Rosemount World Class 3000 O2 Analyzer CENELEC with IFT 3000 Intelligent Field Transmitter-Rev 4.2 Manuals & Guides

Instruction Manual
106-300NFX Rev. 4.2 January 2002
World Class 3000
Oxygen Analyzer (CENELEC) with IFT 3000 Intelligent Field Transmitter (CENELEC)
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, 1997 Rev. 4
Page Summary
--- General. Added snubber version of probe to manual. Text and art changed as necessary to reflect new style of probe.
Effective February, 1998 Rev. 4.1
Page Summary
Page 2-2 Figure 2-1. Change calibration gas tube dimensions.
Page 3-10 Add note on test gas flowmeter.
Effective January, 2002 Rev. 4.2
Page Summary
Page 2-13 Updated Figure 2-8.
Page 2-14 Updated analog output current/voltage mode selection procedure.
HIGHLIGHTS OF CHANGES
APPENDIX AX
Effective June, 1997 Rev. 2
Page Summary
-- General. Added snubber version of probe to manual. Text and art changed as necessary to reflect new style probe.
Effective February, 1998 Rev. 2.1
Page Summary
Page A-12 Changed screw torque in paragraph A-3h.
HIGHLIGHTS OF CHANGES
APPENDIX BX
Effective February, 1995 Rev. 1.1
Page Summary
B-3 Figure B-3. Updated for IB consistency.
Effective January, 1997 Rev. 1.2
Page Summary
Page B-2 Figure B-2. Added fuse locations.
Page B-5 Insert protective cover and ground lead warning.
Page B-8 Insert protective cover and ground lead warning.
Page B-11 Table B-2. Add expanded fuse specifications to replacement parts.
HIGHLIGHTS OF CHANGES
APPENDIX DX
Effective February, 1995 Rev. 2
Page Summary
-- General. Updated appendix with new version of MPS.
Effective January, 1997 Rev. 2.1
Page Summary
Page D-5 Insert protective cover and ground lead warning.
Page D-7 Insert protective cover and ground lead warning. Add fuse
specifications and clarify fuse replacement.
Page D-11 Add fuse specifications to replacement parts
HIGHLIGHTS OF CHANGES
APPENDIX EX
Effective February, 1995 Rev. 1.1
Page Summary
Page E-4 Figure E-2. Updated for IB consistency.
Page E-7 Figure E-4. Updated Flowchart.
Effective May, 1995 Rev. 1.2
Page Summary
Page E-4 Figure E-2. Added callout text “Heater Power Supply (Optional)”.
Effective January, 1997 Rev. 1.3
Page Summary
Page E-5 Insert protective cover and ground lead warning.
Page E-9 Insert protective cover and ground lead warning.
Page E-15 Added expanded fuse specifications to replacement parts
HIGHLIGHTS OF CHANGES
APPENDIX JX
Effective January, 1997 Rev. 1.0
Page Summary
Page J-4 Insert warning concerning protective equipment covers and safety
ground leads.
Page J-11 Insert warning concerning protective equipment covers and safety
ground leads.
World Class 3000
PREFACE.........................................................................................................................P1
Definitions ......................................................................................................................... P1
Safety Instructions ........................................................................................................... P2
1-0 DESCRIPTION ................................................................................................................ 1-1
1-1 Component Checklist Of Typical System (Package Contents) ....................................... 1-1
1-2 System Overview............................................................................................................. 1-1
2-0 INSTALLATION .............................................................................................................. 2-1
2-1 Oxygen Analyzer (Probe) Installation .............................................................................. 2-1
2-2 Intelligent Field Transmitter (IFT) Installation .................................................................. 2-9
2-3 Heater Power Supply Installation .................................................................................. 2-16
2-4 Multiprobe Test Gas Sequencer Installation ................................................................. 2-20
3-0 SETUP AND OPERATION ........................................................................................... 3-1
3-1 Overview.......................................................................................................................... 3-1
3-2 IFT with GUI and LDP Front Panel Controls and Indicators ........................................... 3-2
3-3 Help Key .......................................................................................................................... 3-2
3-4 Status Line....................................................................................................................... 3-3
3-5 Quick Reference Chart .................................................................................................... 3-3
3-6 Main Menu ....................................................................................................................... 3-3
3-7 Probe Data Sub-Menu .................................................................................................... 3-6
3-8 Calibrate O
3-9 Setup Sub-Menu.............................................................................................................. 3-6
3-10 System Calibration........................................................................................................... 3-9
ub-Menu ..................................................................................................... 3-6
2
Instruction Manual
106-300NFX Rev. 4.2
January 2002
TABLE OF CONTENTS
4-0 LDP OPERATION .......................................................................................................... 4-1
4-1 Overview.......................................................................................................................... 4-1
4-2 IFT with LDP Front Panel Controls and Indicators .......................................................... 4-1
4-3 LDP Displays ................................................................................................................... 4-1
4-4 LDP Defaults.................................................................................................................... 4-2
4-5 Calibration........................................................................................................................ 4-2
5-0 TROUBLESHOOTING .................................................................................................... 5-1
5-1 Overview.......................................................................................................................... 5-1
5-2 Special Troubleshooting Notes........................................................................................ 5-1
