN SEPARATE CONDUIT FROM 4-20 mA LINE.
Figure 2-10. Model 3081 Transmitter Terminal
Block

2-4 PNEUMATIC INSTALLATION

a. General
Reference air is required for O
calculation,
2
and calibration check gas is required during a calibration check. Refer to Figure 2-11 for the gas connections on the oxygen probe.
4-20 mA
26020005
Two calibration check gas concentrations are used with the Two-Wire In Situ Oxygen Analyzer: Low Gas - 0.4% O
- 8% O
, each with the balance in nitrogen.
2
and High Gas
2
Do not use 100% nitrogen. See Figure 2-11 for the probe connections. Set both calibra­tion check gases at the same flow rate: 5 scfh (2.5 L/min).
1/4 TUBE FITTING
(REFERENCE AIR PORT)
1/4 TUBE FITTING
(CALIBRATION CHECK
GAS PORT)
REFERENCE
AIR VENT
26020006
Figure 2-11. Oxygen Probe Gas Connections
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11
Page 30
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
4.81 (122.17)
FLOW SET
POINT KNOB
0.125-27 NPT FEMALE
OUTLET CONNECTION
1
2
1.19 (30.22)
DRAIN VALVE
OUTLET
10.0
(254)
REF
3.12 (79.25) MAX
3
(SUPPLIED BY CUSTOMER)
1/4” TUBE
2.250 (57.15)
2.0
(50.80)
1.50
(38.10)
1 FLOWMETER 0.2-2.0 SCFH 771B635H08
2 2" PRESSURE GAGE 0-15 PSIG 275431-006
3 COMBINATION FILTER-REG. 0-30 PSIG 4505C21G01
TO PROBE
NOTE: DIMENSIONS ARE IN INCHES WITH
0.25-18 NPT FEMALE INLET CONNECTION
2 MOUNTING HOLES
3.19 (81.03) LG
THROUGH BODY FOR
0.312 (7.92) DIA BOLTS
REF AIR SET
263C152G05
MILLIMETERS IN PARENTHESES.
8.50
(215.90)
MAX
INSTRUMENT AIR SUPPLY 10-225 PSIG MAX PRESSURE
SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYGEN PROBE.
26020034
Figure 2-12. Air Set, Plant Air Connection
2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Page 31
Model 3081FG
3
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
SECTION 3

STARTUP AND OPERATION

c. Operating Display
Install all protective equipment covers and safety ground leads before equipment startup. Failure to install covers and ground leads could result in serious injury or death.
3-1 GENERAL
a. Verify Mechanical Installation
Ensure the Two-Wire In Situ Oxygen Ana­lyzer is installed correctly. See paragraph 2-2 for mechanical installation information.
b. Verify Terminal Block Wiring
Ensure the wiring of both the oxygen probe terminal block and Model 3081 Transmitter terminal block is correct. Refer to paragraph 2-3 for electrical installation and wiring information.

3-2 POWER UP

a. General
The Two-Wire In Situ Oxygen Analyzer dis­plays the current oxygen reading on the LCD face of the Model 3081 Transmitter. The O
concentration, cell temperature, and
2
4-20 mA output current are displayed as shown in Figure 3-1. This and other infor­mation may also be accessed using HART/AMS.
After the probe has reached operating temperatures, the Model 3081 Transmitter display should look similar to Figure 3-1. The display will now track the O tion, cell temperature, and 4-20 mA output current.
O CONCENTRATION
2
CELL
TEMPERATURE
Figure 3-1. Normal Operation Display
concentra-
2
%
mA
4-20 mA OUTPUT
26020007
%
b. Startup Display
When the probe is first inserted into the stack, some time is required until minimum operating temperatures [550°C (1022°F)]
mA
are reached. Some time is also required for the electronics to reach an operating state. Therefore, when the unit is first powered up, a faulted operation display as shown in Fig­ure 3-2 may be displayed by the transmitter until the probe operating temperatures are
26020008
reached and the electronics are working properly (approximately 5 minutes).
Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-1
Figure 3-2. Faulted Operation Display
Page 32
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
3-3 REESTABLISHING PROPER CALIBRATION
CHECK GAS FLOW RATE
The calibration check gas flow must be enough to ensure no combustion flue gases mix with the calibration check gases and only clean, good calibration check gas surrounds the cell without expending excess gas (Figure 3-3). Monitor the O
concentration using an IRC or HART Com-
2
municator. Set the calibration check gas flow rate as follows:
NOTE
Only set the calibration check gas flow rate at startup. It is not necessary to perform this procedure for each cali­bration check.
FLUE GAS
PROTECTIVE
TUBE
a. Adjust the calibration check gas flow to 5
scfh (2.5 L/min.) to ensure the cell is sur­rounded by calibration check gas. Due to the cooling effect of the gas, the cell tem­perature will decrease slightly, causing the O
concentration to drop. Once the elec-
2
tronics compensates for this effect, the O concentration will stabilize.
b. Next, slowly reduce the calibration check
gas flow until the O
concentration changes,
2
which indicates that the calibration check and flue gases are mixing. Increase the flow rate until this effect is eliminated.
STACK OR DUCT METAL WALL
2
CALIBRATION
GAS
CELL
REFRACTORY
CALIBRATION
CHECK GAS LINE
REFERENCE
AIR LINE
Figure 3-3. Proper Calibration Check Gas Flow Rate
26020062
3-2 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Page 33
Model 3081FG
3
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
3-4 OPERATION
a. Overview
This section explains the operator controls and displays of the Two-Wire In Situ Oxy­gen Analyzer. The use of the Infrared Re­mote Control (IRC) and the Model 3081 Transmitter Liquid Crystal Display (LCD) are described in detail. HART/AMS operation is not covered here but is discussed in Section 4, HART/AMS.
b. Display
The Model 3081 Transmitter LCD displays the O
concentration, cell temperature, and
2
CIRCUIT
END
4-20 mA output current during normal op­eration (see Figure 3-4). The LCD will also display fault conditions when they occur. To interact with the transmitter, use the IRC and navigate through a series of menus displayed on the LCD.
c. Menu Tree
The screens that can be displayed are shown in the menu tree of Figure 3-5. These screens are displayed on the LCD and are accessed using the IRC keypad.
TERMINAL
END
MODEL 3081 TRANSMITTER
ELECTRONICS HOUSING
%
mA
26020031
Figure 3-4. Normal Operation Display
Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-3
Page 34
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
ON STARTUP
RESET
OR ON
FROM ANY
SCREEN
NEXT
PROG
CODE
555 ENTER
DISPLAY
CODE
FAULT VAL
NEXT
UPPER RANGE
VAL
NEXT
CELL T HI
NEXT
RESET MAX
CELL T
NEXT
SET O2 FILTER
TIME
NEXT
TRIM 4 mA ?
NEXT
TRIM 20 mA ?
NEXT
SET HI BOTTLE
O2
NEXT
SET LO BOTTLE
O2
NEXT
SET O2
TRACKING
NEXT
PROCESS DISPLAY
OPERATION
PROCESS DISPLAY
OPERATION
2
NEXT
1
PROGRAM
ENTER
EXIT
ENTER
EXIT
NORMAL
FAULTED
MENU
TRIM 4 mA
TRIM 20 mA
EXIT
ON FROM
ANY SCREEN
EXIT
WITHOUT
EXPLICITY
STATED
DIAG
SHOW FAULT IN MANUAL?
T/C mV ACCEPT HIGH O2
O2 CELL mV ACCEPT LOW O2
CELL
IMPEDANCE
PREVIOUS
SLOPE
PREVIOUS
CONSTANT
MAX CELL T
SW VER
UNIT SER #
SW BUILD
NUMBER
NEXT
SW BUILD DATE
ENTER
NEXT NEXT ENTER
NEXT NEXT
NEXT NEXT
NEXT NEXT
NEXT
EXIT
EXIT
DIAGNOSTICS
NEXT
NEXT
NEXT
NEXT
NEXT
FAULT
(IF PRESENT)
FAULT
(IF PRESENT)
MENU
CAL
SLOPE
CONSTANT
RESET OR EXIT
1 - USER ENTERS DISPLAY
ANALYZER CODE
2 - USER ENTERS ANALYZER
ACCESS CODE OR ANALYZER
ACCESS CODE = SECURITY
DISABLE VALUE
CALCHECK
MENU
SET CODE
26020033
Figure 3-5. Model 3081 Transmitter Menu Tree
3-4 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
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Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
d. Navigation
The IRC in Figure 3-6 is used to interact with the Model 3081 Transmitter and navi­gate through the screens on the LCD.
1. Hold the IRC within 6 ft (1.8 m) of the Model 3081 Transmitter and within 15 degrees from the centerline of the transmitter LCD. The amount of ambi­ent light may also affect IRC performance.
NOTE
The LCD may react slowly to IRC commands. Allow sufficient time be­tween key presses to avoid undesired or repeated commands from accumu­lating in the command queue.
2. Use the keys on the IRC to navigate through the menu screens. Refer to Figure 3-6. General usage is as follows:
(h) ENTER. Initiates the editing proc-
ess and causes the most signifi­cant digit of the edited item to start flashing. Also processes the entry so the previous value updates to the new value entered using the ar­row keys. Failure to press ENTER before exiting a screen will cancel the input value and revert to the previous value.
(i) NEXT. Accesses the next user
screen as shown in the menu tree. Any non-entered number in the ex­ited state will be ignored, and the previous data will be used.
(j) EXIT. Exits from sub-branches of
the menu tree where an exit option is explicitly shown. Otherwise, re­turns to the PROCESS DISPLAY screen at the top of the menu tree. Any non-entered number in the ex­ited state will be ignored, and the previous data will be used.
(a) RESET. Returns to the PROCESS
DISPLAY screen at the top of the menu tree. Any non-entered num­ber in the exited state will be ig­nored, and the previous data will be used.
(b) HOLD. Not used.
(c) Left/Right Arrow. Moves left and
right among editable digits on the display.
(d) Up/Down Arrow. Increases or de-
creases the value of the currently selected digit on the display.
(e) CAL. Accesses the CALCHECK
MENU branch of the menu tree. Only works from the PROCESS DISPLAY screen.
(f) PROG. Accesses the PROGRAM
MENU branch of the menu tree. Only works from the PROCESS DISPLAY screen.
(g) DIAG. Accesses the DIAGNOS-
TICS MENU branch of the menu tree. Only works from the PROC­ESS DISPLAY screen.
RESET HOLD
ENTERCAL
PROG
DIAG EXIT
REMOTE CONTROL
ROSEMOUNT
NEXT
MODEL 3081
FISHER-ROSEMOUNT
26020032
Figure 3-6. Infrared Remote Control (IRC)
Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-5
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Instruction Manual
IB-106-3081 Rev. 1.5 September 2002

