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.
Emerson Process Management
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
PageSummary
---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
PageSummary
Page 2-2Figure 2-1. Change calibration gas tube dimensions.
Page 3-10Add note on test gas flowmeter.
Effective January, 2002 Rev. 4.2
PageSummary
Page 2-13Updated Figure 2-8.
Page 2-14Updated analog output current/voltage mode selection procedure.
HIGHLIGHTS OF CHANGES
APPENDIX AX
Effective June, 1997 Rev. 2
PageSummary
--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
PageSummary
Page A-12Changed screw torque in paragraph A-3h.
HIGHLIGHTS OF CHANGES
APPENDIX BX
Effective February, 1995 Rev. 1.1
PageSummary
B-3Figure B-3. Updated for IB consistency.
Effective January, 1997 Rev. 1.2
PageSummary
Page B-2Figure B-2. Added fuse locations.
Page B-5Insert protective cover and ground lead warning.
Page B-8Insert protective cover and ground lead warning.
Page B-11Table B-2. Add expanded fuse specifications to replacement parts.
HIGHLIGHTS OF CHANGES
APPENDIX DX
Effective February, 1995 Rev. 2
PageSummary
--General. Updated appendix with new version of MPS.
Effective January, 1997 Rev. 2.1
PageSummary
Page D-5Insert protective cover and ground lead warning.
Page D-7Insert protective cover and ground lead warning. Add fuse
specifications and clarify fuse replacement.
Page D-11Add fuse specifications to replacement parts
HIGHLIGHTS OF CHANGES
APPENDIX EX
Effective February, 1995 Rev. 1.1
PageSummary
Page E-4Figure E-2. Updated for IB consistency.
Page E-7Figure E-4. Updated Flowchart.
Effective May, 1995 Rev. 1.2
PageSummary
Page E-4Figure E-2. Added callout text “Heater Power Supply (Optional)”.
Effective January, 1997 Rev. 1.3
PageSummary
Page E-5Insert protective cover and ground lead warning.
Page E-9Insert protective cover and ground lead warning.
Page E-15Added expanded fuse specifications to replacement parts
HIGHLIGHTS OF CHANGES
APPENDIX JX
Effective January, 1997 Rev. 1.0
PageSummary
Page J-4Insert warning concerning protective equipment covers and safety
ground leads.
Page J-11Insert warning concerning protective equipment covers and safety
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 ManagementP-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-2Rosemount 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 DescriptionRosemount 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 DescriptionRosemount 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
[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 DescriptionRosemount 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 InstallationRosemount 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 InstallationRosemount 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 InstallationRosemount 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.
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 FLOWMETER0.2-2.0 SCFH 771B635H02
2 2" PRESSURE GAGE0-15 PSIG275431-006
3 COMBINATION FILTER-REG. 0-30 PSIG4505C21G01
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 InstallationRosemount 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 InstallationRosemount 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