5-3 System Troubleshooting.................................................................................................. 5-2
6-0 RETURN OF MATERIAL .............................................................................................. 6-1
7-0 APPENDICES ................................................................................................................. 7-1
8-0 INDEX.............................................................................................................................. 8-1
9-0 DRAWINGS AND SCHEMATICS................................................................................. 9-1
Rosemount Analytical Inc. A Division of Emerson Process Management i
Instruction Manual
106-300NFX Rev. 4.2 January 2002
Figure 1-1. Typical System Package ....................................................................................... 1-1
Figure 1-2. Typical System Installation .................................................................................... 1-5
Figure 1-3. World Class 3000 Typical Application with Intelligent Field Transmitters -
Figure 2-1. Probe Installation ...................................................................................................2-2
Figure 2-2. Orienting the Optional Vee Deflector ..................................................................... 2-7
Figure 2-3. Air set, Plant Air Connection.................................................................................. 2-8
Figure 2-4. Outline of Intelligent Field Transmitter ................................................................... 2-9
Figure 2-5. Power Supply Board Jumper Configuration ........................................................ 2-10
Figure 2-6. IFT Power Supply Board Jumpers....................................................................... 2-11
Figure 2-7. Wiring Layout for IFT 3000 (CENELEC approved) System without HPS............ 2-12
Figure 2-8. IFT Microprocessor Board Jumper Configuration................................................ 2-13
Figure 2-9. IFT Microprocessor Board Jumpers .................................................................... 2-14
Figure 2-10. Interconnect Board Jumper Configuration........................................................... 2-14
Figure 2-11. IFT Interconnect Board Output Connections ....................................................... 2-15
Figure 2-12. Outline of CENELEC Approved Heater Power Supply........................................ 2-16
Figure 2-13. Wiring layout for IFT 3000 (CENELEC approved) with HPS ............................... 2-17
Figure 2-14. CENELEC Approved Heater Power Supply Wiring Connections ........................ 2-19
Figure 2-15. Jumper Selection Label. ...................................................................................... 2-19
Figure 2-16. Jumpers on HPS Motherboard ............................................................................ 2-20
Figure 2-17. MPS Module ........................................................................................................ 2-21
Figure 2-18. MPS Gas Connections ........................................................................................ 2-22
Figure 2-19. MPS Electrical Connections ................................................................................ 2-23
Figure 3-1. IFT with GUI and LDP Front Panel ........................................................................ 3-2
Figure 3-2. Typical Calibration Setup..................................................................................... 3-11
Figure 3-3. Portable Rosemount Oxygen Test Gas Kit......................................................... 3-12
Figure 3-4. Typical Portable Test Calibration Setup .............................................................. 3-13
Figure 3-5. Typical Automatic Calibration System ................................................................. 3-15
Figure 4-1. IFT with LDP Front Panel ...................................................................................... 4-1
World Class 3000
LIST OF ILLUSTRATIONS
CENELEC Approved ............................................................................................. 1-6
LIST OF TABLES
Table 3-1. Sample HELP Messages....................................................................................... 3-2
Table 3-2. Main Menu .............................................................................................................3-3
Table 3-3. PROBE DATA Sub-Menu. ................................................................................... 3-3
Table 3-4. CALIBRATION O
Table 3-5. SETUP Sub-Menu ................................................................................................. 3-8
Table 3-6. Efficiency Constants .............................................................................................. 3-9
Table 4-1. LDP Defaults.........................................................................................................4-3
ii Rosemount Analytical Inc. A Division of Emerson Process Management
Sub-Menu ................................................................................ 3-7
2
World Class 3000
The purpose of this manual is to provide information concerning the components, func­tions, installation and maintenance of this particular oxygen analyzer.
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
106-300NFX Rev. 4.2
January 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
106-300NFX Rev. 4.2 January 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.
World Class 3000
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
World Class 3000
1
Instruction Manual
106-300NFX Rev. 4.2
January 2002
SECTION 1

DESCRIPTION

1-1 COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
A typical Rosemount World Class 3000 Oxygen Analyzer (CENELEC approved) with IFT 3000 Intelligent Field Transmitter (CENELEC approved) 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 cover of this manual.
The IFT 3000, Oxygen Analyzer (Probe), and probe abrasive shield are heavy. Lifting and carrying procedures should take account of this weight.
1-2 SYSTEM OVERVIEW
a. Scope
This Instruction Bulletin has been designed to supply details needed to install, start up, oper­ate, and maintain the Rosemount World Class 3000 Oxygen Analyzer (CENELEC approved) with IFT 3000 Intelligent Field Transmitter (CENELEC approved). The Intelligent Field Transmitter (IFT) can be interfaced with one World Class 3000 probe. The IFT provides all necessary intelligence for controlling the probe and optional MPS 3000 Multiprobe Gas Sequencer.