3-5 PROGRAM MENU

The PROGRAM MENU branch of the menu tree allows you to program and edit some proc­ess parameters, faults, outputs, and security codes. To access this branch of the menu tree, press the PROG key on the IRC when in the PROCESS DISPLAY screen (Normal or Faulted). If security is enabled, you must enter the analyzer code to gain further access to the screens in this branch. Each screen in this branch is accessed sequentially using the NEXT key. Refer to Figure 3-5 during the following menu and screen descriptions.
Model 3081FG
O CONCENTRATION
2
%
NOTE
To edit a screen value, press ENTER to access the data field. Use the left and right arrow keys to move among the digits in the data field. Note that the editable position will be flashing. To change the value of a digit, use the up and down arrow keys to increase or decrease the value. When finished ed­iting, press ENTER to accept the value. To go to the next screen in the menu, press NEXT.
a. CODE
Refer to Figure 3-7. After pressing the PROG key, this screen will display if secu­rity is enabled (see paragraph 3-5m). Use this screen to identify a specific analyzer in a process to prevent accessing an adjacent analyzer when using the IRC.
Press ENTER to begin editing. At this point, you can either specify the analyzer by its access code or view its code if it is un­known.
1. To gain further access to the screens in the PROGRAM MENU branch, en­ter the correct three-digit analyzer ac­cess code using the arrow keys and press ENTER. If security is disabled, this screen does not appear and the system displays the FAULT VAL screen.
2. If the analyzer access code is un­known, enter 555 and press ENTER to access the DISPLAY CODE screen. In that screen, you will be able to view the analyzer access code.
ANALYZER
ACCESS CODE
OR SECURITY
ACCESS CODE
Figure 3-7. CODE
b. DISPLAY CODE
Refer to Figure 3-8. This screen is accessi­ble from the CODE screen by entering 555 and pressing ENTER. The DISPLAY CODE screen identifies the analyzer access code so you can return to the CODE screen and enter the code as described in paragraph 3-5a. To return to the CODE screen, press NEXT.
O CONCENTRATION
2
%
ANALYZER
ACCESS CODE
Figure 3-8. DISPLAY CODE
26020009
26020047
3-6 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
3
O CONCENTRATION
2
%
mA
INDICATOR
FAULT VALUE
26020010
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
lowed cell temperature before a fault condi­tion is indicated. Press ENTER to begin editing. Use the arrow keys to select and change the value. The value must be be­tween 550° and 1600°C. Press ENTER to accept the value. Pressing NEXT displays the RESET MAX CELL T screen.
O CONCENTRATION
2
%
Figure 3-9. FAULT VAL
c. FAULT VAL
Refer to Figure 3-9. Use this screen to set the value that the 4-20 mA output will drive to and display during a fault condition. Press ENTER to begin editing. Use the arrow keys to enter a fault value. The fault value can be between 3.8 and 24 mA. Then, press EN­TER to accept the value. Pressing NEXT displays the UPPER RANGE VAL screen.
Refer to Section 6, TROUBLESHOOTING, for the actual fault conditions.
d. UPPER RANGE VAL
Refer to Figure 3-10. Use this screen to set the value of the upper range limit. This value is the maximum limit of the O centration measurement and is used to scale the 4-20 mA output. Press ENTER to begin editing. Use the arrow keys to select and change the value. The upper range value can be between 0 and 25%. Then, press ENTER to accept the value. Pressing NEXT displays the CELL T HI screen.
e. CELL T HI
Refer to Figure 3-11. Use this screen to set the value of the upper cell temperature fault condition. This value is the maximum al-
con-
2
%
RANGE LIMIT
Figure 3-10. UPPER RANGE VAL
O CONCENTRATION
2
%
UPPER CELL
TEMPERATURE
FAULT VALUE
Figure 3-11. CELL T HI
UPPER
26020011
26020012
Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-7
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Instruction Manual
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Model 3081FG
f. RESET MAX CELL T
Refer to Figure 3-12. The transmitter tracks the maximum cell temperature obtained. Use this screen to reset the maximum cell temperature attained value to the current cell temperature. Press ENTER to begin editing. Use the arrow keys to select and change the value (Y/N). Then, press EN­TER to accept the value. Pressing NEXT displays the SET O
FILTER TIME screen.
2
O CONCENTRATION
2
%
g. SET O
FILTER TIME
2
Refer to Figure 3-13. In some applications, it is beneficial to dampen the raw O coming from the cell. Use this screen to enter the amount of time it will take the O reach 90% of the new reading. Press EN­TER to begin editing. Use the arrow keys to select and change the screen value to the O
filter value (in seconds). Enter a value
2
between 0 and 300 seconds and press EN­TER to accept the value. Press NEXT to access the TRIM 4 mA? screen.
h. TRIM 4 mA?
Refer to Figure 3-14. Use this screen to trim the 4 mA value of the 4-20 mA output.
NOTE
Before trimming the 4 mA value, you must break the loop to add the amme­ter. Power down the unit, connect the ammeter in series with Model 3081 Transmitter terminals 15(-) and 16(+), power up the unit, and return to the TRIM 4 mA? screen.
signal
2
2
to
Y/N (TO RESET
MAXIMUM CELL
TEMPERATURE)
Figure 3-12. RESET MAX CELL T
O CONCENTRATION
2
%
ANALYZER
ACCESS CODE
Figure 3-13. SET O2 FILTER TIME
26020013
26020047
Press ENTER to begin editing. Use the ar­row keys to select and change the screen value to the value displayed on the installed ammeter. Press ENTER to accept the value. After the value is entered, the unit calibrates itself to ensure it outputs 4 mA. Both the display and the ammeter will dis­play 4 mA. Pressing EXIT returns to the ini­tial TRIM 4 mA? screen, and pressing NEXT displays the TRIM 20 mA? screen.
O CONCENTRATION
2
%
26020014
Figure 3-14. TRIM 4 mA?
3-8 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
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Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
O CONCENTRATION
2
%
26020015
Figure 3-15. TRIM 20 mA?
i. TRIM 20 mA?
Refer to Figure 3-15. Use this screen to trim the 20 mA value of the 4-20 mA output.
NOTE
Before trimming the 20 mA value, you must break the loop to add the amme­ter. Power down the unit, connect the ammeter in series with Model 3081 Transmitter terminals 15(-) and 16(+), power up the unit, and return to the TRIM 4 mA? screen.
Press ENTER to begin editing. Use the ar­row keys to select and change the screen value to the value displayed on the installed ammeter. Press ENTER to accept the value. After the value is entered, the unit calibrates itself to ensure it outputs 20 mA. Both the display and the ammeter will up­date to 20 mA. Pressing EXIT returns to the initial TRIM 20 mA? screen, and pressing NEXT displays the SET HI BOTTLE O screen.
O CONCENTRATION
2
%
HIGH CALIBRATION
CHECK GAS O
PERCENTAGE
Figure 3-16. SET HI BOTTLE O
2
2
26020049
the value. Press NEXT to display the SET LO BOTTLE O
k. SET LO BOTTLE O
screen.
2
2
Refer to Figure 3-17. Use this screen to identify, within the electronics, the percent­age of O
used as the low calibration check
2
gas. Press ENTER to begin editing. Use the arrow keys to select and change the screen value to the O
percentage of the low cali-
2
bration check gas. Press ENTER to accept the value. Press NEXT to display the SET O
TRACKING screen.
2
O CONCENTRATION
2
%
2
j. SET HI BOTTLE O
2
Refer to Figure 3-16. Use this screen to identify, within the electronics, the percent­age of O gas. Press ENTER to begin editing. Use the arrow keys to select and change the screen value to the O bration check gas. Press EN TER to accept
Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-9
used as the high calibration check
2
percentage of the high cali-
2
LOW CALIBRATION
CHECK GAS O
PERCENTAGE
Figure 3-17. SET LO BOTTLE O
2
26020050
2
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Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
O CONCENTRATION
2
%
TRACK O
DURING CALCHECK
Figure 3-18. SET O2 TRACKING
l. SET O
TRACKING
2
Refer to Figure 3-18. Use this screen to permit the 4-20 mA line to track the O during a calibration check. Press ENTER to begin editing. Use the arrow keys to select Y or N. Entering Y (yes) will allow the 4-20 mA line to track the O
value during the
2
calibration check. Entering N (no) will hold the O
value steady during the calibration
2
check. Press ENTER to accept the value. Press NEXT to display the SET CODE screen.
m. SET CODE
2
26020051
value
2
O CONCENTRATION
2
%
26020016
Figure 3-19. SET CODE
returns to the FAULT VAL screen at the be­ginning of the PROGRAM MENU.
n. Model 3081 Transmitter Parameters
Table 3-1 lists the range and default value of operator-adjustable variables used by the Model 3081 Transmitter. These variables may all be changed from the PROGRAM MENU screens.
Table 3-1. Model 3081 Transmitter Parameters
Parameter Range Default
Refer to Figure 3-19. Use this screen to set the security code for the Model 3081 Transmitter. Press ENTER to begin editing. Use the arrow keys to select and change the value. Select any value between 000 and 999, excluding 000 and 555. Code 000
Indicator Fault Value
high value (24 mA) low value (3.8 mA)
low value (3.8 mA)
Upper Range Limit 2.0-25.0% 10.0%
Upper Cell Temp.
650-1600°C 1600°C
Fault Value
indicates that no code is set. Code 555 ac­cesses the DISPLAY CODE screen. Press ENTER to accept the value. Pressing NEXT
3-10 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Analyzer Access Code
000-999 (excluding 000 and 555)
000 (no code)
Page 41
Model 3081FG
3
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
Figure 3-20. SHOW FAULT

