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

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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.

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

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

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

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

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. 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)

Figure 1-1. Typical System Package

E L I

G I

P O T

I N

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

in the measured gas on one side of the cell,

2. P

is the partial pressure of the oxygen

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

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

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

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

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

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

DIM

DIMENSIONS

TABLE II. REMOVAL/INSTALLATION

DIN

"B"

755

"A"

459

(IN.)

1U05680G01

210

1209

(29.7)

913

(18.07)

18 IN. PROBES

1U05680G02

(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)

110 (4.33)

1.57 (0.062) THK GASKET

(P/N 1M03237H01)

ELECTRICAL

CONNECTION

BOTTTOM VIEW

DIM "A"

(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

23800006

VIEW A-A

INCHES IN PARENTHESES UNLESS

NOTE: DIMENSIONS ARE IN MILLIMETERS WITH

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

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

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

DIM

DIMENSIONS

TABLE II. REMOVAL/INSTALLATION

DIN

"B"

755

"A"

554

(IN.)

1U05680G01

210

1209

(29.7)

1008

(21.81)

18 IN. PROBES

1U05680G02

(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)

110 (4.33)

1.57 (0.062) THK GASKET

(P/N 1M03237H01)

ELECTRICAL

CONNECTION

BOTTTOM VIEW

DIM "A"

(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

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

Instruction Manual

106-300NFX Rev. 4.2

January 2002

"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

DIMENSIONS

DIN

DIMENSIONS

(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

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

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

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

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

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.

(20.95% oxygen in nitrogen).

(d) Other equivalent clean, dry, oil-free

air supply.

79.25 (3.12) MAX

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 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

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

SM. BR

PROBE JUNCTION

BOX WIRING

GN/YE

World Class 3000

3D3911BG REV

HEATER

}

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

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

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

EEN

LINE

VOLTAGE

LG. BR BL

GN/YE SHIELD

SM. BR

WH GN

INTELLIGENT FIELD TRANSMITTER IFT3000

LINE OUT

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

SHIELD STACK TC STACK TC +

SHIELD

PROBE TC -

GN RD

PROBE TC +

SHIELD

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

J8J7J6J5J4J3J2J1

LINE IN

LO GAS

LINE VOLTAGE

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

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

JM7

CURRENT/VOLTAGE SELECTOR SWITCH

SW1

JM6

TO I/O

BOARD

JM6

TP5 TP6

TP4

+30VISO-C GNDC +5VISO-C

TP3

-15V

TP8

+5V

TP2

TP7

+15V

TP1

-5V

TO POWER

SUPPLY CARD

3D39513G REV

TO LDP CARD

TO GUI CARD

Figure 2-8. IFT Microprocessor Board Jumper Configuration

29850004

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-13

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

OUTPUT JUMPER

HPS Probe (No HPS)

(See Figure 2-8 for jumper locations.)

Figure 2-9. IFT Microprocessor Board Jumpers

OUTPUT JUMPER

HPS Probe (No HPS)

Figure 2-10. Interconnect Board Jumper

Configuration

6. Before supplying power to the IFT, verify that the jumpers have been properly set in the IFT, Figure 2-5, Figure 2-8, and Figure 2-10.

7. Terminal strip J5 on the power supply board is used for supplying the IFT with power. Terminal strip J6 on the power supply board is used to supply the probe heater with power if an HPS is not used (Figure 2-6).

8. Ensure that the IFT 3000 is properly earthed by way of both the internal and external earthing hardware.

Remove JM6 Install JM6

Remove JM1 Install JM1

c. Analog Output and Relay Output

Connections

1. The microprocessor board has a switch to select voltage or current operations. Figure 2-8 shows the switch location. In voltage mode, output is 010 V. In the current mode, the output can be configured from the setup menu to be 0-20 mA or 4-20 mA.

2. The analog output and relay outputs are programmed by the user as needed. The analog output is typically sent to recording equipment such as chart recorders. Relay outputs are typically sent to annunciators.

3. Relays K1 and K2 are user configurable from the PROBE SETUP submenu (Table 3-5). Typically these are used to indicate O below specified tolerances. OK relay is energized when unit is functioning properly.

4. All wiring must conform to local and national codes.

5. Connect the analog output and relay outputs as shown in Figure 2-11.

values above or

9. Ensure that the installation does not obscure the message on either the IFT nameplate or the IFT lid.

2-14 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

NOTES:

DENOTES SHIELD CONNECTION.

OK RELAY IS ENERGIZED WHEN UNIT IS FUNCTIONING PROPERLY.

OK-NC

K1-NC

K2-NC

CAL INIT-2

CAL INIT-1

CALRET

NOGAS

LOGAS

HIGAS

INCAL

RELAY

RELAY+

AD590

AD590+

TRIAC

TRIAC+

Instruction Manual

106-300NFX Rev. 4.2

January 2002

24 23

21 20 19

18 17 16 15

14 13 12

11 10

7 6

4 3 2

OK-COM

OK-NO

K1-COM

K1-NO

K2-COM

20 19

K2-NO

14 13 12

ANOUT-

ANOUT+

STACK T/C

7 6

PROBE T/C

3 2

PROBE MV

PROBE MV+

JM1 (UNDER SHIELD)

730002

Figure 2-11. IFT Interconnect Board Output Connections

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-15

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

2-3 HEATER POWER SUPPLY INSTALLATION

The Rosemount encode sheets (Product Ordering Matrix) allow a customer to order either the hazardous area version of the HPS 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 version of the IFT 3000.

Before HPS installation, consult Safety Data Sheet 1M03243.

264.0

(10.39)

253

(9.96)

233

(9.17)

EExd IIC T6

14.22 (0.56) DIA

MTG HOLE (2 PLS)

ENCLOSURE

120

(4.72)

NOTE: DIMENSIONS ARE IN MILLIMETERS

WITH INCHES IN PARENTHESES UNLESS OTHERWISE INDICATED.

216.0

(8.50)

157

(6.18)

219005

a. Mechanical Installation

The outline drawing of the CENELEC approved heater power supply enclosure in Figure 2-12, shows mounting centers and clearances. The CENELEC approved enclosure is designed to be mounted on a wall or bulkhead. The heater power supply should be installed no further than 45 m (150 ft) from the probe. The heater power supply must be located in a location free from significant ambient temperature changes and electrical noise. Ambient temperature must be between 0° to 60°C (32° to 140°F).

b. Electrical Connections

1. Electrical connections should be made as described in the electrical installation diagram, Figure 2-13. The wiring terminals are divided into two layers: the bottom (FROM PROBE) terminals should be connected first, the top (FROM ELECTRONICS) terminals should be connected last (Figure 2-14). Each terminal strip has a protective cover which must be removed when making connections. To remove the

Figure 2-12. Outline of CENELEC Approved Heater

Power Supply

terminal covers, remove two slotted screws holding cover in place. Always reinstall terminal covers after making connections.

2. Power Input: 120, 220 or 240 Vac. For 120 Vac usage, install jumpers JM4 and JM1 and remove JM5 if installed. For 220 or 240 Vac usage, install jumper JM5 and remove JM1 and JM4 if installed (see label, Figure 2-15).

NOTE

Fuse specifications are shown in Figure 2-14.

2-16 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

PROBE INTERIOR

HEATER

GN CELL -VE

OR CELL +VE

YE CHROMEL

RD ALUMEL

}

12345678

SM. BR

PROBE JUNCTION

BOX WIRING

GN/YE

LG. BR

WC PROBE 3000 CENELEC APPROVED

LINE VOLTAGE

SELECTION

120 V.A.C.

220/240 V.A.C.

PROBE HEATER

VOLTAGE SECTION

WORLD CLASS PROBE JM7

JUMPER

(INSTALL)

JM4, JM1

JM5

JUMPER

(INSTALL)

JUMPER

CONFIGURATIONS

NOTES

RELAY WIRE IS OPTIONAL; RELAY CAN BE PERMANENTLY ENABLED WITH JUMPER IF NOT USED

STACK TC WIRING AS REQUIRED

ALL WIRES #16-#22 AWG TWISTED PAIR WITH SHIELD BY CUSTOMER EXCEPT AS NOTED

SPECIAL PROBE CABLE BETWEEN PROBE AND HPS BY ROSEMOUNT

REMOVE JM1 ON INTERCONNECT BOARD (IFT 3000)

REMOVE JM6 ON MICROPROCESSOR BOARD

IF RELAY WIRE OF NOTE 1 INSTALLED THEN REMOVE JM2 ON HPS 3000

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)

ALWAYS DISCONNECT LINE VOLTAGE FROM HEATER POWER SUPPLY AND ANALOG ELECTRONICS (IF USED) BEFORE CHANGING JUMPERS.

HEATER POWER

REMOTE

ELECTRONICS

SELECTION

NEW GENERATION

ELECTRONICS

JUMPER

REMOVE JM2

INSTALL JM2

JUMPER

REMOVE JM3, JM6

TOP

TRIAC RELAY

+++

STACKTCANALOG

---

HEATER

2 TWISTED PAIR SHIELDED #22 AWG BY CUSTOMER (OPTIONAL)

PROBE

SM. BR CELL+ WH CELL -

RD HTR TC +

GN HTR TC -

BL LG. BR GN/YE

SHIELD

PROBE

BOTTOM

PROBE

STACK

J2 J1

PROBE

HEATER

AD590

4 TWISTED PAIR SHIELDED #22 AWG BY CUSTOMER

LINE

LINE VOLTAGE

HPS 3000 INTERFACE MODULE

35870008

Figure 2-13. Wiring layout for IFT 3000 (CENELEC approved) with HPS (Sheet 1 of 2)

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-17

Instruction Manual

106-300NFX Rev. 4.2 January 2002

3D39118G

MICROPROCESSOR

BOARD

World Class 3000

JM6 JM5

LINE VOLTAGE SECTION

100 V.A.C. 120 V.A.C. 200 V.A.C. 220 V.A.C. 240 V.A.C.

ALWAYS DISCONNECT LINE VOLTAGE FROM INTELLIGENT FIELD TRANSMITTER BEFORE CHANGING JUMPERS.

JUMPER CONFIGURATION

JUMPER

(INSTALL) JM3, JM7, JM2 JM8, JM7, JM1 JM4, JM5, JM2 JM6, JM5, JM2 JM6, JM5, JM1

PROBE HEATER

VOLTAGE SECTION

3D39122G REV

POWER SUPPLYBOARD

JUMPER

NOT USED REMOVE

(INSTALL)

JM9, JM10

3D39120G REV

INTERCONNECT BOARD

CAL RET

J5 J6

NOT USED

LINE

VOLTAGE

NO GAS

LO GAS HI GAS IN CAL

SHIELD RELAY – RELAY + SHIELD AD590 –

AD590 + SHIELD TRIAC –

TRIAC +

SHIELD STACK TC – STACK TC +

SHIELD

PROBE TC – PROBE TC +

SHIELD

PROBE MV – PROBE MV +

JM1

INTELLIGENT FIELD

TRANSMITTER IFT 3000

PROBE 1

LINE OUT LINE IN

IN CAL

HI GAS

J10

NC C NO NC C NO NC C NO

J19

J11

J20 J21

PROBE 1

MPS3000 MULTIPROBE CALIBRATION GAS SEQUENCER (OPTIONAL)

J2J1

PROBE 2 PROBE 3 PROBE 4

IN CAL

HI GAS

LO GAS

NO GAS

CAL RET

PROBE 2 PROBE 3

CAL RET

MPS TERMINATION BOARD

5 CONDUCTOR SHIELDED CABLE PER PROBE #16 AWG BY CUSTOMER

3D390646 REV

LO GAS

NO GAS

NC C NO

J22

PROBE 4

IN CAL

HI GAS

CAL RET

PROBE 1

SOLENOID

J13 J14 J15 J16 J17 J18

NO GAS

PROBE 2

LO GAS

SOLENOID

PROBE 3

SOLENOID

HI GAS

IN CAL

PROBE 4

SOLENOID

J8J7J6J5J4

LO GAS

NO GAS

CAL RET

HIGH GAS

SOLENOID

LOW GAS

SOLENOID

SWITCH

PRESSURE

J12

LINE

VOLTAGE

34990011

Figure 2-13. Wiring layout for IFT 3000 (CENELEC approved) with HPS (Sheet 2 of 2)

2-18 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

SCREW

(2 PER COVER)

JM8

JM7

TERMINAL

COVERS

(PROVIDED)

INTERNAL

EARTHING

HARDWARE

EXTERNAL

EARTHING

HARDWARE

JM4

JM5

JM2

1 JM

FUSE

FUSES

FRONT VIEW SIDE VIEW

NOTE: FUSES SHOWN (F1 THROUGH F4) ARE 5 AMP, ANTI-SURGE,

TYPE T TO IEC127 (ROSEMOUNT PART NUMBER 1L01293H02).