1
3
1. Intelligent Field Transmitter (CENELEC approved)
2. Instruction Bulletin
3. Multiprobe Test Gas Sequencer (Optional)
4. Heater Power Supply (CENELEC approved)(Optional)
5. Oxygen Analyzer (Probe) (CENELEC approved)
6. System Cable
7. Mounting Plate with Mounting Hardware and Gasket
8. Reference AIR set (optional)
R
O
S
E
M
O
U
N
T
8
7
6
Figure 1-1. Typical System Package
2
4
E
N
E
E L I
R
H
G I
W
S
E
N
D
E
P O T
G
O
N
N
I N
O
E
D
P
O
S
E
E
R
E
O
L
F
A
E
B
B
E
L
5
26030001
Rosemount Analytical Inc. A Division of Emerson Process Management Description 1-1
Instruction Manual
106-300NFX Rev. 4.2 January 2002
World Class 3000
NOTE
The Rosemount encode sheets (Prod­uct Ordering Matrix) allow a customer to order either the hazardous area ver­sion of the IFT 3000 or the non­hazardous area version. The hazard­ous area version has the symbol "EExd" on the apparatus nameplate. The non-hazardous area version does not. Ensure that if you have received the non-hazardous version that you do not install it in a potentially explosive atmosphere. This also applies to the hazardous/non-hazardous versions of the HPS 3000.
b. System Description
The Rosemount Oxygen Analyzer (Probe) 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 probe is permanently posi­tioned within an exhaust duct or stack and performs its task without the use of a sam­pling system.
The equipment measures oxygen percent­age by reading the voltage developed across a heated electrochemical cell, which consists of a small Yttria-stabilized, Zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output voltage of the cell is given by the following Nernst equation:
EMF = KT log
10(P1/P2
) + C
Where:
is the partial pressure of the oxygen
1. P
2
in the measured gas on one side of the cell,
2. P
is the partial pressure of the oxygen
1
in the reference gas on the other side,
3. T is the absolute temperature,
4. C is the cell constant,
5. K is an arithmetic constant.
For best results, use clean, dry, in­strument air (20.95% oxygen) as a ref­erence gas.
When the cell is at operating temperature, and there are unequal oxygen concentra­tions across the cell, oxygen ions will travel from the high partial pressure of oxygen side to the low partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade. Because the magnitude of the output is proportional to the logarithm of the inverse of the sample of the oxygen partial pres­sure, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the oxygen analyzer to provide exceptional sensitivity 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 Orsat 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 three major components: the oxygen analyzer (CENELEC approved) (probe), the intelligent field transmitter (CENELEC approved) (IFT), and an op­tional heater power supply (CENELEC approved) (HPS). The HPS is required when the cable run between the electronics and the probe exceeds 45 m (150 ft). There is also an optional multiprobe test gas sequencer (MPS), which can be used to facilitate the automatic calibration of a multiple probe configuration.
1-2 Description Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
1
Instruction Manual
106-300NFX Rev. 4.2
January 2002
CENELEC approved probes are available in three length options, giving the user the flexibility to use an in situ penetration ap­propriate to the size of the stack or duct. The options on length are 457 mm (18 in.),
0.91 m (3 ft), and 1.83 m (6 ft). The probe is certified EExd IIB T1 [370°C (698°F)] to CENELEC standards EN50014 and EN50018.
The IFT contains electronics that control probe temperature (in conjunction with the optional HPS) and supply power, and pro­vide isolated outputs that are proportional to the measured oxygen concentration. The oxygen sensing cell is maintained at a con­stant temperature by modulating the duty cycle of the probe heater. The IFT accepts millivolt signals generated by the sensing cell and produces outputs to be used by remotely connected devices. The IFT output is isolated and selectable to provide linearized voltage or current.
The heater power supply CENELEC approved (HPS) can provide an interface between the IFT and the probe. The HPS contains a transformer for supplying proper voltage to the probe heater. The unit is certified EExd IIC T6 to CENELEC stan­dards EN50014 and EN50018.
Systems with multiprobe and multiple IFT applications may employ an optional MPS 3000 Multiprobe Test Gas Sequencer. The MPS 3000 provides automatic test gas sequencing for up to four probes and IFTs to accommodate automatic calibration. The MPS 3000 must be installed in a non­hazardous, explosive-free environment.
3. User friendly, menu driven operator interface with context-sensitive on-line help.
4. Field replaceable cell.
5. Analyzer constructed of rugged 316 LSS for all wetted parts.
6. The intelligent field transmitter (IFT) can be located up to 45 m (150 ft) from the probe when used without optional heater power supply (HPS). When the system includes the optional HPS, the HPS can be located up to 45 m (150 ft) from the probe and the IFT may be lo­cated up to 364 m (1200 ft) from the HPS.
7. All electronic modules are adaptable to 120, 220, and 240 line voltages.
8. Five languages may be selected for use with the IFT. These are:
English French German Italian Spanish
9. An operator can set up, calibrate, or troubleshoot the IFT in one of two ways:
(a) Optional General User Interface
(GUI). The GUI is housed within the IFT electronics enclosure and makes use of an LCD display and keypad.
d. System Features
1. Unique and patented electronic cell protection action that automatically protects sensor cell when the analyzer detects reducing atmospheres.
2. Output voltage and sensitivity increase as the oxygen concentration de­creases.
Rosemount Analytical Inc. A Division of Emerson Process Management Description 1-3
(b) Optional LED Display Panel (LDP).
The LED display and a limited function keypad permit calibration only.
Instruction Manual
106-300NFX Rev. 4.2 January 2002
World Class 3000
e. Handling the Oxygen Analyzer
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 analyzer is designed for industrial application. Treat each component of the system with care to avoid physical damage. The probe contains components made from ce­ramics, which are susceptible to shock when mishandled. See Safety Data Sheets 1M03243, 1M03226, and 1M03296 for safety related informa­tion.
NOTE
Retain packaging in which the 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.
f. System Considerations
Once you have verified that you have all the components, select mounting locations and determine how each component will be placed in terms of available power supply, ambient temperatures, environmental con­siderations, convenience, and serviceability. A typical system installation is illustrated in Figure 1-2. Figure 1-3 shows a typical system wiring. For details on installing the individual components of the system, refer to Section 2, Installation.