3-6 DIAGNOSTICS MENU

The DIAGNOSTICS MENU branch of the menu tree allows you to examine outputs, current faults, and unit information. None of the items in the DIAGNOSTICS MENU are editable. This branch of the menu tree may be accessed by pressing DIAG on the IRC when in the PROC­ESS DISPLAY screen (Normal or Faulted). Each screen in this branch is accessed sequen­tially by pressing NEXT. Refer to Figure 3-5 during the following menu and screen descriptions.
%
26020017
%
THERMOCOUPLE mV
26020018
Figure 3-21. T/C mV
CELL mV
c. O
2
Refer to Figure 3-22. Use this screen to ex­amine the O
cell mV output. Pressing
2
NEXT accesses the CELL IMPEDANCE screen.
a. SHOW FAULT
Refer to Figure 3-20. After pressing DIAG, this screen displays. Pressing ENTER ac-
%
cesses a screen displaying the current fault (if any). If more than one fault exists, and you are in the FAULT screen, press NEXT to go to the next fault. Information on the fault screens can be found in Section 6, TROUBLESHOOTING. Press EXIT to re­turn from this fault sub-menu and press NEXT to access the T/C mV screen.
b. T/C mV
Refer to Figure 3-21. Use this screen to ex­amine the cell thermocouple mV output. Three decimal places are displayed. Press­ing NEXT accesses the O screen.
Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-11
CELL mV
2
Figure 3-22. O2 CELL mV
O CELL mV
2
26020019
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Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
O CONCENTRATION
2
%
O CELL
IMPEDANCE STATUS
2
26020020
Figure 3-23. CELL IMPEDANCE
d. CELL IMPEDANCE
Refer to Figure 3-23. Use this screen to ex­amine the O
cell impedance status. GOOD
2
indicates the cell is operating normally. WARN indicates the cell has degraded but is still operational. HI indicates that the cell has degraded but is still operational; how­ever, failure will occur soon. Pressing NEXT accesses the PREVIOUS SLOPE screen.
O CONCENTRATION
2
%
CALCHECK CELL
SLOPE VALUE
Figure 3-24. PREVIOUS SLOPE
f. PREVIOUS CONSTANT
Refer to Figure 3-25. Use this screen to ex­amine the cell zero constant calculated from the most recent calibration check. The con­stant represents the voltage generated by the cell when no difference exists between the amount of O
on the reference and pro-
2
cess sides of the cell. Press NEXT to ac­cess the MAX CELL T screen.
26020052
O CONCENTRATION
NOTE
2
Temperature influences cell imped­ance. Wait until the cell is at operating temperature before checking cell im­pedance. If checked before the cell
%
reaches operating temperature [550°C (1022°F)], this screen displays a fail indication.
e. PREVIOUS SLOPE
Refer to Figure 3-24. Use this screen to ex­amine the slope calculated from the most recent calibration check. The slope is the amount of cell voltage generated for a given O
value. For each calibration check, record
2
the slope over the life of the probe. Tracking
CALCHECK CELL
CONSTANT VALUE
26020053
the slope will indicate if the probe is de­grading. Press NEXT to access the PREVI-
Figure 3-25. PREVIOUS CONSTANT
OUS CONSTANT screen.
3-12 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management
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September 2002
j. SW BUILD NUMBER
Use this screen to see the software build number for the Model 3081 Transmitter.
%
Pressing NEXT accesses the SW BUILD DATE screen.
k. SW BUILD DATE
Use this screen to see the software build date for the Model 3081 Transmitter. Pressing NEXT returns to the beginning of the DIAGNOSTICS MENU branch (the SHOW FAULT screen).
TEMPERATURE
MAXIMUM
Figure 3-26. MAX CELL T
g. MAX CELL T
Refer to Figure 3-26. Use this screen to ex­amine the maximum temperature attained by the O
cell. This value can be reset under
2
the PROGRAM MENU. Pressing NEXT accesses the SW VER screen.
h. SW VER
Use this screen to see the software version number for the Model 3081 Transmitter. Pressing NEXT accesses the UNIT SER # screen.
i. UNIT SER #
Use this screen to see the unit serial num­ber for the Model 3081 Transmitter. Press­ing NEXT accesses the SW BUILD NUMBER screen.
CELL
26020021