TRANSFORMER

TERMINAL STRIP (FROM ELECTRONICS)

TERMINAL STRIP (FROM PROBE)

219006-1

Figure 2-14. CENELEC Approved Heater Power Supply Wiring Connections

ALWAYS DISCONNECT LINE VOLTAGE FROM HEATER POWER SUPPLY AND ANALOG ELECTRONICS (IF USED) BEFORE CHANGING JUMPERS.

HEATER

POWER

*ON

REMOTE

ELECTRONICS

SELECTION

NEW GENERATION

ELECTRONICS

JUMPER

INSTALL JM2

REMOVE JM2

JUMPER

REMOVE JM3, JM6

219007

LINE VOLTAGE

SELECTION

120 V.A.C.

220/240 V.A.C.

PROBE HEATER

VOLTAGE SELECTION

*WORLD CLASS PROBE

(44V)

JUMPER

(INSTALL)

JM4, JM1

JM5

JUMPER

(INSTALL)

JM7

JUMPER

CONFIGURATIONS

Figure 2-15. Jumper Selection Label.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-19

Instruction Manual

106-300NFX Rev. 4.2 January 2002

3. The power cable should comply with safety regulations in the user's country and should not be smaller than 16 gauge, 3 amp.

Before supplying power to the heater power supply, verify that jumpers JM3 and JM6 are removed, and JM7 is installed. If relay wire (Figure 2-13, Note

1) is installed, JM2 must be removed from HPS Motherboard (Figure 2-16).

4. Before supplying power to the heater power supply, verify that the jumpers on the motherboard, Figure 2-16, are properly configured. Jumpers JM3, JM6, should be removed and JM7 should be installed. Additionally, make sure that the proper jumper for your line voltage is installed, Figure 2-15. If relay wire (Figure 2-13, note 1) is not installed, JM2 should be installed on the HPS Motherboard (Figure 2-16).

World Class 3000

Figure 2-16. Jumpers on HPS Motherboard

2-4 MULTIPROBE TEST GAS SEQUENCER

INSTALLATION

5. Ensure that the HPS 3000 is properly earthed by way of both the internal and external earthing points.

6. Ensure the installation does not obscure the messages on either the HPS nameplate or HPS lid.

NOTE

Refer to Figure 2-8 and Figure 2-10 for proper IFT jumper configuration. IFT microprocessor and interconnect board jumper configurations must be set correctly in order for HPS to work properly.

The MPS 3000 Multiprobe Test Gas Sequencer must be installed in a nonhazardous, explosive-free environment.

NOTE

A Z-Purge option is available for the MPS 3000. Appendix DX contains information concerning the Z-Purge.

a. Mechanical Installation

The outline drawing of the MPS module in Figure 2-17 shows mounting centers and clearances. The box is designed to be mounted on a wall or bulkhead. The MPS module should be installed no further than 91 m (300 ft) piping distance from the probe, and no more than 303 m (1000 ft) cabling distance from the IFT. Install the MPS module in a location where the ambient temperature is between -30° and 71°C (-20° and 160°F).

2-20 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

304.80

(12.00)

254.00

(10.00)

Instruction Manual

106-300NFX Rev. 4.2

January 2002

304.80

(12.00)

LOWCAL

HIGHCAL

GASIN

INSTR

AIR

355.60 (14.00) REF

b. Gas Connections

Figure 2-18 shows the bottom of the MPS where the gas connections are made. 1/4 in. threaded fittings are used.

1. Connect the reference air supply to INSTR. AIR IN. The air pressure regulator valve is set at the factory to

PROBE1 PROBE 2 PROBE 3 PROBE4

TESTGAS

REFAIR

TESTGAS

OUT

REFAIR

OUT

REFAIR

OUT

21.34 (0.84)

49.78 (1.96)

78.49 (3.09)

106.93 (4.21)

133.35 (5.25)

140.72 (5.54)

Figure 2-17. MPS Module

DIMENSIONS ARE IN

NOTE:

MILLIMETERS WITH INCHES IN PARENTHESES.

35870002

138 kPa (20 psi). If the reference air pressure should need readjustment, turn the knob on the top of the valve until the desired pressure is obtained.

2. Connect the high O

test gas to HIGH

GAS. The test gas pressure should be set at 138 kPa (20 psi).

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-21

Instruction Manual

106-300NFX Rev. 4.2 January 2002

DRAIN

PROBE 1 PROBE2 PROBE 3 PROBE4

LOW CAL

TEST GAS

HIGH CAL

GAS IN

INSTR

GAS IN

OUT

REF AIR

OUT

AIR

OUT

REF AIR

OUT

TEST GAS

OUT

REF AIR

OUT

Figure 2-18. MPS Gas Connections

World Class 3000

LINE IN

SIGNAL IN

35870003

Do not use 100% nitrogen as a low (zero) gas. It is suggested that the low gas be between 0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

3. Connect the low O2 test gas to LOW GAS. The test gas pressure should be set at 138 kPa (20 psi).

4. Connect the REF AIR OUT to the reference gas fitting on the probe junction box.

5. Connect the TEST GAS OUT to the calibration gas fitting on the probe junction box.

6. If the MPS is configured for multiple probes (up to four), repeat steps 4 and 5 for each additional probe.

A check valve is required for each probe connected to an MPS to prevent condensation of flue gas in the calibration gas lines. The check valve must be located between the calibration fitting and the gas line.

c. Electrical Connections

Electrical connections should be made as described in the electrical installation diagram, Figure 2-19. All wiring must conform to local and national codes. The electrical connections will exist only between the electronics package and the MPS to enable automatic and semiautomatic calibration. If more than one probe system is being used, the additional probes and electric packages would be wired similarly to the first probe.

NOTE

MPS power supply fuse locations and specifications are shown in Figure 2-19.

2-22 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

Figure 2-19. MPS Electrical Connections

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-23

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

1. Run the line voltage through the bulkhead fitting on the bottom of the MPS where marked LINE IN, Figure 2-18. Refer to Figure 2-19. Connect the line voltage to the LINE IN terminal on the MPS terminal board located inside the unit. Tighten the cord grips to provide strain relief.

2. The MPS can accommodate up to four probes. The terminal strips on the MPS termination board are marked PROBE 1, PROBE 2, PROBE 3, and PROBE 4.

NOTE

Upon completing installation, make sure that the probe is turned on and operating prior to firing up the combustion process. Damage can result from having a cold probe exposed to the process gases.

Select PROBE 1 if this is the first probe and electronic package installed on the MPS.

3. Make the connections from the MPS to the IFT as shown in Figure 2-19. Run wires from the MPS Termination Board inside the unit through the bulkhead fitting on the bottom of the unit where marked SIGNAL IN, Figure 2-18. After the connections are made, tighten the cord grips to provide strain relief.

During outages, and if possible, leave all probes running to prevent condensation and premature aging from thermal cycling.

If the ducts will be washed down during outage, MAKE SURE to power down the probes and remove them from the wash area.

2-24 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

See Safety Data Sheet 1M03296 for safety related information.

Instruction Manual

106-300NFX Rev. 4.2

January 2002

SECTION 3

SETUP AND OPERATION

3-1 OVERVIEW

Ensure that the oxygen analyzer, heater power supply, and intelligent field transmitter have been properly connected. It is important to check that grounding and screening of terminations are correctly made to prevent the introduction of ground loops. The IFT is equipped with noise suppression circuitry on the power supply and signal input lines. Proper grounding at installation will ensure accuracy of function.

The following five languages can be selected within the IFT:

English Italian French Spanish German

The Intelligent Field Transmitter may be supplied with any one of three configurations. These configurations are the blind version, display only version, and the deluxe version. The three versions differ as follows.

a. Blind Version

HART connections must be made outside of the hazardous area. Because the Hart option is not protected by energy limiting barriers, it must not be interfaced from within a hazardous area. The signal cables should be routed outside the hazardous area and the connections made external to the hazardous area.

The blind version has no display and no keypad. With this version, an external HART communications device is required. Refer to Appendix JX regarding the HART Communications option.

b. Display Only Version (LDP)

The display only version is also known as the LED Display Panel (LDP) version. This IFT contains a bright LED display and a four-key pad. The LDP version provides for calibration capability only.

c. Deluxe Version (GUI)

The deluxe version is also known as the General User Interface (GUI) version. This IFT contains an LED display, liquid crystal display panel, and an eight-key pad that allows probe and electronics configuration, calibration, and troubleshooting of the probe and electronics.

This section of the manual deals with operator controls and displays available with the GUI equipped IFT. Operating parameters are listed and instructions are included for viewing and changing them.

Operating instructions for the IFT equipped with the LDP and four membrane keys are included in Section 4.

Any procedures not associated with normal operation are included in Section 2, Installation, or Section 5, Troubleshooting.

Rosemount Analytical Inc. A Division of Emerson Process Management Setup and Operation 3-1

Instruction Manual

106-300NFX Rev. 4.2 January 2002

CAL TGH

ESC

13 12 11 10

TGL

SETUP

CALHELP

DATA

ENTER

Figure 3-1. IFT with GUI and LDP Front Panel

3-2 IFT WITH GUI AND LDP FRONT PANEL

CONTROLS AND INDICATORS (See Figure 3-1.)

Fig. 3-1

Index

No.

Control/

LED Description

1 HELP Context sensitive HELP is

displayed when this key is pressed.

2 DATA DATA key is used to access

DATA menu.

3LCD

Display

Top line displays system status, menu and probe number.

4LED

Display

Indicates current O value (only in LDP equipped units).

5 CAL Calibration in progress

indicator light (only in LDP equipped units).

6 TGH High test gas indicator light.

High test gas is being used in calibration process (only in LDP equipped units).

7 TGL Low test gas indicator light.

Low test gas is being used in calibration process (only in LDP equipped units).

34990016

or test

World Class 3000

8 CAL CAL key used to access

CALIBRATE menu.

9 SETUP SETUP key used to access

SETUP menu.

10 ENTER The ENTER key is used to

select a lower level menu, initiate calibration, or select a parameter to change.

▲

▼

13 ESC The escape key is used to

3-3 HELP KEY

The HELP key will display explanatory information about a menu, sub-menu, or parameter that the asterisk is next to when pressed. The HELP key is not available during calibration routines. Refer to Table 3-1 for sample HELP messages.

Table 3-1. Sample HELP Messages

MENU, SUB-MENU,

HELP OR

PARAMETER NAME MESSAGE

PROBE DATA Press ENTER key

CALIBRATE O

SETUP The SETUP menu

The increase key is used to move the cursor (asterisk) when scrolling through lists or to increase a parameter value.

The decrease key is used to move the cursor (asterisk) when scrolling through lists or to decrease a parameter value.

exit to a high level menu or to abort a parameter change.

to access DATA menu.

