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3081FG
User Manual
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Emerson 3081FG User Manual

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

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

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.
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
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
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
Instruction Manual
IB-106-3081 Rev. 1.5 September 2002
Model 3081FG
iv Rosemount Analytical Inc. A Division of Emerson Process Management
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
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
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
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
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
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.
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
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
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
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
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.
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
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
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
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
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
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