After selecting the probe mounting location, provision should be made for a platform where the probe can be easily serviced. The intelligent field transmitter (IFT) can be located up to 45 m (150 ft) cabling distance from the probe when used without optional heater power supply (HPS). When the sys­tem includes the optional HPS, the HPS can be located up to 45 m (150 ft) cabling distance from the probe and the IFT may be located up to 364 m (1200 ft) cabling distance from the HPS.
A source of instrument air is required at the probe for reference gas use. Since the probe is equipped with an in-place calibra­tion feature, provision should be made for connecting test gas tanks to the oxygen analyzer when the probe is to be calibrated.
Prior to installation of your Rosemount CENELEC approved World Class 3000 Oxygen Analyzer with Intelligent Field Transmitter make sure that you have all of the components necessary to make the system installation. Ensure that all the com­ponents are properly integrated to make the system functional.
1-4 Description Rosemount Analytical Inc. A Division of Emerson Process Management
If the test gas bottles will be permanently hooked up, a check valve must be con­nected to the calibration gas fitting on the probe junction box. This is to prevent breathing of calibration gas line and subse­quent gas condensation and corrosion. The check valve is in addition to the stop valve in the test gas kit or the solenoid valve in the multiprobe test gas sequencer units.
World Class 3000
1
Instruction Manual
106-300NFX Rev. 4.2
January 2002
CALIBRATION
INSTRUMENT
AIR SUPPLY
(REF. GAS)
FIELD TRANSMITTER
GAS
PRESSURE
REGULATOR
FLOWMETER
INTELLIGENT
EExd IIB T6
GASES
STACK
STANDARD
DUCT
OXYGEN ANALYZER EExd IIB T1 (370°C) (PROBE)
HEATER POWER SUPPLY EExd IIC T6
ADAPTER PLATE
LINE VOLTAGE
}
GASES
OPTIONS
DUCT
*MULTIPROBE TEST
GAS SEQUENCER
(NON-HAZARDOUS AREA)
*NOTE: THE MPS 3000 MUST BE
INSTALLED IN A NON-HAZARDOUS EXPLOSIVE FREE ENVIRONMENT.
ADAPTER
CALIBRATION
SUPPLY
INST. AIR
TEST GAS 1
TEST GAS 2
REFERENCE AIR
FIELD TRANSMITTER
STACK
PLATE
GAS
INTELLIGENT
EExd IIB T6
OXYGEN ANALYZER EExd IIB T1 (370°C) (PROBE)
HEATER POWER SUPPLY EExd IIC T6
}
LINE VOLTAGE
23800017
Figure 1-2. Typical System Installation
Rosemount Analytical Inc. A Division of Emerson Process Management Description 1-5
Instruction Manual
106-300NFX Rev. 4.2 January 2002
Stack Thermocouple
(optional)
2-Conductor T/C
Wire [46 (150) max]
(optional)
(OPTIONAL)
Line Voltage
World Class 3000
4 Twisted Pair Plus 2 Twisted Pair
for Options [366 (1200) max]
Line Voltage
World Class 3000
Probe
World Class 3000
Probe
7-Conductor Cable
[46 (150) max]
2-Pneumatic Lines
by Customer
[91 (300) max]
HPS 3000
HPS 3000
Explosion Proof Required only for Hazardous Area Applications, otherwise use NEMA 4X. Lengths Exceeding 150 feet.
(OPTIONAL)
*MPS 3000
TEST GAS
SEQUENCER
Modular Design
Up to 4 Probes
[HPS not required for lengths of less than 46 (150) max]
7-Conductor Cable
[46 (150) max]
Line Voltage
Test Gas
by
Customer
IFT 3000
Intelligent Field Transmitter
Line Voltage 100 to 120 Volt 220 to 240 Volt
5 Conductor
[305 (1000) max]
Line Voltage
Stack Thermocouple
(optional)
*NOTE 1:
NOTE 2:
2-Conductor T/C
Wire [46 (150) max]
(optional)
THE MPS 3000 MUST BE INSTALLED IN A NON-HAZARDOUS EXPLOSIVE FREE ENVIRONMENT.
ALL DIMENSIONS APPEAR IN METERS WITH FEET IN PARENTHESES.
IFT 3000
Intelligent Field Transmitter
Line Voltage 100 to 120 Volt 220 to 240 Volt
P00003
Figure 1-3. World Class 3000 Typical Application
with Intelligent Field Transmitters - CENELEC Approved
1-6 Description Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
2
Instruction Manual
106-300NFX Rev. 4.2
January 2002
SECTION 2

INSTALLATION

2-1 OXYGEN ANALYZER (PROBE)
INSTALLATION
Before probe installations, consult probe Safety Data Sheet 1M03226.
The probe and probe abrasive shield are heavy. Use proper lifting and carrying procedures to avoid personnel injury.
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.
a. Selecting Location
provides you with 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 necessary repairs or install the probe upstream of any leakage.
3. Ensure that the area is clear of obstructions internal and external that will interfere with installation. Allow adequate clearance for removal of probe (Figure 2-1).
Do not allow the temperature of the probe junction box to exceed 150°C (302°F) or damage to the unit may result. If the probe junction box tem­perature exceeds 150°C (302°F), the user must fabricate a heat shield or provide adequate cooling air to the probe junction box.