The CAL menu is used to start calibration and view calibration.

is used to configure the IFT-3000.

3-2 Setup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

3-4 STATUS LINE

The top line of the LCD display (3, Figure 3-1) is a status line that always displays system status, menu name, and O

level. The system status

displays are:

a. OK - System is functioning correctly.

b. CAL - Calibration in progress.

c. C Err - Calibration error.

d. H Err - Heater error.

e. TGLow - Test gas is low.

f. HiO

- O

value is above the high alarm

limit.

- O

g. LoO

value is below the low alarm limit.

h. R Hi - Resistance is above the high limit.

i. Off - The probe has been turned off be-

cause the IFT cannot control the heater temperature.

3-5 QUICK REFERENCE CHART

The quick reference chart on pages 3-4 and 3-5 is designed to help you determine how to get where you want to be in the menu system. The chart shows all the available menu and submenu options for the IFT. Follow the lines to determine which choices to make. Moving down a level on the chart is accomplished by use of the ENTER key. To move up a level on the chart, press the ESCAPE key.

3-6 MAIN MENU

When power is first applied to the IFT, the MAIN menu (Table 3-2) is initially displayed. It is from the MAIN menu that the PROBE DATA (Table 3-3), CALIBRATE O

(Table 3-4), and SETUP

(Table 3-5) menus can be accessed.

Table 3-2. Main Menu

MENU SELECTION DESCRIPTION

PROBE DATA Refer to Table 3-3.

CALIBRATE O

Refer to Table 3-4.

j. PRBE - The probe is disconnected, cold, or

SETUP Refer to Table 3-5.

leads are reversed.

Table 3-3. PROBE DATA Sub-Menu.

SUB-MENU

SELECTION PARAMETER DESCRIPTION

Process Data O

__% Efficiency ENA/DIS Stack Temp __DegC

value for the probe.

Enable/Disable efficiency display. Stack temperature.

Diagnostic Data

Temperature Cell __DegC

Stack __DegC Cold Junct __DegC

Voltages Cell __mV

Cell T/C __mV Stk T/C __mV Cold Jnt __mV

Output Values Analog __% FS

K1 State OFF/ON K2 State OFF/ON

Cell temperature of the probe. Stack temperature. Cold junction temperature.

Cell voltage of the probe. Cell thermocouple voltage of the probe. Stack thermocouple voltage. Cold junction voltage.

Analog output voltage. Status of relay 1. Status of relay 2

Rosemount Analytical Inc. A Division of Emerson Process Management Setup and Operation 3-3

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

QUICK REFERENCE CHART

MAIN MENU

PROBE DATA

PROCESS DATA DIAGNOSTIC DATA

EFFICIENCY

STACK TEMP

TEMPERATURE

CELL

STACK

COLD JUNCT

VOLTAGES

CELL

CELL T/C

STK T/C

COLD JNT

OUTPUT VALUES

ANALOG

K1 STATE

K2 STATE

CALIBRATE O

PERFORM

CALIBRATION

VIEW

CONSTANTS

SLOPE

CONSTANT

RESIST

CALIBRATION

STATUS

NEXT CAL

SLOPE

CONSTANT

RESIST

3-4 Setup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

SETUP

Instruction Manual

106-300NFX Rev. 4.2

January 2002

CALIBRATION

HIGH GAS

LOW GAS

AUTO CAL

OUTPUT TRACKS

CAL INTRVL

NEXT CAL

GAS TIME

PURGE TIME

RES ALARM

EFFICIENCY CALC

ENABLE CALC

K1 VALUE

K2 VALUE

K3 VALUE

O CALCULATION

SLOPE

CONSTANT

SET POINT

LOAD CONSTANTS

RELAY OUTPUT

K1 SETUP

EVENT 1

EVENT 2

EVENT 3

O ALARMS

K2 SETUP

EVENT 1

EVENT 2

EVENT 3

HI ALARM

LO ALARM

ALARM DB

ANALOG OUTPUTS

SOURCE

AOUT TYPE

Rosemount Analytical Inc. A Division of Emerson Process Management Setup and Operation 3-5

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

3-7 PROBE DATA SUB-MENU

The PROBE DATA sub-menu is a list of all the parameters of the system as it is currently configured. To access the PROBE DATA submenu, press the DATA key at any time. The increase and decrease keys are used to scroll through the list. The PROBE DATA sub-menu can be viewed but not changed. The operator must use the SETUP menu to change any of the parameters.

There are two selections available on the PROBE DATA sub-menu; Process Data and Diagnostic Data. Refer to Table 3-3 for contents of the sub-menu.

3-8 CALIBRATE O

The CALIBRATE O

SUB-MENU

sub-menu (Table 3-4) is

used to enter the calibration mode. To access the CALIBRATE O

sub-menu, press the CAL

key at any time. The increase and decrease keys are used to scroll through the list.

The CALIBRATE O

sub-menu has three selec-

tions available: Perform Calibration, View Constants, and Calibration Status. Refer to Table 3-4 for contents of the sub-menus.

Perform Calibration has two options depending on how Auto Cal is selected in Probe Setup. Refer to SETUP Setting in Table 3-4.

3-9 SETUP SUB-MENU

The SETUP sub-menu is used to enter all operator set variables into the system. To access the SETUP sub-menu, press the SETUP key at any time. To select the parameter to be changed, move the cursor to the desired parameter using the arrow keys. Press ENTER to select that parameter. To change the value for that parameter, use the arrow keys to increase or decrease the value. Press ENTER to save changes.

There are six selections available on the SETUP sub-menu: Calibration, O O

Alarms, Efficiency Calc., Relay Outputs, and

Analog Outputs. Refer to Table 3-5 for the contents of the SETUP sub-menu.

NOTE

Dip shunt is to be set for voltage or current operation. Refer to Figure 2-7.

Calculation,

3-6 Setup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

Table 3-4. CALIBRATION O2 Sub-Menu

SUB-MENU

SELECTION

Perform Calibration

View Constants

Calibration Status

SETUP SETTING (SEE TABLE 3-4) DISPLAY DESCRIPTION

Auto Cal in Probe Setup is YES

Auto Cal in Probe Setup is NO.

(N/A) Slope _____mV/D

(N/A) Slope _____

Press ENTER to start Auto Calibration. MPS will start calibration probe.

Starting Automatic Calibration

High Gas _____%O Time Left 0:00

Cell mV ______mV Cell voltage of the probe.

Low Gas _____%O Time Left 0:00

Cell mV ______mV Cell voltage of the probe.

Resistance Check Time Left 0:00

Cell _____mV _____C Cell voltage and probe temperature.

Calibration Complete Purging 0:00

Cell _____mV _____C Cell voltage and probe temperature.

Calibration Complete

Press ENTER to start Manual Calibration. Manual calibration sequence will begin

Switch ON high test gas. Press ENTER when ready.

High gas ______%O

Press ENTER when O2 reading is stable.

Turn off high test gas and ON low test gas. Press ENTER when ready.

Low gas ______%O

Press ENTER when O2 reading is stable.

Resistance Check Resistance check in progress.

Turn off low test gas. Press ENTER when ready.

Press ENTER when probe has returned to process.

Constant _____mV Resist _____ohms

Next Cal XD XH Time until next calibration in number of

Constant _____ Resist _____

Value for high O Amount of time necessary to complete the current testing phase in min:sec.

Value for low O Amount of time necessary to complete the current testing phase in min:sec.

Resistance check in progress.

Gas lines are being purged of test gas.

when ENTER is pressed.

High O2 test gas value.

Low O2 test gas value.

Slope for probe. Offset for probe. Resistance for probe.

days and number of hours.

Status of the slope. Status of the offset. Status of the resistance.

test gas.

Rosemount Analytical Inc. A Division of Emerson Process Management Setup and Operation 3-7

Instruction Manual

106-300NFX Rev. 4.2 January 2002

Table 3-5. SETUP Sub-Menu

SUB-MENU SELECTION PARAMETERS DESCRIPTION

World Class 3000

Calibration High Gas ____%O

Low Gas ____%O Auto Cal YES/NO Output Tracks YES/NO Cal Intrvl XD XH

Value of high O

Value of low O

If system has MPS, select YES or NO. Select output tracks. Select time between calibrations in number of

test gas.

days and number of hours. (1 year max.)

Next Cal XH

Time until next calibration in number of hours. (1 year max.)

Gas Time 0:00

Amount of time the test gases will be turned on in number of minutes and seconds, allow

enough time for signal values to stabilize. Purge Time 0:00 Res Alarm _______

O2 Calculation Slope ____ mV/D

Constant ____ mV Set Point ____°C

Amount of time for gas lines to clear of test gas.

Resistance alarm set from 50 to 10,000 ohms.

Set value between 34.5 and 57.5.

Set value between -20.0 and +20.0 mV.

Set either 736 for World Class 3000 probes or

843 for 218 probes.

Ensure the correct voltage is selected when using HPS 3000 with either WC 3000 probes or 218 probes. Refer to Figure 2-14, Jumper Selection Label for proper voltage selections. If incorrect SET POINT is selected, damage to the probe may occur.

Load Constants Press ENTER to load constants from last

calibration.

O2 Alarms

Efficiency Calc.

Relay Outputs

K1 Setup

K2 Setup

Analog Outputs

Hi Alarm ____% O Lo Alarm ____% O Alarm DB ____% O

Enable Calc. YES/NO K1 Value _____ K2 Value _____ K3 Value _____

Event 1 _____ Event 2 _____ Event 3 _____

Source (EFF or O

) 0-100%

Aout Type 0-10V

Set value for high alarm limit.

Set value for low alarm limit.

Set value for alarm dead band.

Select YES to enable, NO to disable.

Set between 0.0000 and 1.0. Refer to Table 3-6.

Set between 1.000 and 20.0. Refer to Table 3-6.

Set event to activate relay.

Source can be set to 0-1%, 0-5%, 0-10%, 0-

25%, 0-100% of O

, or 0-100% Efficiency

Aout Type can be set to 0-10 V, 0-20 mA, or

4-20 mA

3-8 Setup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

Table 3-6. Efficiency Constants

UNITED STATES

CONSTANT

GAS OIL

K1 0.407 0.432 0.66 0.69

K2 0.0 0.0 0.0082 0.0051

K3 5.12 5.12 12.28 8.74

3-10 SYSTEM CALIBRATION

a. Overview

The primary purpose of an oxygen analyzer is to give an accurate representation of the percentage of O

in the gas stream. The

system should be calibrated periodically to maintain an accuracy which may otherwise reduce over time due to cell aging.

A requirement for calibration is a set of two accurate test gases spanning the oxygen range of most interest. For example, 0.4% and 8% for a 0-10% oxygen range.

Under normal conditions the probe should not need frequent calibration. Because calibration is necessary, the system can be equipped with the optional MPS 3000 Multiprobe Test Gas Sequencer for fully automatic calibration at regular intervals. Without an MPS, the probes must be calibrated manually (semi-automatically).

b. Probe Calibration

1. Previous Calibration Constants Functionality. Three sets of registers are used to store calibration constants. These are: Latest Calibration, Previous Calibration, and Calculation. Only the values in the Calculation registers are used to calculate the oxygen value for display and representation on the analog output signal. These values may be changed in two ways:

(a) The operator may change the Cal-

culation values by entering the SETUP menu and then entering

EUROPE

GAS OIL

the O

Calculations sub-menu. The

operator may adjust the slope and constant individually or reset both to the values calculated during the last good calibration. Simultaneously resetting both values is done by selecting Load Constants and pressing ENTER.

(b) The IFT will automatically change

the values after each successful calibration.

The values in the Latest Calibration registers are updated after every complete calibration even if the calibration is not successful. If the calibration is successful, the values in the Latest Calibration registers are copied into the Previous Calibration registers. This function is accomplished prior to the update of the Latest Calibration registers. The values from successful calibrations are automatically loaded into the Calculation registers for use in future O

calculations. If a calibration

fails, the Previous Calibration registers and Calculation registers retain their existing values, while the Latest Calibration registers record the values of the failed calibration.