3-7 CALCHECK MENU

The CALCHECK MENU branch of the menu tree (Figure 3-5) allows you to perform a cali­bration check of the analyzer. Before performing a calibration check, ensure the high calibration check gas and low calibration check gas O percentages are entered into the electronics via the PROGRAM MENU. To set these values, refer to paragraphs 3-5j and 3-5k.
Once these values are set, access the CAL­CHECK MENU branch by pressing CAL on the IRC when in the PROCESS DISPLAY screen (Normal or Faulted). Each screen in this branch identifies a process step in the calibration check procedure. The first screen in the sequence is the IN MANUAL? screen.
2
Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-13
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Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
a. IN MANUAL?
Refer to Figure 3-27.
Failure to remove the analyzer from automatic control loops prior to per­forming this procedure may result in a dangerous operating condition.
Model 3081FG
O CONCENTRATION
2
%
If the O2 output value is used in any auto­matic process control loops, the loop must be placed in manual before beginning a calibration check.
Once the analyzer is removed from any automatic control loops, press ENTER to edit the screen. Use the arrow keys to se­lect Y (yes) and press ENTER to process the selection and to display the ACCEPT HIGH O
screen.
2
O CONCENTRATION
2
%
%
HIGH CALIBRATION
CHECK GAS O VALUE
Figure 3-28. ACCEPT HIGH O
b. ACCEPT HIGH O
2
2
Refer to Figure 3-28. After pressing ENTER to begin the calibration check, the high cali­bration check gas starts to flow. After wait­ing approximately three minutes for the displayed O
value to settle, press NEXT to
2
accept the high calibration check gas read­ing and apply the low calibration check gas. The next screen to display is the ACCEPT LOW O
c. ACCEPT LOW O
screen.
2
2
2
26020055
Refer to Figure 3-29. Once the low calibra­tion check gas is applied, wait approxi-
Y/N (FOR USER
RESPONSE)
26020054
mately three minutes for the displayed O value to settle. Once the value settles, press NEXT to accept the reading and to display the SLOPE screen.
2
Figure 3-27. IN MANUAL?
3-14 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Page 45
Model 3081FG
3
O CONCENTRATION
2
%
%
LOW CALIBRATION
CHECK GAS O VALUE
2
26020056
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
e. CONSTANT
Refer to Figure 3-31. Use this screen to ex­amine the cell zero constant calculated from the current calibration check. The constant represents the voltage generated by the cell when no difference exists between the amount of O sides of the cell. Note this value for com­parison against future calibration checks. Press RESET or EXIT to return to the PROCESS DISPLAY screen.
on the reference and process
2
O CONCENTRATION
2
Figure 3-29. ACCEPT LOW O
2
d. SLOPE
Refer to Figure 3-30. Use this screen to ex­amine the slope calculated from current calibration check. The slope is the amount of cell voltage generated for a given O value. After each calibration check, record the slope over the life of the probe. Tracking the slope will indicate if the probe is de­grading. Press NEXT to access the CON­STANT screen.
O CONCENTRATION
2
%
%
2
CALCHECK CELL
CONSTANT VALUE
26020058
Figure 3-31. CONSTANT
CALCHECK CELL
SLOPE VALUE
26020057
Figure 3-30. SLOPE
Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-15
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Instruction Manual
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Model 3081FG
3-16 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
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Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
SECTION 4

HART/AMS

4-1 OVERVIEW
The HART Communicator is a handheld com­munications interface device. It provides a common communications link to all microproc­essor-based instruments that are HART com­patible. The handheld communicator contains an 8 x 21 character liquid crystal display (LCD) and 25 keys. A pocket-sized manual, included with the HART Communicator, details the spe­cific functions of all the keys.
To interface with the Two-Wire In Situ Oxygen Analyzer, the HART Communicator requires a termination point along the 4-20 mA current loop and a minimum load resistance of 250 ohms between the communicator and the power sup­ply. The HART Communicator accomplishes its task using a frequency shift keying (FSK) tech­nique. With the use of FSK, high-frequency digital communication signals are superimposed on the 4-20 mA transmitter current loop. The communicator does not disturb the 4-20 mA signal since no net energy is added to the loop.
The HART Communicator may be interfaced with a personal computer (PC) providing special software has been installed. To connect the HART Communicator to a PC, an interface adapter is required. Refer to the proper HART Communicator documentation regarding the PC interface option.
4-2 HART COMMUNICATOR SIGNAL LINE
CONNECTIONS
The HART Communicator can connect to the Two-Wire In Situ Oxygen Analyzer analog out­put signal line at any wiring termination in the 4­20 mA current loop. There are two methods of connecting the HART Communicator to the sig­nal line. For applications in which the signal line has a load resistance of 250 ohms or more, re­fer to method 1 and Figure 4-1. For applications in which the signal line load resistance is less than 250 ohms, refer to method 2 and Figure 4-2.
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 4-1
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Instruction Manual
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7
6
5
4
3
12
8
9
4-20 mA
Model 3081FG
10
11
12
13
14
15
16
+
4-20 mA SIGNAL LINE
RL 250
MODEL 3081 TRANSMITTER
TERMINAL BLOCK
LOOP CONNECTORS
SERIALPORT & BATTERY
CHARGER MUST
NOT BE USED IN
HAZARDOUS AREAS
LOOP CONNECTORS
HART COMMUNICATOR
REAR PANEL
USE INTERFACE 00275 0013 ONLY
SERIAL PORT
Figure 4-1. Signal Line Connections, > 250 Ohms Lead Resistance
a. Method 1, For Load Resistance ≥≥≥≥ 250
Ohms
Refer to Figure 4-1 and the following in­struction to connect the HART Communi­cator to a signal line with 250 ohms or more of load resistance.
ANALOG OUTPUT DEVICE
HART
COMMUNICATOR
LEAD SET
26020040
b. Method 2, For Load Resistance < 250
Ohms
Refer to Figure 4-2 and the following steps to connect the HART Communicator to a signal line with less than 250 ohms load resistance.
Explosions can result in death or seri­Explosions can result in death or seri­ous injury. Do not make connections to the HART Communicator's serial port, 4-20 mV signal line, or NiCad re­charger jack in an explosive
ous injury. Do not make connections
to the HART Communicator's serial
port, 4-20 mA signal line, or NiCad re-
charger jack in an explosive
atmosphere. atmosphere.
1. At a convenient point, break the analog
Using the supplied lead set, connect the HART Communicator in parallel to the Two-
output 4-20 mA signal line and install the optional 250 ohm load resistor.
Wire In Situ Oxygen Analyzer. Use any wir­ing termination points in the analog output 4-20 mA signal line.
4-2 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
2. Plug the load resistor into the loop connectors (located on the rear panel of the HART Communicator).
Page 49
Model 3081FG
4
8
7
6
5
4
3
12
9
10
4-20 mA
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
11
12
13
14
15
16
+
4-20 mA SIGNAL LINE
RL < 250Ω
MODEL 3081 TRANSMITTER
TERMINAL BLOCK
LOOP CONNECTORS
SERIALPORT & BATTERY
CHARGERMUST
NOTBE USED IN
HAZARDOUSAREAS
HART COMMUNICATOR
LOOPCONNECTORS
REAR PANEL
USEINTERFACE 002750013 ONLY
SERIAL PORT
Figure 4-2. Signal Line Connections, < 250 Ohms Lead Resistance
4-3 HART COMMUNICATOR PC
CONNECTIONS
There is an option to interface the HART Com­municator with a personal computer. Load the designated AMS software into the PC. Link the HART Communicator to the PC using the inter­face PC adapter that connects to the serial port (on the communicator rear panel).
Refer to the proper HART Communicator docu­mentation in regard to the PC interface option.