1. The location of the probe in the stack or flue is most important for maximum accuracy in the oxygen analyzing pro­cess. The probe must be positioned so that 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 (40 to 60% insertion). A point too near the edge or wall of the duct may not pro­vide a representative sample because of the possibility of gas stratification. In addition, the sensing point should be selected so that the process gas tem­perature falls within a range of 10° to 704°C (50° to 1300°F). Figure 2-1
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
b. Mechanical Installation
1. Ensure that all components are avail­able for installation of the probe. Check the ceramic filter to ensure that it is not damaged and that the system cable is the required length.
2. The probe may be installed intact as it is received. It is recommended that you disassemble the adapter plate for each installation.
3. Weld or bolt adapter plate (Figure 2-1) onto the duct.
Instruction Manual
106-300NFX Rev. 4.2 January 2002
World Class 3000
o
DIM
DIM
MM
DIMENSIONS
TABLE II. REMOVAL/INSTALLATION
DIN
"B"
755
"A"
459
(IN.)
1U05680G01
210
1209
(29.7)
913
(18.07)
18 IN. PROBES
1U05680G02
18
(8.25)
2126
(47.6)
1831
(35.95)
3 FT PROBES
1U05680G03
170
(0.708)
(83.7)
EXTERNAL EARTH
(72.09)
6 FT PROBES
(6.693)
(HARDWARE)
INTERNAL EARTH
VIEW B-B
(TERMINAL 6)
AT BOTTOM
(ROTATED 90 CCW)
INSTALL WITH CONNECTIONS
DIM "B"
REMOVAL ENVELOPE
200 (7.87)
B
110 (4.33)
1.57 (0.062) THK GASKET
(P/N 1M03237H01)
ELECTRICAL
CONNECTION
B
BOTTTOM VIEW
DIM "A"
MM
(IN.)
DIMENSIONS
TABLE I. MOUNTING FLANGE
FLANGE
DIA
HOLE SIZE
DIA
4 HOLES EQ
SP ON B.C. DIA
PROCESS FLOW MUST BE IN
THIS DIRECTION WITH RESPECT
TO VEE SHIELD WHEN USING
OPTIONAL CERAMIC DIFFUSOR.
76 (3.0)
DIA MAX
CENELEC APPROVED WORLD CLASS PROBE WITH SNUBBER DIFFUSOR
A
23800006
VIEW A-A
INCHES IN PARENTHESES UNLESS
NOTE: DIMENSIONS ARE IN MILLIMETERS WITH
A
OTHERWISE INDICATED.
Figure 2-1. Probe Installation (Sheet 1 of 5)
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
2
WITH INCHES IN PARENTHESES
UNLESS OTHERWISE INDICATED.
NOTE: DIMENSIONS ARE IN MILLIMETERS
DIM "D"
(REMOVAL
ENVELOPE)
378
(14.9)
DETAILS
SEE SHEET 1
FOR CONNECTION
Instruction Manual
106-300NFX Rev. 4.2
January 2002
ELECTRICAL
CONNECTION
CHECK
VALV E
REF, VENT,
AND CAL GAS
CONNECTIONS
DIM "D"
(REMOVAL
DIM
REMOVAL/INSTALLATION
MM
DIMENSIONS
769
(30.3)
ENVELOPE)
"C"
387
(15.3)
(IN.)
18 IN. PROBE 1U05680G04
SHIELD 1N04966H01
1224
2144
(48.2)
(84.4)
843
1762
(33.2)
(69.4)
3 FT PROBE 1U05680G05
SHIELD 1N04966H02
6 FT PROBE 1U05680G06
SHIELD 1N04966H03
DIM "C"
178
(7.00)
(P/N 4507C52H03)
1.52 (0.06) THK GASKET
FURNISHED IN
HARDWARE PACKAGE
SEAL HUB
DIFFUSOR/DUST
(P/N 1U05677G03)
ABRASIVE SHIELD INSTALLATION WITH CENELEC APPROVED WORLD CLASS 3000
23800007
Figure 2-1. Probe Installation (Sheet 2 of 5)
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
Instruction Manual
106-300NFX Rev. 4.2 January 2002
World Class 3000
o
DIM
DIM
MM
DIMENSIONS
TABLE II. REMOVAL/INSTALLATION
DIN
"B"
755
"A"
554
(IN.)
1U05680G01
210
1209
(29.7)
1008
(21.81)
18 IN. PROBES
1U05680G02
18
(8.25)
2126
(47.6)
1926
(39.68)
3 FT PROBES
1U05680G03
170
(0.708)
(83.7)
EXTERNAL EARTH
(75.83)
6 FT PROBES
(6.693)
(HARDWARE)
VIEW B-B
(TERMINAL 6)
INTERNAL EARTH
AT BOTTOM
(ROTATED 90 CCW)
INSTALL WITH CONNECTIONS
DIM "B"
REMOVAL ENVELOPE
200 (7.87)
B
110 (4.33)
1.57 (0.062) THK GASKET
(P/N 1M03237H01)
ELECTRICAL
CONNECTION
B
BOTTTOM VIEW
DIM "A"
MM
(IN.)
DIMENSIONS
TABLE I. MOUNTING FLANGE
FLANGE
DIA
HOLE SIZE
DIA
4 HOLES EQ
SP ON B.C. DIA
OPTIONAL CERAMIC DIFFUSOR WITH VEE DEFLECTOR
PROCESS FLOW MUST BE IN
THIS DIRECTION WITH RESPECT
TO VEE SHIELD.