2. Calibration Methods. There are three calibration methods: manual (semiautomatic), manually initiated automatic, and fully automatic. Manual (semiautomatic) calibration is done without an MPS unit. Test gases are switched on and off by the operator and the IFT is sequenced through the calibration procedure by the operator with the front panel keyboard. The IFT prompts the operator for the correct action. Manually initiated automatic calibration is done with an MPS. The operator manually initiates the calibration at the IFT or through a remote switch, and the IFT controls the operation of the MPS unit and the calibration sequencing. Fully automatic calibration requires no action from the operator. The setup is the same as semiautomatic except the IFT automatically

Rosemount Analytical Inc. A Division of Emerson Process Management Setup and Operation 3-9

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

initiates the calibration at a fixed calibration interval. In this mode the operator can also manually initiate calibrations between the intervals in the same manner as semiautomatic calibrations.

c. Manual (Semiautomatic) Calibration

1. Test Gases for Manual (Semiautomatic) Calibration. There are two options for supplying test gases to the probe during semiautomatic calibration. The first "A" uses refillable bottles and adjustable 2-stage pressure regulators; the second, "B" uses disposable bottles and a fixed single-stage regulator to provide a mixed flow. Normally, the first (method "A") will have a higher cost and not be portable. The second ("B") is less costly, portable, and weighs about 4.54 kg (10 lbs).

Test Method "A" Fixed Tanks and Manifolds.

(a) Required Equipment.

700 South Alameda Street Los Angeles, California 90058 213/585-2154

767 Industrial Road San Carlos, California 94070 415/592-7303

9950 Chemical Road Pasadena, Texas 77507 713/474-4141

12054 S.W. Doty Avenue Chicago, Illinois 60628 312/568-8840

603 Bergen Street Harrison, New Jersey 07029 201/485-1995

255 Brimley Road Scarborough, Ontario, Canada 416/266-3161

SCOTT ENVIRONMENTAL TECHNOLOGY, INC. SCOTT SPECIALTY GASES

Do not use 100% nitrogen as a zero gas. It is suggested that gas for the zero be between 0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

1 Two tanks of precision cali-

bration gas mixtures. Recommended calibration gases are nominally 0.4 percent and

8.0 percent oxygen in nitrogen.

Two sources of calibrated gas mixtures are:

LIQUID CARBONIC GAS CORP. SPECIALTY GAS LABORATORIES

2600 Cajon Blvd. San Bernardino, CA 92411 714/887-2571 TWX: 910-390-1159

1290 Combermere Street Troy, MI 48084 314/589-2950

Route 611 Plumsteadville, PA 18949 215/766-8861 TWX: 510-665-9344

2616 South Loop West, Suite 100 Houston, TX 77054 713/669-0469

2 A check valve is required at

the probe (between the calibration fitting and the gas line) to prevent the migration of process gases down the calibration gas line.

3-10 Setup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

3 Two, 2-stage pressure regu-

lators with stainless steel diaphragms for tanks. Maximum output required: 138 kPa (20 psi).

4 One instrument air pressure

regulator: 138 kPa (20 psi) maximum and a supply of clean, dry instrument air.

5 Two zero-leakage shutoff

valves.

6 Miscellaneous oil-free tubing

and fittings.

(b) Calibration

1 A typical calibration setup is

shown in Figure 3-2. Care must be taken that all fittings are tight and free from oil or other organic contaminants. Small openings can cause back diffusion of oxygen from the atmosphere even though positive pressures are maintained in the lines.

NOTE

The probe calibration gas fitting has a seal cap which must be in place at all times except during calibration.

In addition to the precision calibration gas mixtures, clean, dry, oil-free instrument air should be used for calibration.

For optimum accuracy, this calibration should be run with the process at normal temperature and operating conditions.

When the calibration gas line exceeds 1.8 m (6 ft) in length from the leak tight valves, a

check valve, Rosemount P/N 6292A97H02, should be installed next to the calibration gas connection on the probe to prevent breathing of the line with the process gas and subsequent gas condensation and corrosion.

CALIBRATE

IN-PLACE

FITTING

FLOW METER

LEAK TIGHT

VALV ES

NOTE:

PROBE CALIBRATION GAS FITTING HAS A SEAL CAP THAT MUST BE IN PLACE AT ALL TIMES EXCEPT DURING CALIBRATION.

PROBE (END VIEW)

REFERENCE AIR

CONNECTION

5 SCFH

REG

0.4% O

CHECK VALV E

8.0% O

Figure 3-2. Typical Calibration Setup

2 SCFH

REFERENCE

AIR

SET

INSTR. AIR IN

730013

Rosemount Analytical Inc. A Division of Emerson Process Management Setup and Operation 3-11

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

NOTE

Only set the test gas flowmeter upon initial installation and after changing the diffusion element. A slightly lower test gas flow rate may indicate a plugged diffusion element.

2 Set the test gas pressure

regulators and the flow meter for a flow of 5 scfh at (20 psig) 138 kPa for both gases. The reference gas should be flowing as in normal operation.

3 Refer to paragraph 3-10d of

this section for Manual (Semiautomatic) Calibration setup and procedure using the IFT.

4 Test gases will be switched

on and off using the shutoff valves.

Test Method "B" Rosemount Oxygen Test Gas and Service Kit.

(a) Required Equipment

2 Extra gas bottles are available

at:

Rosemount Analytical Inc. Box 901 Orrville, Ohio 44667 U.S.A.

Rosemount Limited Burymead Road Hitchin, Herts. U.K.

Rosemount Italy VIA Guido Cavalcanti 8 20127 Milan, Italy

Rosemount Spain Saturnino Calleja 6 28002 Madrid, Spain

Rosemount France 165 Boulevard de Vallmy

92706, Colombes, France

Rosemount Part Number 3530B07G01 for probe 0.4% oxygen in nitrogen in disposable bottle.

1 Portable Rosemount Oxygen

Test Gas Kits (Figure 3-3), Rosemount Part Number

TEST GAS

KIT #1

(P/N 6296A27G1)

6296A27G01, containing 8% and 0.4% gases in a portable carrying case with regulator, built-in valve, hose and hose connecting adapter to the calibration gas connection.

35870004

Figure 3-3. Portable Rosemount

Oxygen Test Gas Kit

3-12 Setup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

Rosemount Part Number 3530B07G02 for probe 8% oxygen in nitrogen in disposable bottle.

3 A check valve is required at

the probe (between the calibration fitting and the gas line) to prevent the migration of process gases down the calibration gas line.

(b) Calibration with a Portable Rose-

mount Oxygen Test Gases Kit.

1 A typical portable test calibra-

tion setup is shown in Figure 3-4. For Manual (semiautomatic) calibration, remove cap plug from the calibrate-inplace fitting. The cap plug must be retained to seal this fitting after calibration is complete; failure to do so may render the probe useless if the system pressure is slightly negative. The reference gas should be flowing as in normal operation.

2 Refer to paragraph 3-10d of

this section for Manual (Semiautomatic) Calibration setup and procedure using the IFT.

3 Screw the push button regu-

lator with contents gage on to the test gas of choice and inject the test gas by opening the valve. Gas is on continuously when the valve is opened.

d. Manual (Semiautomatic) Calibration

Procedure

Consult Safety Data Sheet 1M03296 before performing any work on the CENELEC approved IFT 3000.

The following procedure relates to an operator initiated calibration selected at the IFT by pressing the CAL key. The calibration is manually performed by the operator upon data queues from the IFT. Any system without an MPS 3000 Multiprobe Test Gas Sequencer must follow these steps.

CALIBRATE

IN PLACE

CONNECTION

CHECK

VALV E

PUSHBUTTON

REGULATOR

WITH CONTENTS

GAGE - SET 5 SCFH

NOTE: PROBE CALIBRATION GAS

FITTING HAS A SEAL CAP THAT MUST BE IN PLACE EXCEPT DURING CALIBRATION.

REFERENCE

AIR

CONNECTION

TEST HOSE CONNECTS TO CHECK VALV E

0.4 %

23800010

8.0 %

1. Press SETUP to display the SETUP menu. Select PROBE CALIBRATION sub-menu. Ensure that Auto Cal is disabled. Set the cursor on Auto Cal. Press ENTER. Set Auto Cal to NO if not already done.

2. Press the CAL key. Select PERFORM CALIBRATION sub-menu. "Press ENTER to start Manual Calibration" will appear on the LCD display. Press ENTER to start. Follow the data queues. Refer to Table 3-4. CALIBRATE O

Menu.

Figure 3-4. Typical Portable Test Calibration Setup

Rosemount Analytical Inc. A Division of Emerson Process Management Setup and Operation 3-13

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

e. Fully Automatic Calibration

Consult Safety Data Sheet 1M03296 before performing any work on the CENELEC approved IFT 3000.

1. Test Gases for Fully Automatic Calibration. For fully automatic calibration, an MPS 3000 Multiprobe Test Gas Sequencer is required as well as the two types of test gas.

Two tanks of precision calibration gas mixtures. Recommended calibration gases are nominally 0.4 percent and

8.0 percent oxygen in nitrogen.

A typical automatic calibration system is shown in Figure 3-5.

2. Fully Automatic Calibration Setup. In order for the IFT system to calibrate automatically, the following parameters from the CALIBRATE sub-menu in the IFT have to be entered. Refer to Table 3-5. SETUP Sub-Menu.

(a) Auto Cal YES/NO

Set to YES

Set the desired time between calibrations in number of days and hours. (1 year max.)

(d) Next Cal. XD XH

Displays the time left to the start of the next calibration. Set the desired time until the start of the next calibration. If nothing is entered here, the unit will automatically enter the cal intrvl and count down from that. (1 year max.)

(e) Gas Time 0:00

Set the amount of time for the test gasses to be turned on in number of minutes and seconds, allow enough time for signal values to stabilize.

(f) Purge Time 0:00

Set the amount of time for the gas lines to clear in number of minutes and seconds.

(g) Abort Time 0:00

Set the amount of time allowed between key functions before the calibration procedure is aborted in number of minutes and seconds.

(h) Res Alarm _____

Set the desired resistance alarm between 50 - 10000 ohms.

Once these parameters have been set, the system will initiate calibration without operator intervention as set by the CAL INTVL parameter.

(b) Output Tracks YES/NO

Set as desired to configure analog output tracking.

3-14 Setup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

3. Manually Initiated Fully Automatic Calibration Procedure. The following procedure relates to an operator initiated calibration, either by a remote switch (CAL INIT on interconnect board) or selected at the IFT by pressing the CAL key using an MPS 3000 Multiprobe Gas Sequencer.

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

(a) Press SETUP to display the

SETUP sub-menu. Select Calibration. Ensure that Auto Cal is enabled. Set the cursor on Auto Cal. Press ENTER. Set Auto Cal to YES if not already done.

CHECK

VALV E

TEST GAS

PROBE

(END VIEW)

REFERENCE AIR

HPS

PROBE SIGNAL CONNECTIONS

(b) Press the CAL key. Select Perform

Calibration. "Press ENTER to start Automatic Calibration" will appear on the LCD display. Press ENTER to start. Refer to Table 3-4. CALIBRATE O

Sub-Menu.

IFT

MPS

INSTRUMENT

AIR IN

NOTE: 1. THE MPS CAN BE USED WITH UP

TO FOUR PROBES. ONLY ONE PROBE CAN BE CALIBRATED AT A TIME. PROBE CALIBRATIONS MUST BE SCHEDULED IN MULTIPLE PROBE APPLICATIONS.