4-4 OFF-LINE AND ON-LINE OPERATIONS

The HART Communicator can be operated both off-line and on-line.
a. Off-line operations are those in which the
communicator is not connected to the Two­Wire In Situ Oxygen Analyzer. Off-line op­erations can include interfacing the HART Communicator with a PC. (Refer to applica­ble HART documentation regarding HART/PC applications.)
HART
COMMUNICATOR
4-5 MENU TREE FOR HART COMMUNICATOR/
ANALOG OUTPUT DEVICE
250 OHM LOAD RESISTOR (SEE NOTE)
NOTE: THE SIGNAL LOOP MUST BE BROKEN
TO INSERT THE OPTIONAL 250 OHM LOAD RESISTOR.
26020041
b. In the on-line mode, the communicator is
connected to the 4-20 mA analog output signal line. The communicator is connected in parallel to the Two-Wire In Situ Oxygen Analyzer or in parallel to the 250 ohm load resistor.
c. The opening menu displayed on the HART
LCD is different for on-line and off-line op­erations. When powering up a disconnected (off-line) communicator, the HART LCD will display the Main Menu. When powering up a connected (on-line) communicator, the HART LCD will display the On-line Menu. Refer to the HART Communicator manual for detailed menu information.
TWO-WIRE IN SITU OXYGEN ANALYZER APPLICATIONS
This section consists of a menu tree for the HART Communicator (Figure 4-3). This menu is specific to Two-Wire In Situ Oxygen Analyzer applications.
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 4-3
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Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
DEVICE SETUP
O2 value
O2 output
LRV
URV
Device SN
Alarm Value
PROCESS VARIABLES
VIEW FLD DEV VARS
VIEW OUTPUT VARS
Device Status
LOOP TEST
O2 value Cell Temp Imp
VIEW PV-AOUT
VIEW SV
VIEW TV
VIEW 4V
Loop Test Method
PV is O2 value % rnge O2 output
SV is TC Temp TC value
TV is O2 cell mv TV value
4V is Cell Imp 4V value
Start Calcheck method
Refer to para. 4-6 for the complete Start Calcheck method using the HART Communicator.
Reset Max Temp method
26020044
DIAG/SERVICE
(CONTINUED ON
SHEET 2)
O2 CALCHECK
D/A TRIM
MAX CELL TEMP
(CONTINUED ON
SHEET 2)
START CALCHECK
OPtrakTG? HighTG LowTG Slope Constant
D/A trim method
Max Temp
RESET MAX TEMP
Figure 4-3. Menu Tree for HART/AMS on the Two-Wire In Situ Oxygen Analyzer (Sheet 1 of 3)
4-4 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
4
Instruction Manual
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September 2002
DEVICE SETUP
O2 value
O2 output
LRV
URV
Device SN
Alarm Value
(CONTINUED
SHEET )
BASIC SETUP
FROM
1
(CONTINUED
SHEET )
Ta g
SELECT O2 RANGE
Alarm Value
DEVICE INFORMATION
S/W VERSION INFO
FROM
1
URV
Dev id Descriptor Message Date Final Asmbly num Snsr s/n
Ver Bld Bld Date
O2
O2 value Snsr unit USL LSL Min span
Cell Temp
DETAILED SETUP
(CONTINUED ON
SHEET )3
SENSORS
(CONTINUED ON
SHEET )3
CELL TEMP
O2 CELL IMP
Snsr unit USL LSL Min span
Cell mV Snsr unit USL LSL Min span
26020045
Figure 4-3. Menu Tree for HART/AMS on the Two-Wire In Situ Oxygen Analyzer (Sheet 2 of 3)
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 4-5
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Model 3081FG
DEVICE SETUP
O2 value
O2 output
LRV
URV
Device SN
Alarm Value
(CONTINUED
SHEET )
DETAILED SETUP
REVIEW
FROM
2
(CONTINUED
SHEET )
SIGNAL CONDITION
OUTPUT CONDITION
Filter
DEVICE INFORMATION
OUTPUTS CONFIG
FROM
2
URV LRV % rnge
ANALOG OUTPUT
HART OUTPUT
Manufacturer Model Dev id Ta g Descriptor Message Date Final asmbly num Snsr s/n Fld dev rev Hardware rev Software rev Universal rev
URV Filter Poll addr Num req preams
O2 output AO Alrm typ
LOOP TEST
D/A TRIM
Poll addr Num req preams
Loop test method
D/A trim method
Figure 4-3. Menu Tree for HART/AMS on the Two-Wire In Situ Oxygen Analyzer (Sheet 3 of 3)
26020046
4-6 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
Page 53
Model 3081FG
4
4-6 HART COMMUNICATOR START CAL-
CHECK METHOD
To perform a calibration check on the Two-Wire In Situ Oxygen Analyzer with the HART Com­municator, use the following procedure. If nec­essary, use the menu tree in Figure 4-3 (sheet 1 of 3) for reference.
NOTE
To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right ar­row key or use the number keypad to select the menu item number.
To return to a preceding menu, press the left arrow key.
NOTE
Pressing ABORT at any time during this process will purge the calibration check gases and end the calibration check procedure.
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
Failure to remove the analyzer from automatic control loops prior to per­forming this procedure may result in a dangerous operating condition.
e. In the first screen, a “Loop should be re-
moved from automatic control” warning ap­pears. Remove the analyzer from any automatic control loops to avoid undesirable equipment performance and press OK.
f. The next screen prompts you to apply the
high calibration check gas. This message will only display for approximately three seconds. Press OK.
g. At this point, calibration check gas will flow
for approximately three minutes until the gas reading is taken. Once the gas is measured, the message, “Hi gas reading taken,” displays for three seconds.
h. Next, the screen prompts you to apply the
low calibration check gas. Press OK.
a. From the DEVICE SETUP SCREEN, se-
lect DIAG/SERVICE.
b. From the DIAG/SERVICE screen, select O
CALCHECK.
c. Before starting the calibration check proce-
dure, first set up the high calibration check gas, low calibration check gas, and tracking using HART/AMS.
d. From the O
menu item 1, START CALCHECK, to ac­cess the calibration check procedure.
CALCHECK screen, select
2
i. The low calibration check gas will flow for
approximately three minutes until the read­ing is taken. Once the gas is measured, the
2
message, “Low gas reading taken,” displays for three seconds.
j. Next, the screen prompts you to disconnect
the calibration check gases. Press OK. Once the gases are disconnected, the sys­tem will purge the gases for approximately three minutes.
k. When the “Loop may be returned to auto-
matic control” note appears, return the ana­lyzer to the automatic control loops previously removed and press OK.
Rosemount Analytical Inc. A Division of Emerson Process Management HART/AMS 4-7
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Model 3081FG
4-8 HART/AMS Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
5