VIEW A-A
INCHES IN PARENTHESES UNLESS
NOTE: DIMENSIONS ARE IN MILLIMETERS WITH
OTHERWISE INDICATED.
76 (3.0)
DIA MAX
A
A
23800011
Figure 2-1. Probe Installation (Sheet 3 of 5)
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
2
Instruction Manual
106-300NFX Rev. 4.2
January 2002
"A"
"A"
PROBE TO STACK
(NEW INSTALLATIONS)
TABLE IV. MOUNTING PLATE:
MOUNTING PLATE OUTLINE
ABRASIVE SHIELD TO STACK
(NEW INSTALLATIONS)
TABLE III. MOUNTING PLATE:
215
DIN
MM
DIMENSIONS
DIN
MM
DIMENSIONS
(IN.)
(IN.)
"A"
235
"A"
(8.5)
(9.25)
M-16x2
"B"
THREAD
100
(3.94)
"B"
DIA
170
(6.7)
"C"
DIA
M-20 x 2.5
"C"
THREAD
18 IN., 3 FT AND6FT
MOUNTING PLATE FOR
SEE SHEET 2.
ABRASIVE SHIELD INSTALLATIONS
MOUNTING PLATE FOR
CENELEC WORLD CLASS 3000
SEE SHEET 1.
PROBE INSTALLATIONS
"A"
AND NUTS, EQUALLY
SPACED ON "C" DIA B.C.
4 STUDS, LOCKWASHERS,
"B"
DIA
"C" DIA
82.5 (3.25)
WITH INCHES IN PARENTHESES
UNLESS OTHERWISE INDICATED.
"A"
"C"
NOTE: DIMENSIONS ARE IN MILLIMETERS
o
22.5
8 THREADED HOLES
189.992 (7.48) DIA B.C.
EQUALLY SPACED ON
P00006
Figure 2-1. Probe Installation (Sheet 4 of 5)
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
Instruction Manual
106-300NFX Rev. 4.2 January 2002
INSTALLATION FOR METAL
WALL STACK OR DUCT
CONSTRUCTION
World Class 3000
INSTALLATION FOR MASONRY
WALL STACK CONSTRUCTION
MTG HOLES
SHOWN ROTATED
o
22.5 OUT OF
TRUE POSITION
WELD OR BOLT
MOUNTING PLATE TO
METAL WALL OF STACK
OR DUCT. JOINT MUST
BE AIR TIGHT.
13 (0.50)
95 (3.75)
MIN DIA HOLE IN WALL
STACK OR DUCT METAL WALL
BOLT ADAPTOR
PLATE TO OUTSIDE
WALL SURFACE
FIELD WELD
PIPE TO
ADAPTOR PLATE
MTG HOLES
SHOWN ROTATED
o
22.5 OUT OF
TRUE POSITION
JOINT MUST
BE AIRTIGHT
OUTSIDE WALL
SURFACE
NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPT
MOUNTING PLATE NOT FURNISHED BY ROSEMOUNT.
ABRASIVE SHIELD MOUNTING
13 (0.50)
114 (4.50) O.D. REF
PIPE 4.00 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH BY CUSTOMER
MASONRY STACK WALL
WELD OR BOLT MOUNTING
PLATE TO METAL WALL
OF STACK OR DUCT.
JOINT MUST BE AIR TIGHT.
82.5 (3.25)
MIN DIA HOLE IN WALL
STACK OR DUCT METAL WALL
BOLT MOUNTING
PLATE TO OUTSIDE
WALL SURFACE
BE AIRTIGHT
OUTSIDE WALL
PROBE MOUNTING
JOINT MUST
SURFACE
FIELD WELD PIPE TO ADAPTOR PLATE
102 (4.0) O.D. REF
PIPE 3.5 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH BY CUSTOMER
MASONRY STACK WALL
P00007
Figure 2-1. Probe Installation (Sheet 5 of 5)
2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
2
Instruction Manual
106-300NFX Rev. 4.2
January 2002
4. If using the optional ceramic diffuser element, the vee deflector must be cor­rectly oriented. Before inserting the probe, check the direction of flow of the gas in the duct. Orient the vee deflector on the probe so that the apex points upstream toward the flow (Figure 2-2). This may be done by loosening the setscrews, and rotating the vee de­flector to the desired position. Retighten the setscrews.
5. In horizontal installations, the probe cover should be oriented so that the system cable drops vertically from the probe cover. In a vertical installation, the system cable can be oriented in any direction.
6. If the system has an abrasive shield, check the diffusion element dust seal packings. The joints in the two pack­ings must be staggered 180°. Also, make sure that the packings are in the hub grooves as the probe slides into the 15° forcing cone in the abrasive shield.
GAS FLOW DIRECTION
VEE
APEX
FILTER
DEFLECTOR
CERAMIC
DIFFUSION
ELEMENT
VEE
DEFLECTOR
SETSCREW
23800008
Figure 2-2. Orienting the Optional Vee Deflector
7. Insert the probe through the opening in the mounting flange and bolt the unit to the flange.
8. Ensure that probe is properly earthed by way of both the internal and external points.
NOTE
If process temperatures will exceed 1000°F (538°C), use anti-seize com­pound on stud threads to ease future removal of probe.