2. HPS OPTION SHOWN.

MPS-IFT SIGNAL CONNECTIONS

TEST GAS 1

(HIGH O )

TEST GAS 2

(LOW O )

730014

Figure 3-5. Typical Automatic Calibration System

Rosemount Analytical Inc. A Division of Emerson Process Management Setup and Operation 3-15

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

3-16 Setup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Consult Safety Data Sheet 1M03296 before performing any work on the CENELEC approved IFT 3000.

4-1 OVERVIEW

Ensure that the oxygen analyzer, heater power supply (if included with the system), and intelligent field transmitter have been properly connected. It is important to check that grounding and screening of terminations are correctly made to prevent the introduction of ground loops. The IFT is equipped with noise suppression circuitry on the power supply and signal input lines. Proper grounding at installation will ensure accuracy of function.

This section of the manual deals with operator controls and displays available for the IFT equipped with LDP and four membrane keys.

Operating instructions for the GUI equipped IFT are included in Section 3.

Any procedures not associated with normal operations are included in Section 2, Installation, or Section 5, Troubleshooting.

SECTION 4

LDP OPERATION

4-2 IFT WITH LDP FRONT PANEL CONTROLS

AND INDICATORS (Figure 4-1.)

Fig. 4-1

Index

No.

2 CAL Calibration in progress

3 TGH High test gas indicator light.

4 TGL Low test gas indicator light.

5 ENTER The ENTER key is used to

8SEL

Instruction Manual

106-300NFX Rev. 4.2

Control/

LED Description

LED

Display

▲

▼

Indicates current O gas value.

indicator light.

High test gas is being used in calibration process.

Low test gas is being used in calibration process.

initiate calibration or select a test gas parameter to change.

The increase key is used to increase the value of the test gas parameters.

The decrease key is used to decrease the value of the test gas parameters.

The select key is used to scroll through the list of parameters.

January 2002

or test

CAL TGH TGL

ENTERSEL

4-3 LDP DISPLAYS

Consult Safety Data Sheet 1M03296 before performing any work on the CENELEC approved IFT 3000.

The LDP equipped IFT contains four selectable displays. The displays are selected by pressing the SEL key. The display is advanced once each time the SEL key is depressed and continually scrolls. The only parameters which the

34990019

Figure 4-1. IFT with LDP Front Panel

Rosemount Analytical Inc. A Division of Emerson Process Management LDP Operation 4-1

operator is permitted to change change are H (high test gas) and L (low test gas). When a parameter is to be changed, press the ENTER

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

key. To change the parameter, the increase and decrease arrows are depressed until the proper value is displayed. Depress the ENTER key to accept the new value, or the SEL key to abort the change. The four displays are as follows:

a. O

The O2 selection will display the O2 value on the LED display when ENTER key is depressed.

b. H

The high test gas display allows the value of the high test gas parameter to be changed for calibration purposes.

c. L

The low test gas display allows the value of the low test gas parameter to be changed for calibration purposes.

d. CAL

tion. Calibration must be manually initiated. Information on test gases and hardware requirements may be found in paragraph 3-10, Calibration.

b. Manual Calibration

The following procedures relate to an operator initiated calibration. The calibration is manually performed by the operator upon data queues from the IFT. Any system without an MPS 3000 multiprobe test gas sequencer must follow these steps.

Consult Safety Data Sheet 1M03296 before performing any work on the CENELEC approved IFT 3000.

1. Press the SEL key until CAL is shown on the LED display.

2. Press ENTER. The CAL light is now on. Turn on high test gas.

The calibration selection allows the operator to initiate the calibration process when ENTER key is depressed.

4-4 LDP DEFAULTS

The LDP equipped IFT is programmed at the factory with the defaults indicated in Table 4-1. For a description of the defaults refer to Table 3-4. SETUP Sub-Menu.

4-5 CALIBRATION

a. Overview

The LDP equipped IFT is configured at the factory for manual (semiautomatic) calibra-

3. Press ENTER. The TGH light is now flashing.

4. When the value shown on the LED display has stabilized, press ENTER. Turn off high test gas.

5. Turn on low test gas. Press ENTER. The TGL light is now flashing.

6. When the value shown on the LED display has stabilized, press ENTER.

7. Turn off low test gas. Press ENTER.

8. All indicator lights are off. Calibration complete.

4-2 LDP Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

106-300NFX Rev. 4.2

World Class 3000

Table 4-1. LDP Defaults

PARAMETER DEFAULT PARAMETER DEFAULT

January 2002

Probe Calibration

High Gas Low Gas Auto Cal Output Tracks Cal Interval Next Cal Gas Time Purge Time Resistance Alarm

O2 Calculation

Slope Constant Htr Set Point

O2 Alarms

HI Alarm LO Alarm Alarm DB

8.0%

0.4% NO YES OFF Disabled 5:00 MIN 5:00 MIN 1000 ohms

____(value from calibration) ____(value from calibration) 736°C (when implemented)

30%

0.3%

0.0%

Efficiency Calc.

Enable Calc K1 Value K2 Value K3 Value

Relay Outputs (K1)

Event 1 Event 2 Event 3

Relay Outputs (2)

Event 1 Event 2 Event 3

Analog Output

Source Aout Type

0.0

Heater Fail Cal. Fail INCAL

LO O

OFF OFF

0-10%

4-20mA

Rosemount Analytical Inc. A Division of Emerson Process Management LDP Operation 4-3

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

4-4 LDP Operation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

SECTION 5

TROUBLESHOOTING

b. Electrical Noise

Consult Safety Data Sheet 1M03296 before performing any work on the CENELEC approved IFT 3000.

Install all protective equipment covers and safety ground leads after troubleshooting. Failure to install covers and ground leads could result in serious injury or death.

5-1 OVERVIEW

The system troubleshooting describes how to identify and isolate faults which may develop in the Oxygen Analyzer System. Refer to Probe, IFT, HPS, and MPS Appendices.

5-2 SPECIAL TROUBLESHOOTING NOTES

a. Grounding

It is essential that adequate grounding precautions are taken when the system is being installed. A very thorough check must be made at both the probe and electronics to ensure that the grounding quality has not degraded during fault finding. The system provides facilities for 100% effective grounding and the total elimination of ground loops.

The IFT has been designed to operate in the type of environment normally found in a boiler room or control room. Noise suppression circuits are employed on all field terminations and main inputs. When fault finding, the electrical noise being generated in the immediate circuitry of a faulty system should be evaluated. All cable shields must be connected to earth.

c. Loose Integrated Circuits

The IFT uses a microprocessor and supporting integrated circuits. Should the electronics unit receive rough handling during installation in a location where it is subjected to severe vibration, an Integrated Circuit (IC) could work loose. The fault finding guides in paragraph 5-3a. and Table E-2, Appendix EX, show the resulting variety of failure modes. It is recommended that all IC's be confirmed to be fully seated before troubleshooting on the system begins.

d. Electrostatic Discharge

Electrostatic discharge can damage the IC's used in the electronics unit. It is essential before removing or handling the processor board or the IC's used on it, that the user ensure he/she is at ground potential.

Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-1

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

5-3 SYSTEM TROUBLESHOOTING

The IFT provides system failure information with two different error message formats. The error messages vary due to system configuration. Refer to Appendix EX, IFT 3000 Troubleshooting.

a. GUI Equipped IFT

The status line of the GUI equipped IFT will display one of ten conditions: OK, CAL (calibration), C Err (calibration error), H Err (heater error), TGLow (test gas low), HiO (high O2 level), LoO2 (low O2 level), and R Hi (high resistance level), Off and PRBE. Refer to Table E-2, Appendix EX for additional troubleshooting information on the GUI equipped IFT.

Consult Safety Data Sheet 1M03296 before performing any work on the CENELEC approved IFT 3000.

1. OK - The system is operating normally.

2. CAL - The system is currently undergoing calibration.

3. C Err - An error was detected during the calibration process.

4. H Err - There is a fault within the heater system.

5. TGLow - There is no test gas pressure.

6. HiO

- The O2 value is above the high

alarm limit.

7. LoO

- The O2 value is below the low

alarm limit.

8. R Hi - The cell resistance is above the high limit.

9. Off - The probe has been turned off because the IFT cannot control the heater temperature.

10. PRBE - The probe is disconnected, cold, or leads are reversed.

5-2 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

106-300NFX Rev. 4.2

January 2002

SECTION 6

RETURN OF MATERIAL

6-1 If factory repair of defective equipment is re-

quired, proceed as follows:

a. Secure a return authorization number from

a Rosemount Analytical Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions, or it will not be accepted.

In no event will Rosemount be responsible for equipment returned without proper authorization and identification.

b. Carefully pack defective unit in a sturdy box

with sufficient shock absorbing material to insure that no additional damage will occur during shipping.

c. In a cover letter, describe completely:

1. The symptoms from which it was determined that the equipment is faulty.

2. The environment in which the equipment has been operating (housing, weather, vibration, dust, etc.).

5. Complete shipping instructions for return of replacement or repaired equipment to you.

6. Reference the return authorization number.

d. Enclose a cover letter and purchase order

and ship the defective equipment, according to instructions provided in Rosemount Return Authorization, prepaid, to:

Rosemount Analytical Inc. RMR Department 1201 N. Main Street Orrville, Ohio 44667

If warranty service is requested, the defective unit will be carefully inspected and tested at the factory. If failure was due to conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount's option, and an operating unit will be returned to the customer in accordance with shipping instructions furnished in the cover letter.

3. The site from which equipment was removed.

4. Whether warranty or nonwarranty service is requested.

Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 6-1

For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by your purchase order and shipping instructions.

Instruction Manual

106-300NFX Rev. 4.2 January 2002

World Class 3000

6-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

106-300NFX Rev. 4.2

World Class 3000

January 2002

SECTION 7

APPENDICES

APPENDIX AX. WORLD CLASS 3000 OXYGEN ANALYZER PROBE (CENELEC

APPROVED VERSION)

APPENDIX BX. HPS 3000 HEATER POWER SUPPLY FIELD MODULE (CENELEC

APPROVED VERSION)

APPENDIX DX. MPS 3000 MULTIPROBE TEST GAS SEQUENCER

APPENDIX EX. IFT 3000 INTELLIGENT FIELD TRANSMITTER

APPENDIX JX. HART COMMUNICATOR MODEL 275D9E IFT 3000 APPLICATIONS

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 7-1

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

NOTES:

SEE SAFETY DATA SHEET 1M03226 FOR A LIST OF PROBE REPAIRS A CUSTOMER MAY MAKE.

ITEM B , CALIBRATION GAS TUBE, FITS INTO HOLE A WHEN PROBE IS ASSEMBLED.

NOT ALL PARTS SHOWN ARE AVAILABLE

3. FOR PURCHASE SEPARATELY. FOR A LIST OF AVAILABLE PARTS, SEE TABLE A-3.

1. Snubber Diffuser

2. Retainer Screw

3. Calibration Tube Insert

4. Retainer

5. Cell and Flange Assembly

6. Corrugated Seal

7. Probe Tube and Junction Box Assembly

8. Tube Nut, Ferrule, and Tie-Rap

9. Hose Clamp

10. Label

11. Terminal Block

12. Label Attaching Hardware Mounting Plate

13. Gas Connection

14. Terminal Block Marker

15. Seal Cap

16. Terminal Block

17. V-Strut Assembly

18. Terminal Block Screw

19. Ground Wires

20. Junction Box Gasket

21. Hose

22. Junction Box Lid

APPENDIX AX

23. Probe Head Hardware

24. Cover Setscrew

19780003

Figure A-1. Oxygen Analyzer (Probe - CENELEC Approved) Exploded View

A-0 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

WORLD CLASS 3000 OXYGEN ANALYZER PROBE

(CENELEC APPROVED VERSION)

Instruction Manual

Appendix AX Rev. 2.1

February 1998

APPENDIX AX, REV. 2.1

DESCRIPTION

a. Cell and Flange Assembly

Consult Safety Data Sheet 1M03226 for probe safety related information.