MAINTENANCE AND SERVICE

Install all protective equipment covers and safety ground leads after equip­ment repair or service. Failure to in­stall covers and ground leads could result in serious injury or death.
Disconnect and lock out power before working on any electrical components.
5-1 MODEL 3081 ELECTRONICS
REPLACEMENT
Before replacing any electronic components, verify that the power to the Model 3081 Trans­mitter is removed. Refer to Table 8-1 for re­placement part numbers.
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
SECTION 5
6. Reposition display board (11) on the standoffs. Rotate the display board 90 degrees either way as desired.
7. Install and tighten all three screws (12).
8. Install circuit end cap (13).
9. Tighten cover lock screw (14) until cover lock (15) engages knurled sur­face of circuit end cap (13).
b. PC Board Stack Replacement
PC board stack (10, Figure 5-1) is com­posed of the CPU board and the analog board. Use the following procedure to re­place these boards as a set.
1. Loosen cover lock screw (14) until cover lock (15) disengages from the knurled surface of circuit end cap (13).
a. Display Board Replacement
Use the following procedure to replace dis­play board (11, Figure 5-1).
1. Loosen screw (14) until cover lock (15) disengages from the knurled surface of circuit end cap (13).
2. Remove circuit end cap (13).
3. Remove three screws (12) retaining the electronics in place.
4. Lift display board (11) and disconnect the ribbon cable connector between the display board and the CPU board of PC board stack (10).
5. Using a replacement display board, connect the ribbon cable connector between the display board and the CPU board of PC board stack (10). Ensure the cable connector is fully seated.
2. Remove circuit end cap (13). Remove three screws (12).
3. Lift display board (11) and disconnect the ribbon cable connector between the display board and the CPU board of PC board stack (10).
4. Lift the CPU board from housing (1) by the standoffs.
5. Remove two screws (4) and lockwash­ers (3). Lift terminal block (6) until the analog board is unplugged from the terminal board.
6. Reinstall terminal block (6), lockwash­ers (3), and screws (4).
7. Lift the analog board from housing (1) by the standoffs.
8. Install replacement PC board stack (10) into housing (1). Carefully seat the analog board onto housing pins. Press firmly on the CPU board standoffs to ensure good contact.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 5-1
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Instruction Manual
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Model 3081FG
1. Housing
2. O-ring
3. Lockwasher
4. Screw
5. Terminal End Cap
6. Terminal Block
7. Ground Screw
8. Washer
1
9. O-ring
10. PC Board Stack (CPU and Analog Boards)
11. Display Board
12. Screw
13. Circuit End Cap
4
3
14. Screw
15. Cover Lock
2
5
6
7
8
9
10
15
13
14
STANDOFF
11
12
CPU BOARD
RIBBON
CABLE
Figure 5-1. Two-Wire In Situ Oxygen Analyzer Exploded View
STANDOFF
ANALOG BOARD
29750006
5-2 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
5
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
9. Connect the ribbon cable connector between display board (11) and the CPU board of PC board stack (10). Ensure the cable connector is fully seated.
10. Reposition display board (11) on the standoffs. Rotate the display board 90 degrees either way as desired.
11. Install and tighten all three screws (12) and circuit end cap (13).
12. Tighten cover lock screw (14) until cover lock (15) engages knurled sur­face of circuit end cap (13).
Use heat resistant gloves and clothing when removing the probe. The probe can be as hot as 1600°°°°C (2912°°°°F). This can cause severe burns.

5-2 OXYGEN PROBE REPLACEMENT

The oxygen probe is designed with ceramic materials to provide maximum life at elevated temperatures and is not rebuildable. The condi­tion of the sensing cell can be determined peri­odically by two methods:
• Note the cell impedance at the electronics. When the impedance displays a warning in­dication (WARN), increase the frequency of impedance readings. A cell with a sustained high impedance indication (HI) indicates a probe that is beyond its useful life.
• Conduct a calibration check. Follow the prompts provided by the electronics through the process of flowing two calibration check
gases of known values. Record the generated slope and constant values.
Probe replacement may be conducted online as long as the process in which the probe is mounted is operating at a negative, or slightly positive, pressure. Refer to Section 6, TROU­BLESHOOTING, for more information.
Do not install or remove probes from a process where pressures are more than a few inches of H2O positive pressure. Hot gases may escape from the stack and cause severe personal injury.
Do not insert or withdraw a probe into or out of a hot process faster than 1 in. (25.4 mm) per minute or instrument damage from thermal shock may occur.
Also, ash, slag, or other materials can build up on the probe body in some applications. If this buildup is causing difficulty when withdrawing the probe, DO NOT FORCE. Rotate the probe back and forth to attempt to loosen the material on the probe body. Or, wait until the process cools down and ac­cess the buildup from inside the furnace.
Refer to Table 8-1 for replacement probe part numbers. Before replacing the probe, verify that the reference air and calibration check gas lines are turned off and disconnected from the probe.
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Instruction Manual
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a. Remove the end cap of the probe to expose
the terminal block.
b. Refer to Figure 5-2. Disconnect the four
wires (two oxygen signal wires and two thermocouple wires) from the terminal block.
c. Disconnect the reference air and the cali-
bration check gas lines.
d. Unscrew the probe from the stack and
remove.
Model 3081FG
TERMINAL BLOCK
e. Using a replacement probe, refer to para-
graph 2-2c for mechanical installation in­structions.
f. Refer to paragraph 2-3b for electrical in-
stallation instructions.
g. Refer to paragraph 2-4 for reference air and
calibration check gas installation instruc­tions.
CONDUIT
THERMOCOUPLE + (GY)
THERMOCOUPLE - (RD)
CELL - (WH)
CELL + (BK)
26020004
Figure 5-2. Oxygen Probe Terminal Block
5-4 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
6
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
SECTION 6

TROUBLESHOOTING

Life of the probe is negatively impacted by:
Install all protective equipment covers and safety ground leads after trouble­shooting. Failure to install covers and ground leads could result in serious injury or death.
6-1 GENERAL
This troubleshooting section describes how to identify and isolate faults that may develop in the Two-Wire In Situ Oxygen Analyzer.

6-2 PROBE LIFE

The zirconium oxide technology for measuring oxygen is very stable and should provide accu­rate service for several years.
50
40
• Continued operation at elevated tempera- tures above 1300°C (2372°F).
• Operation in processes that contain high levels of sulfur, SO
, or other acidic com-
2
pounds.
Operating conditions with simultaneously high levels of SO
and low levels of O2 are particu-
2
larly damaging.
The health and accuracy of a given cell is closely related to the resistance, or impedance, of the cell. Figure 6-1 illustrates that the amount of output from a cell for a given O
value (repre-
2
sented as slope) will remain very stable to the point where cell impedance increases to ap­proximately 100 ohms.
30
20
SLOPE (mV/Dec)
10
0
NORMAL OPERATIONAL CONDITIONS
48.0<S<51 mV/Dec
DETERIORATED PERFORMANCE, SLOW RESPONSE, HIGH MEASUREMENT ERROR
45.0<S<48 mV/Dec
IMPEDANCE,
DETERIORATED PERFORMANCE, SLOW RESPONSE, HIGH MEASUREMENT ERROR. CONDUCT FREQUENT CALIBRA­TION CHECKS.
S<45 mV/Dec
Ω
26020059
Figure 6-1. Slope vs. Impedance
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Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
500
400
90
SPEED OF RESPONSE (t ), sec
300
200
100
0
AIR TO 0.4% O
0.4% O TO AIR
2
Figure 6-2. Speed of Response
Frequently conduct calibration checks to look for the following conditions:
• Continued degradation of cell slope.
• Sluggish response. (Note how long it takes
the cell to respond to the application of cali­bration check gases.) See Figure 6-2.
2
IMPEDANCE,
Ω
26020060
%
The slope will be valid only for the process tem­perature at which the calibration check gases are flowed, so no adjustments to the electronics are made as a result of a calibration check.
mA
Note that cells exposed to temperatures above 1300°C (2372°F) may lose the ability to meas­ure accurately and respond quickly when re­turned to the lowest end of the operating temperature range [550°C (1022°F)].
26020022