9. Ensure that the installation does not obscure the messages on either the probe nameplate or the junction box lid.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7
Instruction Manual
106-300NFX Rev. 4.2 January 2002
World Class 3000
c. Reference Air Package
After the oxygen analyzing (probe) unit is installed, connect the reference gas air set to the probe cover. The reference gas air set should be installed in accordance with Figure 2-3.
d. Service Required.
1. Power input: 44 VAC from HPS 3000 or IFT 3000.
2. Compressed air: 68.95 kPa (10 psig) minimum, 1551.38 kPa (225 psig)
0.125-27 NPT FEMALE
OUTLET CONNECTION
122.17 (4.81)
FLOW SET
POINT KNOB
1
2
OUTLET
30.22 (1.19)
DRAIN VALVE
maximum at 56.6 L/hr (2 scfh) maxi­mum; supplied by one of the following (less than 40 parts-per-million total hy­drocarbons).
(a) Instrument air - clean, dry.
(b) Bottled standard air with step-down
regulator.
(c) Bottled compressed gas mixture
(20.95% oxygen in nitrogen).
(d) Other equivalent clean, dry, oil-free
air supply.
79.25 (3.12) MAX
3
57.15 (2.250)
50.80 (2.0)
38.10 (1.50)
0.25-18 NPT FEMALE INLET CONNECTION
NOTE: DIMENSIONS ARE IN MILLIMETERS
WITH INCHES IN PARENTHESES.
215.90 MAX (8.50)
2 MOUNTING HOLES
81.03 (3.19) LG
THROUGH BODY FOR
7.92 (0.312) DIA BOLTS
254 REF
(10.0)
6 (0.250) OD
TUBE COMPRESSION
FITTING (SUPPLIED BY WECO)
TO PROBE
JUNCTION BOX
6 (0.250) OD TUBING
(SUPPLIED BY CUSTOMER)
SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYGEN ANALYZER PROBE HEAD.
REF GAS SET
1 FLOWMETER 0.2-2.0 SCFH 771B635H02
2 2" PRESSURE GAGE 0-15 PSIG 275431-006
3 COMBINATION FILTER-REG. 0-30 PSIG 4505C21G01
COMPRESSED AIR SUPPLY 10-225 PSIG MAX PRESSURE
263C152G01
NOTE: DIMENSIONS ARE IN MILLIMETERS
WITH INCHES IN PARENTHESES.
Figure 2-3. Air set, Plant Air Connection
17300016
2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
2
2-2 INTELLIGENT FIELD TRANSMITTER (IFT)
INSTALLATION
The Rosemount Encode Sheet (Prod­uct Ordering Matrix) allows a customer to order either the hazardous area ver­sion of the IFT 3000 or the non­hazardous area version. The hazard­ous area version has the symbol "EExd" on the apparatus nameplate. The non-hazardous area version does not. Ensure that if you have the non­hazardous area version that you do not install it in a potentially explosive environment. This warning applies equally to the hazardous area and non-hazardous area versions of the HPS 3000.
Instruction Manual
106-300NFX Rev. 4.2
January 2002
The IFT 3000 is heavy. Lifting and car­rying procedures should take account of this weight.
a. Mechanical Installation
The outline drawing of the IFT module (CENELEC approved) in Figure 2-4 shows mounting centers and clearances. The en­closure is designed to be mounted on a wall. The IFT should be installed no more than 364 m (1200 ft) from the optional HPS or 45 m (150 ft) from the probe if HPS is not installed in the system. Ambient tempera­ture must be between 0°C and 50°C (32°F and 122°F).
NOTE
Fuse specifications are included in Figure 2-4.
Before IFT 3000 Installation, consult Safety Data Sheet 1M03296.
310 (12.2)
270 (10.6)
EXTERNAL
EARTH
FUSES
INTERNAL
EARTH
350 (13.8)
NOTES: ALL DIMENSIONS ARE IN MILLIMETERS WITH INCHES IN PARENTHESES UNLESS
OTHERWISE INDICATED.
FUSES SHOWN (F3 THROUGH F6) ARE 5 AMP, ANTI-SURGE, TYPE T TO IEC127 (ROSEMOUNT PART NUMBER 1L01293H02). IF INTERNAL HEATER IS INSTALLED, TWO ADDITIONAL 5 AMP FUSES (F1 AND F2) ARE USED.
320
(12.6)
18 (0.7)
350
(13.8)
300
(11.8)
225
(8.9)
35870001
Figure 2-4. Outline of Intelligent Field Transmitter
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9
Instruction Manual
106-300NFX Rev. 4.2 January 2002
ALWAYS DISCONNECT LINE VOLTAGE FROM INTELLIGENT FIELD TRANSMITTER BEFORE CHANGING JUMPERS.
PROBE HEATER
VOLTAGE SELECTION
WORLD CLASS PROBE (44V)
LINE VOLTAGE
SELECTION
120 V.A.C.
220 V.A.C.
240 V.A.C.
JUMPER
(INSTALL)
JM8, JM7, JM1
JM6, JM5, JM2
JM6, JM5, JM1
JUMPER
CONFIGURATION
If you reconfigure the equipment for a line voltage other than the one marked on the serial label and the mains filter of the power supply then you should change the marking on the serial label and the mains filter to state the new line voltage.