A-1 OXYGEN ANALYZER (PROBE) – GENERAL

The CENELEC approved Oxygen Analyzer (Probe), Figure A-1 consists of three component groups (Figure A-2): probe exterior, inner probe, and probe head. Specifications for the CENELEC approved probe are contained in Table A-1.

A-2 PROBE ASSEMBLY EXTERIOR

Primary probe exterior components include a flange-mounted zirconium oxide cell, mounted on a tube assembly and protected by a flame arrestor and snubber diffuser.

PROBE

EXTERIOR

The primary component in the cell and flange assembly, Figure A-3, is a yttriastabilized zirconium oxide cell. It creates an electrical signal when theoxygen level on one side is out of balance with the oxygen level on the other side. This signal is proportional to the difference in oxygen levels.

b. Probe Tube Assembly

Screws and a retainer ring secure the cell and flange assembly, Figure A-3, to the probe tube assembly. When in place, the cell is inside the tube. The retainer ring is high temperature chrome plated to prevent galling and seizing. It is also coated with anti-seize compound to help avoid seizing.

PROBE

TUBE

CORRUGATED

SEAL

RETAINER

JUNCTION

BOX

PROBE

INTERIOR

CELL AND

FLANGE

ASSEMBLY

CALIBRATION

19780004

TUBE INSERT

730009

Figure A-2. Main Probe Components

Figure A-3. Cell and Tube Assemblies

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-1

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

Table A-1. Specifications for Oxygen Analyzing Equipment

1, 2

Probe lengths, nominal ................................................... 457 mm (18 in.), 0,91 m (3 ft), 1,83 m (6 ft),

depending on duct dimensions.

Temperature limits in process measurement area ......... 10-704°C (50-1300°F)

Standard/current output .................................................. 4-20 mA dc signal (factory set)

indication (Digital display and analog output) ............ 0.1% O2 or ±3% of reading, whichever is

greater using Rosemount test gases.

Cell speed of response ................................................... 1 millisecond

System speed of response ............................................. less than 3 seconds (amplifier output)

Resolution sensitivity ...................................................... 0.01% O

transmitted signal

Probe reference air flow.................................................. 56,6 L/hr (2 scfh) clean, dry, instrument quality

air (20.95% O

)

Calibration gas mixtures ................................................. Rosemount Hagan Test Gas Kit Part No.

6296A27G01 contains 0.4% O

2N2

Nominal and 8% O2N2 Nominal

Calibration gas flow......................................................... 141,6 L/hr (5 scfh)

Probe heater power supply............................................. 44 Vac from HPS 3000

HPS 3000 power requirement ........................................ 225 VA

Ambient operating temperature of probe junction box.... 0°-150°C (32°-302°F)

HPS 3000 ambient operating temperature ..................... 0°-50°C (32°-120°F)

Approximate shipping weights:

457 mm (18 in.) package...................................... 30 kg (66 lbs)

0,91 m (3 ft) package............................................ 40 kg (88 lbs)

1,83 m (6 ft) package............................................ 55 kg (121 lbs)

All static performance characteristics are with operating variables constant.

Temperatures over 537°C (1000°F) may affect the ease of field cell replaceability.

The tube assembly includes a flange which mates with a stack-mounted flange. Studs on the stack flange make installation easy. There is also a tube to carry calibration gas from the probe head to the process side of the cell during calibration.

c. Flame Arrestor Diffuser

The flame arrestor diffuser, Figure A-4, protects the cell from heavy particles and isolates the cell from changes in temperature. The assembly consists of a flame arrestor and a snubber diffuser. The flame arrestor and diffuser thread onto the probe tube. Pin spanner wrenches (probe disas-

sembly kit 1L03825G01) are applied to holes in the diffusion element hub to remove or install the diffuser assembly.

The Flame Arrestor and Flame Arrestor Hub are among the critical components in this type of protection (Flameproof Enclosure Type ‘D'). See Safety Data Sheet 1M03226.

Systems that use an abrasive shield require a special flame arrestor and diffuser assembly with a hub that is grooved to accept two dust seal gaskets.

A-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

Appendix AX Rev. 2.1

February 1998

WRENCH

SNUBBER

DIFFUSOR

19780006

Figure A-4. Flame Arrestor Diffuser Assembly

d. Cell – General

The components which make up the cell are machined to close tolerances and assembled with care to provide accurate oxygen measurements. Any replacement requires attention to detail and care in assembly to provide good results.

Failure to follow the instructions in this manual could cause danger to personnel and equipment. Read and follow instructions in this manual carefully.

The oxygen probe includes an inner electrode for the cell assembly. It consists of a platinum pad and a platinum/inconel composite wire which produces the cell constant offset voltage described in the Nernst equation.

With this pad and wire, the constant will be between -10 to +15 mV. The cell constant is noted in the calibration data sheet supplied with each probe.

HEATER

REFERENCE

GAS TUBE

CERAMIC

SUPPORT TUBE

V-ST RU T

P00005A

Figure A-5. Inner Probe Assembly

A-3 INNER PROBE ASSEMBLY

The inner probe assembly, Figure A-5, consists of six main parts:

a. Ceramic support rod with four holes running

through the length. The holes serve as insulated paths for the cell signal wire and thermocouple wires.

b. A heater that is helically wrapped on a

quartz support cylinder and insulated.

c. A chromel-alumel thermocouple which acts

as the sensing element for the temperature controller. (Not visible in Figure A-4; located within ceramic support rod.)

d. A platinum screen pad which forms electri-

cal contact with the inner electrode of the electrochemical cell. (Not visible in Figure A-5; located at end of ceramic support rod.) The pad is attached to an inconel wire which carries the signal to the terminal strip.

e. A V-strut assembly to give support to the

inner probe assembly.

Every probe should be calibrated and checked after repair or replacement of cell, pad and wire, heater, or thermocouple, or after disassembly of the probe.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-3

f. A tube to carry reference gas to the cell.

Turn to Maintenance and Service for repair procedures for probe components.

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

TERMINAL

STRIP

CALIBRATION

GAS FITTING

VENT

REFERENCE

GAS FITTING

Figure A-6. Junction Box

A-4 JUNCTION BOX

The junction box, Figure A-6, is positioned at the external end of the probe and contains a terminal strip for electrical connections and fittings for reference and calibration gases. Fittings are for 0.250 inch stainless steel tubing. The calibration fitting has a seal cap which must remain in place except during calibration. A tubing fitting is also supplied to be used with the calibration gas supply during calibration.

If the calibration gas bottles will be permanently hooked up to the probe, an optional check valve is recommended to prevent condensation of flue gas in the calibration lines.

During operation and calibration, reference gas is supplied through the reference gas fitting to the reference side of the cell. This gives the system a known quantity of oxygen with which to compare the oxygen level in the process gas. Unlike the non-CENELEC World Class 3000 Probe, reference air must be used in conjunction with the CENELEC World Class 3000 probe.

P00006A

During calibration, two gases of different known oxygen concentrations are injected one at a time through the calibration gas fitting. Stainless steel tubing delivers this gas to the process side of the cell. In a healthy cell, the difference in oxygen pressure from the process side to the reference side of the cell will cause a millivolt output proportional to the difference in oxygen levels. The electronics unit can use the two millivolt outputs caused by the two calibration gases for either automatic or semi-automatic calibration.

Do not attempt to remove a process gas sample through either gas fitting. Hot gases from the process would damage gas hoses in the probe head.

A-5 CABLE ASSEMBLY

Cable used to interconnect apparatus must conform to the applicable codes of practice in the country of installation (example: BS4345 in Great Britain). Rosemount can supply a cable (P/N 1U03066) which is fitted with EExd IIC barrier glands. The installer should note that on some earlier versions of the cable, the glands, although EExd IIC approved, are not of the barrier gland variety. These glands should not be used. Rosemount can supply a gland kit for the corresponding barrier gland (P/N 1U03066G07). Each kit contains one pair of glands. The Rosemount supplied cable is a 7 conductor cable to connect the probe to the HPS 3000, and to connect the HPS 3000 to the electronics package. Standard length for this cable is 6 m (20 ft), but lengths up to 45 m (150 ft) are available. The 7 conductors include 1 shielded pair of wires for the cell millivolt signal, 1 shielded pair of type K wires for the thermocouple, and 3 individual 16-gauge wires for the heater and for ground. All metal shields are isolated at the probe end and connect by drain wires to ground at the electronics. The cable is suitable for use in ambient temperatures up to 90°C (194°F).

A-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

Appendix AX Rev. 2.1

February 1998

BC A

GROUP NOTE

PARTS LIST

UNITS: INCHES

PARTS LIST

G03

G02

G01

GROUP

MAT'L CODE

PART NUMBER

OR REF DWG

1U05680G20

) PROBE 18"

SIZE-REFERENCE

INFORMATION

DEFINER

DWG

PART NAME

CENELEC

ITEM

NOTE

4507C26G07

4507C26G08

)3FT

)6FT

DWG

WORLD CLASS 3000

GAS PICK-UP

4507C26G09

1M03241H01

4507C51H03

1L03826G02

)9FT

DWG

GAS PICK-UP

ANALYZER HOUSING

MTG HARDWARE

ASSY HARDWARE

GAS TUBE PICK-UP

GROUP NOTE

3FT

GAS TUBE PICK-UP

6FT

CAL

GAS

ELECT

CABLE

REF

GAS

100

(3.93)

FLOW

DIRECTION

VIEW ‘A-A'

REFERENCE AIR SUPPLY

CONNECTION BITE TYPE

FITTING (PARKER CPI) FOR

NOTES:

0.250 O.D. TUBING. 2 SCFH

AT 3 PSIG MAX. CLEAN DRY

AIR REQUIRED. FITTING IS

LOCATED ON FAR SIDE.

CABLE

693.67

CALIBRATION AND PURGE

GAS CONNECTION. BITE

TYPE FITTING (PARKER CPI)

10 SCFH AT 32 PSIG MAX.

CALIBRATION GAS REQUIRED.

(27.31)

REQUIRED

INSERTION

CLEARANCE

FOR PROBE

LAG TO ENSURE GAS

TEMPERATURE DOES NOT

GO BELOW DEW POINT

FLANGE

AND

REMOVAL

oo o o

WELD BY

CUSTOMER

RECOMMENDED 2 IN. THK

INSULATION. THERMAL CONDUCTIVITY

K EQUALS 0.5 FOR INSULATION.

DIMENSIONS ARE IN MILLIMETERS WITH INCHES

INSTALL WITH ANALYZER IN A VERTICALLY

OR EXCEED 500 C (932 F).

GASKET

DOWNWARD DIRECTION ONLY.

AND

FLUE GAS OPERATING TEMPERATURE

RANGE 650 - 980 C (1200 - 1800 F).

HARDWARE

IN PARENTHESES UNLESS OTHERWISE INDICATED.

GASKET

AND HARDWARE

584.0

Figure A-7. Bypass Probe Option

(23.0)

DRAIN

165.10 (6.50) REF

940 (37) REF ON 3 FT (4507C26G07)

1850 (73) REF ON 6 FT (4507C26G08)

1727.2 (68) REF ON 9 FT PICK-UP (4507C26G09)

825.5 (32.5) REF ON 3 FT AND6FTPICK-UP (4507C26G07 AND G08)

19780009

2770 (109) REF ON 9 FT (4507C26G09)

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-5

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

A-6 PROBE OPTIONS

a. Abrasive Shield Assembly

The abrasive shield assembly (IB-106300NX Series, Figure 2-1) is a stainlesssteel tube that surrounds the probe assembly. The shield protects the probe against particle abrasion and corrosive condensations, provides a guide for ease of insertion, and acts as a probe position support, especially for longer length probes. The abrasive shield assembly uses a modified flame arrestor and diffuser filled with dual dust seal packing.

b. Bypass Probe Options

For processes where the flue gas exceeds the maximum allowable temperature of

704°C (1300°F) a bypass sensor package can be employed. The bypass system uses an 18 inch probe mounted externally on the stack or duct. The process or exhaust gases are directed out to the probe through an extension/return duct. The bypass arrangement does not require the use of aspiration air and the gas which flows past the probe is returned to the stack or duct.