6-3 FAULT INDICATIONS

Figure 6-3. Faulted Operation Display
The fault conditions for the Two-Wire In Situ Oxygen Analyzer will be indicated by the faulted operation display as shown in Figure 6-3. This screen displays when a fault that invalidates the O
reading is present. When the error is cor-
2
rected, the screen will return to a normal opera­tion display unless another error exists.
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Instruction Manual
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September 2002
6-4 IDENTIFYING AND CORRECTING FAULT
INDICATIONS
A fault in the operation of the Two-Wire In Situ Oxygen Analyzer is indicated by the faulted op­eration display. If no faults exist, the display will indicate NONE. Information on the current fault is found under the DIAGNOSTICS MENU as detailed in Section 3, STARTUP AND OPERATION.
The following paragraphs describe the faults, possible causes, and corrective actions. Refer to Figure 6-4 as needed for test points and wir­ing information.
NOTE
Allow adequate time for the oxygen probe to reach its operating tempera­ture [approximately 500°°°°C (932°°°°F)] be­fore investigating a fault. The SHOW FAULTS screen of the DIAGNOSTICS menu will indicate a fault until the unit reaches operating temperature.
NOTE
The probe uses a Type B thermocou­ple to measure the cell temperature. A Type B thermocouple output table may be useful for troubleshooting.
CELL - (WH)
THERMOCOUPLE - (RD)
FACTORY-INSTALLED
JUMPER
TERMINAL
BLOCK (TB1)
PROBE CABLE
SHIELD
GROUND
4
3
12
CELL + (BK)
7
6
5
THERMOCOUPLE + (GY)
8
9
10
11
12
13
14 15
16
EARTH GROUND TERMINALS
4-20 mA (- ) 4-20 mA (+)
CELL AND THERMOCOUPLE
4-20 mA
26020023
Figure 6-4. Model 3081 Transmitter Terminal Block
Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-3
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Model 3081FG
%
Figure 6-5. Fault 1, Open Thermocouple
a. Fault 1, Open Thermocouple
The thermocouple connection is open. The fault displays as shown in Figure 6-5.
1. Refer to Figure 6-4 and check the thermocouple wiring connections at terminals 8 and 10. Ensure the wires are properly connected.
2. Remove power. Disconnect the ther­mocouple wires (gray and red) from terminals 10 and 8. Measure the conti­nuity across the gray and red thermo­couple leads. The measurement should read approximately 1-2 ohms. Larger values indicate the thermocou­ple is open.
3. If the thermocouple is open, replace the oxygen probe per paragraph 5-2.
26020024
%
26020025
Figure 6-6. Fault 2, Reversed Thermocouple
b. Fault 2, Reversed Thermocouple Active
The thermocouple connections are re­versed. The fault displays as shown in Fig­ure 6-6.
1. Allow adequate time for the oxygen probe to reach operating temperatures. Probe temperatures below approxi­mately 500°C (932°F) may result in this fault.
2. Refer to Figure 6-4. Check the gray (to terminal 10) and red (to terminal 8) wires for the proper placement.
3. Using a multimeter, measure between terminals 8(-) and 10(+). If the reading is negative, the thermocouple wiring is reversed. Rewire as necessary.
4. If the wiring is correct and the probe is at operating temperature, then the transmitter electronics are bad. Re­place the PC board stack assembly per paragraph 5-1.
6-4 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management
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September 2002
%
26020026
Figure 6-7. Fault 3, Shorted Thermocouple
c. Fault 3, Shorted Thermocouple
The thermocouple connections are shorted. The fault displays as shown in Figure 6-7.
1. Allow adequate time for the oxygen probe to reach operating temperatures. Probe temperatures below approxi­mately 500°C (932°F) may result in this fault.
%
26020027
Figure 6-8. Fault 4, High Probe Temperature
d. Fault 4, High Probe Temperature
The probe’s temperature has exceeded the maximum cell temperature setpoint. The fault displays as shown in Figure 6-8.
1. If the probe temperature exceeds the maximum cell temperature setpoint, the 4-20 mA signal output will become invalid and go to the default value.
2. Refer to Figure 6-4. Using a multime­ter, measure between terminals 8(-) and 10(+).
2. Verify that the upper cell temperature setpoint is configured as desired under the PROGRAM MENU (see Section 3, STARTUP AND OPERATION).
3. If the multimeter reading, in voltage mode, is between -0.5 and +0.5 mV, the thermocouple is shorted.
4. If the thermocouple is shorted, replace the oxygen probe per paragraph 5-2.
5. If the thermocouple is not shorted, then replace the PC board stack assembly per paragraph 5-1.
Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-5
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Model 3081FG
Figure 6-9. Fault 5, O2 Cell Open
e. Fault 5, O
The O
Cell Open
2
cell connection is open. The fault
2
displays as shown in Figure 6-9.
1. Allow adequate time for the oxygen probe to reach operating temperatures. Probe temperatures below approxi­mately 500°C (932°F) may result in this fault.
2. Refer to Figure 6-4 and check the O cell wiring connections at terminals 7 and 8. Ensure the wires are properly connected.
NOTE
%
26020028
%
26020029
Figure 6-10. Fault 6, Cell Impedance Too High
f. Fault 6, Cell Impedance Too High
The O
cell impedance has exceeded 100
2
ohms. The fault displays as shown in Figure 6-10.
1. This fault is usually indicated in con­junction with Fault 5, Cell Open. Cor­recting Fault 5 should correct Fault 6.
2. If Fault 6 appears independently, the
2
cell has degraded beyond specification.
3. If the O
cell has become too old, re-
2
place the oxygen probe per paragraph 5-2.
Check the cell output voltage at the probe terminals -- not at the electronics.
3. Apply low calibration check gas (0.4% O
). Measure the cell output from the
2
O
cell wires at the probe terminal
2
block. The cell output should be 100 ±20 mV. If no voltage can be meas­ured, the cell is open.
4. If the O
cell is open, replace the oxy-
2
gen probe per paragraph 5-2.
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September 2002
%
Figure 6-11. Fault 7, Reversed O2 Cell
26020030
g. Fault 7, Reversed O
The O
cell connections are reversed. The
2
Cell
2
fault displays as shown in Figure 6-11.
1. Refer to Figure 6-4. Check the black (to terminal 7) and white (to terminal 8) wires for the proper placement. Rewire if necessary.
2. Apply the low calibration check gas (0.4% O
).
2
3. Using a multimeter, measure between terminals 7(+) and 8(-). If the cell out­put reading is negative, the O wiring is reversed.
4. If the wiring is correct, check if the mul­timeter reading is the same as the reading shown on the O agnostics screen (see Section 3, STARTUP AND OPERATION).
5. If the reading is different, the transmit­ter electronics are faulty. Replace the PC board stack assembly per para­graph 5-2.
cell
2
CELL mV di-
2
Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-7
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Instruction Manual
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September 2002
SECTION 7

RETURN OF MATERIAL

7-1 If factory repair of defective equipment is re-
quired, proceed as follows:
a. Secure a return authorization number from
a Rosemount Analytical Sales Office or rep­resentative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted.
In no event will Rosemount be responsible for equipment returned without proper authorization and identification.
b. Carefully pack defective unit in a sturdy box
with sufficient shock absorbing material to ensure that no additional damage will occur during shipping.
c. In a cover letter, describe completely:
1. The symptoms from which it was de­termined that the equipment is faulty.
2. The environment in which the equip­ment has been operating (housing, weather, vibration, dust, etc.).
5. Complete shipping instructions for re­turn of equipment.
6. Reference the return authorization number.
d. Enclose a cover letter and purchase order
and ship the defective equipment according to instructions provided in Rosemount Re­turn Authorization, prepaid, to:
Rosemount Analytical Inc. RMR Department 1201 N. Main Street Orrville, Ohio 44667
If warranty service is requested, the defec­tive unit will be carefully inspected and tested at the factory. If failure was due to conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount's option, and an operating unit will be returned to the cus­tomer in accordance with shipping instruc­tions furnished in the cover letter.
3. Site from which equipment was removed.
4. Whether warranty or nonwarranty service is requested.
Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 7-1
For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.
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7-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management
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Instruction Manual
8
IB-106-3081 Rev. 1.5
Model 3081FG
SECTION 8

REPLACEMENT PARTS

Table 8-1. Replacement Parts List
Figure and
Index No. Part Number Description
1-1, 2 1A99138G01 Model 3081 Transmitter CENELEC
1-1, 2 1A99138G02 Model 3081 Transmitter CSA
1-1, 2 1A99138G03 Model 3081 Transmitter FM
1-1, 3 5R10092G01 20” Replacement Oxygen Probe, with Alumina Outer Protection Tube
1-1, 3 5R10092G02 26” Replacement Oxygen Probe, with Alumina Outer Protection Tube
1-1, 3 5R10092G03 34.625” Replacement Oxygen Probe, with Alumina Outer Protection Tube
1-1, 3 5R10092G09 20” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube
1-1, 3 5R10092G010 26” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube
September 2002
1-1, 3 5R10092G011 34.625” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube
5-1, 10 23574-04 PC Board Stack Assembly (CPU and Analog Boards)
5-1, 11 23601-00 Display Board
5-1, 6 23581-00 Terminal Block
5-1, 13 23593-01 Circuit End Cap (with Glass)
Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 8-1
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8-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management
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Model 3081FG
9
This index is an alphabetized listing of parts, terms, and procedures having to do with the Haz­ardous Area Oxygen/Combustibles Transmitter. Every item listed in this index refers to a location in the manual by one or more page numbers.
A
Absolute Temperature, 1-3 ACCEPT HIGH O ACCEPT LOW O Accuracy, 1-7 Adapter Plate, 2-3 Ambient Temperature Limits, Electronics, 1-8 AMS, 1-4, 1-5 Arithmetic Constant, 1-3
Screen, 3-14
2
Screen, 3-14
2
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
SECTION 9