World Class 3000
JUMPER
(INSTALL)
JM10
P00010
If incorrect heater voltage is selected, damage to the probe may occur. For HPS voltage selection jumper, refer to Figure 2-15.
Figure 2-5. Power Supply Board Jumper Configuration
b. Electrical Connections
1. The IFT can be configured for 100, 120, 220, or 240 line voltages. For 120 Vac usage, install JM8, JM7, and JM1. For 220 Vac usage, install jumpers JM6, JM5, JM2 (refer to Figure 2-5 and
Do not install jumper JM6 on the mi­croprocessor board, or JM1 on the in­terconnect board, if an HPS is installed in the system. This will result in system failure.
Figure 2-6).
3. The IFT must have JM6 on the micro­processor board (Figure 2-8 and Figure
If you reconfigure the equipment for a line voltage other than the one marked on the serial label and the mains filter of the power supply you should change the marking on the serial label and the mains filter to state the new line voltage.
2-9) and JM1 on the interconnect board (Figure 2-10 and Figure 2-11) installed if an HPS is not installed in the system.
4. If an MPS is not used in the system, wire jumper between CAL RET and NO GAS must be installed on the intercon­nect board. Remove wire jumper if
2. The IFT can be configured to connect directly to a probe or to an optional
MPS is installed in the system. Refer to
Figure 2-7, note 6. HPS. The electrical connections for a non-HPS equipped system should be made as described in the electrical in­stallation diagram, Figure 2-7.
5. The power cable should comply with the safety regulations in the user's country and should not be smaller than 16 gauge, 3 amp.
2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
2
Instruction Manual
106-300NFX Rev. 4.2
January 2002
THIS TERMINAL BLOCK IS A 44VAC OUTPUT SPECIFICALLY FOR POWERING THE
!
WC 3000 PROBE.
P00011
Figure 2-6. IFT Power Supply Board Jumpers
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11
Instruction Manual
106-300NFX Rev. 4.2 January 2002
PROBE INTERIOR
GN CELL -VE
OR CELL +VE
YE CHROMEL
RD ALUMEL
123456 78
RD
GN
WH
SM. BR
PROBE JUNCTION
BOX WIRING
GN
GN/YE
World Class 3000
3D3911BG REV
HEATER
}
BK
BK
BL
LG. BR
LINE VOLTAGE SECTION
120 V.A.C. 220 V.A.C. 240 V.A.C.
JUMPER CONFIGURATION
JUMPER
(INSTALL) JM8, JM7, JM1 JM6, JM5, JM2 JM6, JM5, JM1
J1
3D39122G REV
POWER SUPPLYBOARD
ALWAYS DISCONNECT LINE VOLTAGE FROM INTELLIGENT FIELD TRANSMITTER BEFORE CHANGING JUMPERS.
PROBE HEATER
VOLTAGE SECTION
WORLD CLASS PROBE
218 PROBE
JUMPER
(INSTALL)
JM10
JM9
MICROPROCESSOR BOARD
J2
J3
J4
J1
3D39120G REV
INTERCONNECT BOARD
JM5JM6
WC 3000 PROBE (CENELEC APPROVED)
NOTES
STACK TC WIRING AS REQUIRED
SPECIAL PROBE CABLE BETWEEN PROBE AND IFT BY ROSEMOUNT (FITTED WITH EExd GLANDS)
INSTALL JM1 ON INTERCONNECT BOARD
INSTALL JM6 ON MICROPROCESSOR BOARD
IF STACK TEMPERATURE NOT USED
IF MPS 3000 NOT USED
1 RELAY PER PROBE AVAILABLE FOR CALIBRATION STATUS INDICATION (48 V max, 100 mA max)
CABLE COLORS SHOWN HERE APPLY TO ROSEMOUNT SUPPLIED SPECIAL CABLE FITTED WITH EExd GLANDS (P/N 1U03066)
J5 J6
H
L
EEN
LINE
VOLTAGE
LG. BR BL
GN/YE SHIELD
SM. BR
WH GN
RD
INTELLIGENT FIELD TRANSMITTER IFT3000
LINE OUT
ER
PROBE 1
J10
J11
J19 J20 J21 J22
PROBE 1
HI GAS
IN CAL
NC NC NCNC C C CCNONONONO
PROBE 2
MPS3000 MULTI GAS SEQUENCER (OPTIONAL)
CAL RET
CAL RET NO GAS
LO GAS HI GAS IN GAS
SHIELD
5 CONDUCTOR SHIELDED CABLE PER PROBE #16 AWG BY CUSTOMER
3D39064G REV
NO GAS
LO GAS
PROBE 2
IN CAL
HI GAS
PROBE 3
CAL RET
LO GAS
NO GAS
PROBE 4
PROBE 3
HI GAS
MPS TERMINATION BOARD
J5
J6
J7
SHIELD STACK TC ­STACK TC +
J8
SHIELD
PROBE TC -
GN RD
PROBE TC +
J9
SHIELD
WH
PROBE MV -
PROBEMV+
SM.BR
PROBE 4
NO GAS
LO GAS
HI GAS
IN CAL
CAL RET
NO GAS
IN CAL
CAL RET
J13 J14 J15 J16 J17 J18
JM1
J9
J8J7J6J5J4J3J2J1
LINE IN
LL
NN
LO GAS
L
LINE VOLTAGE
N
J12
35870007
Figure 2-7. Wiring Layout for IFT 3000 (CENELEC approved) System without HPS
2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
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