The bypass probe package is normally used for process temperatures of 704°C (1300°F) to 980°C (1800°F). "Inconel 600" has an operating range up to 980°C (1800°F).

Overall dimensions and mounting details of the bypass system are shown in Figure A-7.

TROUBLESHOOTING

Before conducting any work on the probe, consult probe Safety Data Sheet 1M03226.

Install all protective equipment covers and safety ground leads after troubleshooting. Failure to replace covers and ground leads could result in serious injury or death.

A-7 OVERVIEW

The probe troubleshooting section describes how to identify and isolate operating faults which may develop in the probe assembly.

A-8 PROBE TROUBLESHOOTING

a. Probe Faults

The three symptoms of probe failure are:

1. The system does not respond to changes in the oxygen concentration.

2. The system responds to oxygen changes but does not give the correct indication.

3. The system does not give an acceptable indication of the value of the oxygen test gas being applied during calibration.

b. Table A-2 provides a guide to fault finding

for the above symptoms.

c. Figure A-8 and Figure A-9 provide an alter-

nate approach to finding probe related problems.

A-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

SYMPTOM CHECK FAULT REMEDY

1. No response to oxygen concentration change when:

Instruction Manual

Appendix AX Rev. 2.1

February 1998

Table A-2. Fault Finding

Heater is cold and TC mV output is less than setpoint.

Heater is hot and T/C mV output is at setpoint ±0.2 mV.

2. System responds to oxygen concentration changes but does not give correct indication.

Thermocouple continuity Thermocouple failure Replace thermocouple

or return probe to Rosemount.

Heater cold resistance to be 11 ohm - 14 ohm

Triac O/P to heater Failure of electronics Check HPS and

Recorder chart Recorder failure See Recorder Instruc-

Cell mV input to electronics and cell mV at probe junction box

Heater failure Replace heater or return

probe to Rosemount.

electronics package.

tion Manual.

No cell mV at probe when test gas applied

Probe cell mV OK but no input to electronics

Cell mV satisfactory both at probe junction box and input to electronics failure of electronics

Replace cell or return probe to Rosemount.

Check out cable connection.

Check electronics package.

Good response, with incorrect indication.

3. Probe does not give accurate indication of applied test gas.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-7

Recorder or remote indicator

System calibration Calibration error Recalibrate system.

Probe mounting and condition of duct

Cell mV input to electronics

Test gas input port Blocked port Clean port.

Ceramic diffusion element Diffusion element cracked,

Calibration error Recalibrate recorder or

indicator, reference Recorder Instruction Manual.

Air ingress into duct Stop air leaks or resite

probe.

Failure of electronics Check electronics

package.

Replace diffusion

broken, or missing

element.

Instruction Manual

Appendix AX Rev. 2.1 February 1998

CHECK CELL MV TERMINALS 1 & 2 IN PROBE JUNCTION BOX

DOES CELL MV CORRESPOND WITH EXPECTED O CONCENTRATION

World Class 3000

YES

MEANS LOW O OR COMBUSTIBLES IS GAS STREAM. RECONFIRM THE O

CONCENTRATION

CHECK ELECTRONICS AND CELL MV I/P TO ELECTRONICS.

CHECK CABLE

PULL PROBE AND CHECK FOR CRACKED DIFFUSION ELEMENT OR CRACKED CELL

NO - HIGH

NO - ZERO OR VERY LOW

LOW

CHECK CELL RESISTANCE

ZERO

TOO HIGH

REPLACE CELL

CHECK THE CRIMP WHICH CONNECTS THE INCONEL WIRE TO ITS EXTENSION WIRE IN THE PROBE JUNCTION BOX.

BAD

GOOD

CONTACT

CHECK THAT PLATINUM WIRE IS MAKING CONTACT WITH CELL. IF THE PAD ASSEMBLY CAN BE PUSHED FORWARD THEN THERE WAS POOR CONTACT

CONTACT

REPLACE CRIMP

BAD

GOOD

CONTACT

REPLACE CELL

CONTACT

DISASSEMBLE AND CHECK FOR BROKEN CERAMICS RODS, SPRING, OR OTHER RESTRICTIONS.

P00009B

Figure A-8. Flowchart of Probe Related Problems, #1

A-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

CHECK THERMOCOUPLE MV AT TERMINALS 3 AND 4 IN PROBE JUNCTION BOX.

IS IT ABOUT SETPOINT MV ±0,2 MV? [THE MV MEASURED IS NOT YET COLD. JUNCTION COMPENSATED, SO IT WILL VARY BY -0,022 MV PER DEGREE FAHRENHEIT RISE IN THE TEMPERATURE OF THE ELECTRONICS BOX LOCATION. NORMAL IS SETPOINT MV AT 25°C (77 ).]°F

Instruction Manual

Appendix AX Rev. 2.1

February 1998

ALLOW ADDITIONAL TIME

FOR TEMP CONTROL TO SETTLE.

COLD JUNCTION TEMP AT ELECTRONICS BOX MAY BE MUCH LOWER THAN 25°C (77°F).

IS IT HIGHER, LOWER, OR ZERO?

ZERO

YES

LOWERHIGHER

HEATER, THERMOCOUPLE AND CONTROL ARE SATISFACTORY. REFER TO HEATER POWER SUPPLY TROUBLESHOOTING.

HEATER

THERMOCOUPLE

CIRCUIT

OPEN?

HEATER MAY BE DEAD. THERMOCOUPLE

YES

MAY BE READIN STACK TEMPERATURE.

CHECK HEATER FUSE AND TRIAC OUTPUT TO HEATER.

CONFIRM MV VALUE ON ELECTRONICS UNIT. IF OK, RESOLVE DIFFERENCE BETWEEN VOLTMETER AND ELECTRONICS.

REPLACE CONTACT

AND THERMOCOUPLE

ASSEMBLY

CHECK HEATER CONDITION. TURN OFF POWER. RESISTANCE BETWEEN TERMINALS 7 AND 8 SHOULD BE 11-14 OHMS. RESISTANCE BETWEEN TERMINALS 6 AND 7 AND 6 AND 8 SHOULD BE OPEN CIRCUIT. IF FAILED, REPLACE STRUT.

P00009A

Figure A-9. Flowchart of Probe Related Problems, #2

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-9

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

MAINTENANCE AND SERVICE

NOTE

Upon completing installation, make sure that the probe is turned on and operating prior to firing up the combustion process. Damage can result from having a cold probe exposed to the process gases.

During outages, and if possible, leave all probes running to prevent condensation and premature aging from thermal cycling.

If the ducts will be washed down during outage, MAKE SURE to power down the probes and remove them from the wash area.

A-10 PROBE RECALIBRATION

Before carrying out any service or maintenance on the probe, consult Safety Data Sheet 1M03226.

When working on this equipment on the laboratory bench, be aware that the probe, probe tube, and flame arrestor hub can be hot [up to 370°C (698°F)] in the region of the probe heater.

Install all protective equipment covers and safety ground leads after equipment repair or service. Failure to install covers and ground leads could result in serious injury or death.

A-9 OVERVIEW

This section describes routine maintenance of the oxygen analyzer probe. Spare parts referred to are available from Rosemount. Probe disassembly kit 1LO3825G01 contains the required spanner and hex wrenches. Refer to Replacement Parts of this appendix for part numbers and ordering information.

The oxygen analyzer system should be calibrated when commissioned. Under normal circumstances the probe will not require frequent calibration. When calibration is required, follow the procedure described in the Instruction Bulletin applicable to your electronics package.

A-11 CELL REPLACEMENT

This paragraph covers oxygen sensing cell replacement. Do not attempt to replace the cell until all other possibilities for poor performance have been considered. If cell replacement is needed, order cell replacement kit, Table A-3.

The cell replacement kit contains a cell and flange assembly, corrugated seal, calibration tube insert, setscrews, socket head cap screws, and anti-seize compound. Items are carefully packaged to preserve precise surface finishes. Do not remove items from packaging until they are ready to be used. Spanner wrenches and hex wrenches needed for this procedure are part of an available special tools kit, Table A-3.

A-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Before carrying out this procedure, consult Safety Data Sheet 1M03226.

Wear heat resistant gloves and clothing to remove probe from stack. Normal operating temperatures of diffuser and vee deflector are approximately 316° to 427°C (600° to 800°F). They could cause severe burns.

Do not remove cell unless it is certain that replacement is needed. Removal may damage cell and platinum pad. Go through complete troubleshooting procedure to make sure cell needs replacement before removing it.

Instruction Manual

Appendix AX Rev. 2.1

February 1998

a. Follow the power down procedure outlined

in Safety Data Sheet 1M03226 and the official "Codes of Practice" for your country of installation. Shut off and disconnect reference gas and calibration gas supplies from probe junction box, Figure A-10. Wearing heat resistant gloves and clothing, remove probe assembly from stack carefully and allow to cool to room temperature. Do not attempt to work on unit until it has cooled to a comfortable working temperature.

b. The vee deflector is an option used with the

ceramic diffuser. Figure A-11 shows a probe with a snubber diffuser. If the probe has the vee deflector, remove vee deflector and hub setscrews and remove vee deflector. Use spanner wrenches from probe disassembly tools kit, Table A-3, to turn hub free from probe tube. If applicable, inspect optional ceramic diffusion element. If damaged, replace element.

CELL EXTENSION

WIRE (ORANGE)

THERMOCOUPLE WIRE (+)

(YELLOW CHROMEL)

GROUND WIRE

(GREEN)

EXTERNAL

EARTHING

HARDWARE

CALIBRATION

GAS FITTING

CABLE

REFERENCE GAS FITTING

THERMOCOUPLE WIRE (-)

(RED ALUMEL)

GROUND WIRE (GREEN)

HEATER WIRES (BLACK)

INTERNAL EARTHING TERMINAL (TERMINAL 6)

P00010A

Figure A-10. Cell Wiring Installation

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-11

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

c. Loosen 4 socket head screws from retainer.

Pull off retainer and calibration tube insert, Figure A-12. Discard calibration tube insert.

d. Press the cell flange against the probe end

flange and twist through 90° in both the clockwise and counterclockwise directions. This breaks the bond between the cell and the platinum pad. Once the bond is broken, remove the cell.

e. View the platinum pad through the probe

end flange. Reform the platinum pad into a shape to match the cell electrode by gathering in any loose strands which may have become untidy. This may be done with a small flat screwdriver.

f. Remove and discard corrugated seal. Clean

mating faces of probe tube and retainer. Remove burrs and raised surfaces with block of wood and crocus cloth.

g. Rub one or two drops of anti-seize com-

pound #3535B53G01 between fingers. Smear on both sides of corrugated seal.

h. Install new calibration tube insert in retainer,

with the short arm of the tube insert penetrating the calibration gas passage in the outer ring of the retainer. Assemble retainer, cell and flange assembly, corrugated seal,

and probe tube. Make sure the calibration tube insert lines up with the calibration gas passage in each component. Firmly seat the calibration tube insert in the assembly. Apply a small amount of anti-seize compound to screw threads and use screws to secure assembly. Torque to 4 N·m (55 in-lbs).

i. To install snubber diffuser, apply anti-seize

compound to threads of probe tube, Figure A-11, and snubber diffuser. Reinstall diffuser on probe tube. Using pin spanner wrenches, torque to 14 N·m (10 ft-lbs).

j. If using the optional vee deflector and ce-

ramic hub, apply anti-seize compound to threads of probe end flange, hub, and setscrews. Reinstall hub on probe tube. Using pin spanner wrenches, torque to 14 N·m (10 ft-lbs). Reinstall vee deflector, orienting apex toward gas flow. Secure with setscrews and anti-seize compound. Torque to 2.8 N·m (25-in-lbs). Secure hub retaining setscrew.

k. On systems equipped with an abrasive

shield, install dust seal gaskets, with joints 180° apart.