INDEX

F
Fault Indications, 6-2 FAULT VAL Screen, 3-7 Faulted Operation Display, 3-1 FSK, 4-1
G
Grounding, 2-10
C
CAL key, 3-5 CALCHECK Menu, 3-4, 3-13 Calibration Check Gas, 1-7, 2-11, 3-2 Calibration Check Gas Flow Rate, 3-2 CELL IMPEDANCE Screen, 3-12 CELL T HI Screen, 3-7 Cell Constant, 1-3 Cell Impedance Too High Fault, 6-6 Check Valve, 1-6 Component Checklist, 1-1 CONSTANT Screen, 3-15
D
DIAG Key, 3-5 Diagnostics Menu, 3-4, 3-11 Display Board, 2-9 Display Board Positioning, 2-9 Display Board Replacement, 5-1 DISPLAY Code, 3-6 Drip Loop, 2-6
E
Earth Ground, 2-10 Electrical Installation, 2-9 Electromagnetic Interference (EMI), 2-10 ENTER Key, 3-5 EXIT Key, 3-5
H
HART Communicator, 4-1 HART Model 275 Communicator, 1-4
®
HART Hazardous Area Certification, 1-7 Hazardous Area Certification, IRC, 1-8 Hazardous Area Certification, Probe, 1-8 High Probe Temperature Fault, 6-5
Communicator, 1-1
I
IN MANUAL? Screen, 3-14 Infrared Remote Control (IRC), 1-1, 1-4 Inner Probe, 1-7 Inputs, 1-8 Inspect, 2-1 Instrument Air, 1-6, 2-11 Insulation, 2-6 Intrinsic Safe, 1-5 Intrinsic Safety (IS), 1-4 IP65, 1-6, 1-8 IRC, 3-5 IRC Power Requirements, 1-8
L
Lengths, 1-3, 1-7 Liquid Crystal Display (LCD), 3-3 Load Requirements, 1-8 Load Resistance, 4-2
Rosemount Analytical Inc. A Division of Emerson Process Management Index 9-1
Page 72
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
M
Materials of Construction, 1-7 Materials of Construction, Electronics, 1-8 MAX CELL T Screen, 3-13 Mechanical Installation, Probe, 2-1 Menu Arrows, 3-5 Menu Tree, 3-4 Menu Tree for HART Communicator, 4-3 Menu Tree for HART/AMS, 4-4, 4-5, 4-6 Minimum Operating Temperatures, 3-1 Model 3081 Transmitter, 1-1, 1-3, 1-4, 2-6, 2-7, 2-10,
3-10 Model 3081 Transmitter, Installation, 2-7 Mounting Bracket, 2-7 Mounting Dimensions, Transmitter, 2-7, 2-8 Mounting Position, Probe, 1-7
N
NEMA, 1-6 NEMA 4X, 1-8 Nernst Equation, 1-3 NEXT Key, 3-5 Normal Operation Display, 3-1, 3-3
O
O2 CELL mV, 3-11 O
Cell Open Fault, 6-6
2
Open Thermocouple Fault, 6-4 Outer Protection Tube, 1-7 Output, 1-8 Oxygen Probe, 1-1, 1-3, 2-10 Oxygen Probe Gas Connection, 2-11 Oxygen Probe Replacement, 5-3 Oxygen Probe, Installing, 2-1 Oxygen Probe, Locating, 2-1
P
Packaging, 1-6 Packing List, 2-1 Partial Pressure, 1-3 PC Board Stack Replacement, 5-1 Plant Air Connection, 2-12 Pneumatic Installation, 2-11 Power Supply Requirements, 1-8 PREVIOUS CONSTANT screen, 3-12 PREVIOUS SLOPE Screen, 3-12 Probe Insertion Depth, 2-5 Probe Insertion Rate, 2-6 Probe Installation Details, 2-2 Probe Lengths, 1-7 Probe Life, 6-1 Probe Mounting, 1-7
Probe Mounting Flange, 2-3 Product Matrix, 1-2 PROG Key, 3-5 Program Menu, 3-6 Program Menu, 3-4 Protective Cover, 2-1
R
Radio Frequency Interference (RFI), 2-10 Reference Air, 1-3, 1-7, 2-11 Reference Air Set, 1-1 Relative Humidity, 1-8 Replacement Parts, 8-1 RESET MAX CELL T Screen, 3-8 RESET Key, 3-5 Returning Equipment, 7-1 Reversed O Reversed Thermocouple Fault, 6-4
Cell Fault, 6-7
2
S
Selected Distributed Control Systems, 1-4 SET CODE Screen, 3-10 SET HI BOTTLE O SET LO BOTTLE O SET O SET O Shipping Weight, 1-8 Shorted Thermocouple Fault, 6-5 SHOW FAULT Screen, 3-11 Signal Line Connections, 4-1 SLOPE Screen, 3-15 Slope vs. Impedance, 6-1 Specifications, 1-7 Speed of Installation, 1-7 Speed of Response, 6-2 Speed of Withdrawal, 1-7 SW BUILD DATE Screen, 3-13 SW BUILD NUMBER Screen, 3-13 SW VER Screen, 3-13
FILTER TIME, 3-8
2
TRACKING Screen, 3-10
2
Screen, 3-9
2
Screen, 3-9
2
T
T/C mV Screen, 3-11 Temperature Limits, 1-7 Transmitter LCD, 3-3 Transmitter Terminal Block, 6-3 TRIM 20 mA? Screen, 3-9 TRIM 4 mA? Screen, 3-8 Troubleshooting, 6-1 Two-Wire In Situ Oxygen Analyzer, 1-1, 6-1 Type B Thermocouple, 1-3 Typical System Installation, 1-6
9-2 Index Rosemount Analytical Inc. A Division of Emerson Process Management
Page 73
Model 3081FG
9
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
U
UNIT SER # Screen, 3-13 UPPER RANGE VAL Screen, 3-7
Z
Zirconia Disc, 1-3
Rosemount Analytical Inc. A Division of Emerson Process Management Index 9-3
Page 74
Page 75
Model 3081FG
10
Instruction Manual
IB-106-3081 Rev. 1.5
September 2002
SECTION 10
DRAWINGS AND SCHEMATICS
Rosemount Analytical Inc. A Division of Emerson Process Management Drawings and Schematics 10-1
Page 76
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
10-2 Drawings and Schematics Rosemount Analytical Inc. A Division of Emerson Process Management
Page 77

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the com­mercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced.
The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded.
IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WAR­RANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DE­LAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WAR­RANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF AC­TION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDEN­TAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVE­NUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.
Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller's direct control.
The oxygen probe is designed for industrial applications. Treat with care to avoid physical damage. The probe contains components made from ceramic, which are susceptible to shock when mishandled. THE WARRANTY DOES NOT COVER DAMAGE FROM MISHANDLING. WARRANTY IS VOID IF OUTER PROTECTION TUBE IS BROKEN.
3681/9-02
Page 78
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
Two-Wire In Situ Oxygen
Analyzer
Rosemount Analytical Inc. Process Analytic Division
1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com
Pa rt no. _______________ Se ria l no . _______________ Ord er no. _______________
Fisher-Rosemount GmbH & Co.
Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209
ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd.
1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947
http://www.processanalytic.com
© Rosemount Analytical Inc. 2002
EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd.
Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354
LATIN AMERICA Fisher - Rosemount
Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882
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