PROBE TUBE

(NOT INCLUDED KIT)

PROBE

TUBE

SNUBBER

DIFFUSOR

Figure A-11. Removal of Snubber Diffuser

A-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

PIN SPANNER

WRENCH

PROBE

END

FLANGE

CALIBRATION

TUBE PASSAGE

19780017

Figure A-12. Cell Replacement Kit

CORRUGATED

SEAL

FLANGE ASSEMBLY

CELL END

RETAINER

SOCKET

HEAD CAP

SCREW

CALIBRATION TUBE INSERT

730010

World Class 3000

l. Reinstall probe and gasket on stack flange.

If there is an abrasive shield in the stack, make sure dust seal gaskets are in place as they enter 15° reducing cone.

m. Consult Safety Data Sheet 1M03226 then

turn power on to electronics and monitor thermocouple output. It should stabilize at

29.3 mV ±0.2 mV. Set reference air flow at

56.6 L/hr (2 scfh). After probe stabilizes, calibrate probe per Instruction Bulletin applicable to your electronics package. If new components have been installed, repeat calibration after 24 hours of operation.

Instruction Manual

Appendix AX Rev. 2.1

February 1998

Before carrying out this procedure, consult Safety Data Sheet 1M03226.

A-12 CERAMIC DIFFUSION ELEMENT

REPLACEMENT

NOTE

This refers to ceramic diffuser element only.

a. General

The diffusion element protects the cell from particles in process gases. It does not normally need to be replaced because the vee deflector protects it from particulate erosion. In severe environments, the filter may be broken or subject to excessive erosion. Examine the ceramic diffusion element whenever removing the probe for any purpose. Replace if damaged.

Damage to the ceramic diffusion element may become apparent during calibration. Compare probe response with previous response. A broken diffusion element will cause a slower response to calibration gas.

Hex wrenches needed to remove setscrews and socket head screws in the following procedure are available as part of a Probe Disassembly Kit, Table A-3.

Do not remove cell unless it is certain that replacement is necessary. Cell cannot be removed for inspection without damaging it.

b. Replacement Procedure

1. Follow the power down procedure outlined in Safety Data Sheet 1M03226 and the official "Codes of Practice" for your country of installation. Disconnect cable conductors and remove cable, Figure A-10. Shut off and disconnect reference gas and calibration gas supplies from probe junction box. Wearing heat resistant gloves and clothing, carefully remove probe assembly from stack.

2. Loosen setscrews, Figure A-13, using hex wrench from Probe Disassembly Kit, Table A-3 and remove vee deflector. Inspect setscrews. If damaged, replace with stainless setscrews coated with anti-seize compound.

3. On systems equipped with abrasive shield, remove dual dust seal gaskets.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-13

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

4. Use spanner wrenches from Probe Disassembly Kit, Table A-3, to turn hub free from retainer.

5. Put hub in vise. Break out old ceramic diffusion element with chisel along cement line and 9.5 mm (3/8 in.) pin punch through cement port.

6. Break out remaining ceramic diffusion element by tapping lightly around hub with hammer. Clean grooves with pointed tool if necessary.

7. Replace ceramic diffusion element, using replacement kit in Table A-3. This consists of a diffusion element, cement, setscrews, anti-seize compound and instructions.

8. Test fit replacement ceramic diffusion element to be sure seat is clean.

Do not get cement on ceramic diffusion element except where it touches the hub. Any cement on ceramic diffusion element blocks airflow through element. Wiping wet cement off of ceramic only forces cement into pores. Also do not get any cement onto the flame arrestor element.

9. Thoroughly mix cement and insert tip of squeeze bottle into cement port. Tilt bottle and squeeze while simultaneously turning ceramic diffusion element into seat. Do not get any cement on upper part of ceramic diffusion element. Ensure complete penetration of cement around 3 grooves in hub. Cement should extrude from opposite hole. Wipe excess material back into holes and wipe top fillet of cement to form a uniform fillet. (A Q-Tip is useful for this.) Clean any excess cement from hub with water.

WRENCH

RETAINER

OPTIONAL CERAMIC

DIFFUSION ELEMENT

SETSCREW

HUB

CEMENT

PORT

CEMENT

FILLET

VEE

DEFLECTOR

21240026

Figure A-13. Removal of Optional Ceramic

Diffuser and Vee Deflector

10. Allow filter to dry at room temperature overnight or 1 to 2 hours at 93°C (200°F).

11. Wipe a heavy layer of anti-seize compound onto the threads and mating surfaces of the flame arrestor, diffusion hub, and probe tube.

12. Assemble flame arrestor and diffusion hub with two pin spanner wrenches. Torque to 14 N·m (10 ft-lbs). Secure with hub retaining setscrew.

13. On systems equipped with abrasive shield, install dust seal gaskets with joints 180° apart.

14. Reinstall vee deflector, orienting apex toward gas flow. Apply anti-seize compound to setscrews and tighten with hex wrench.

15. Reinstall probe on stack flange.

A-14 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

Appendix AX Rev. 2.1

February 1998

16. Consult Safety Data Sheet 1M03226 then turn power on to electronics and monitor thermocouple output. It should stabilize at 29.3 mV ±0.2 mV. Calibrate probe per Instruction Bulletin applicable to your electronics package.

A-13 REPLACEMENT OF CONTACT AND

THERMOCOUPLE ASSEMBLY

Use heat resistant gloves and clothing when removing probe junction box and inner probe assembly. Do not attempt to work on these components until they have cooled to room temperature. Probe components can be as hot as 800°C (1500°F). This can cause severe burns.

Before carrying this procedure, consult Safety Data Sheet 1M03226.

a. Follow the cell removal procedure in para-

graph A-3, steps a, b, c, and d. Using heat resistant gloves and clothing, remove cover setscrew (24, Figure A-1) and junction box lid (23). Squeezing tabs on hose clamps, remove hoses from inner probe assembly, Figure A-14. Remove 4 screws which secure the inner probe assembly to the junction box. Disconnect all inner probe assembly wires from the terminal block (Figure A-10). Pull inner probe assembly free from junction box. Set on bench and allow to cool to room temperature.

HOSE

CLAMP

PROBE

JUNCTION BOX

HOSE

BACKPLATE

MOUNTING

SCREW

P00013A

Figure A-14 Probe Junction Box Mechanical

Connections

HEATER

SCREWS

STRUT

CONTACT AND

THERMOCOUPLE

ASSEMBLY

GUIDE

LOOPS

SPRING

CLIP

b. Use a pencil to mark locations of spring

clips on ceramic rod, Figure A-15.

c. Pry or squeeze tabs on spring clips, and

pull contact and thermocouple assembly out

Figure A-15. Inner Probe Replacement (Heater,

V-Strut, and Backplate Assembly)

BACKPLATE

MOUNTING

HARDWARE

P00014A

of probe assembly. Retain spring clips and spring; replace if damaged.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-15

Instruction Manual

Appendix AX Rev. 2.1 February 1998

Be very careful when handling contact

and thermocouple assembly. The ce-

ramic rod in this assembly is fragile.

d. While very carefully handling new contact

and thermocouple assembly, lay old assembly next to new one. Transfer pencil marks to new rod. Throw away old contact and thermocouple assembly.

e. Carefully guide new contact and thermo-

couple assembly through V-strut assembly leaf spring (3, Figure A-16), spring (8), spring clips (9) (held open by squeezing tabs), tube supports and heater support until spring clip reaches pencil mark.

World Class 3000

Do not bend wires closer than 6.4 mm (1/4 in.) from end of ceramic rod. Dress wires so they do not touch sides of probe junction box.

h. Reinstall the cell per paragraph A-11, steps

f, g, h, i, j, and k.

i. Consult Safety Data Sheet 1M03226 then

power up system. Monitor thermocouple output. It should stabilize at setpoint mV ±0.2 mV. Recalibrate probe per Instruction Bulletin applicable to your electronics package.

A-14 REPLACEMENT OF HEATER, V-STRUT

AND BACKPLATE ASSEMBLY (Inner Probe Assembly; Includes Contact and Thermocouple Assembly)

f. Slide assembled inner probe assembly into

junction box and probe tube. To align calibration gas tube with corresponding hole in backplate (A, B, Figure A-1) insert scriber through hole in backplate and into calibration gas tube. Secure with screws. Reinstall hoses.

NOTE

The letter "A" is stamped inside the junction box close to the calibration tube. The calibration tube may fall over towards the opposite side. If it has, bring it back towards the letter "A" before inserting the inner probe assembly. Also note that there are grooves cut in the heater plates that fit over the calibration gas tube. Insert inner probe assembly gently to avoid kinking the calibration gas tube.

g. Connect color-coded wires to proper termi-

nals as shown in Figure A-10. Rosemount recommends connecting the thermocouple wires directly to the terminal strip. This is because the junction of different metals at the wires and lugs and at the lugs and the terminal strip could act as additional thermocouple junctions. This could produce a voltage that would affect the thermocouple output signal.

Figure A-17 is a cross-sectional view of the CENELEC approved oxygen analyzer (probe). Use Figure A-17 and the following procedure to replace heater, v-strut, and backplate assembly.

Before carrying out this procedure, consult Safety Data Sheet 1M03226.

a. Follow the cell removal procedure in para-

graph A-3, steps a, b, c, and d. Using heat resistant gloves and clothing, remove cover setscrew (24, Figure A-1) and junction box lid (23). Squeezing tabs on hose clamps, remove hoses from inner probe assembly, Figure A-13. Remove 4 screws which secure the inner probe assembly to the junction box. Disconnect all inner probe assembly wires from the terminal block (Figure A-10). Pull inner probe assembly free from junction box. Set on bench and allow to cool to room temperature.

A-16 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

Appendix AX Rev. 2.1

February 1998

1. Heater Ceramic Rod

2. Contact and Thermocouple Assembly

3. Leaf Spring

Figure A-16. Heater, Strut, and Backplate Assembly (Inner Probe Assembly)

Not all parts shown are available for purchase separately. For a list of available parts, see Table A-3.

POOO15A

4. Extension Wire

5. Ring Lug

6. Connector

7. Backplate

91011

8. Spring

9. Spring Clip

10. Strut

11. Heater

NOTE

211

1. Snubber Diffuser

2. Calibration Tube Insert

3. Socket Head Cap Screw

0.25 In.-28 x 0.63 (16 mm)

4. Cell and Flange Assembly

5. Corrugated Seal

6. Probe Tube Assembly

7. Gasket

8. Cover Head Assembly

9. Hose Clamp

19780022

10. Heater Strut

11. Retainer

12. Junction Box Setscrew

13. Flame Arrestor Hub Setscrew

Figure A-17. Oxygen Analyzer (Probe), Cross-Sectional View

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-17

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

b. Slide new assembled inner probe assembly

into junction box and probe tube. To align calibration gas tube with corresponding hole in backplate (A, B, Figure A-1), insert scriber through hole in backplate and into calibration gas tube. Secure with screws. Reinstall hoses.

NOTE

c. Connect color-coded wires to proper termi-

nals as shown in Figure A-10. Rosemount

recommends connecting the thermocouple wires directly to the terminal strip. This is because the junction of different metals at the wires and lugs and at the lugs and the terminal strip could act as additional thermocouple junctions. This could produce a voltage that would affect the thermocouple output signal.

Do not bend wires closer than 6.4 mm (1/4 in.) from end of ceramic rod. Dress wires so they do not touch sides of probe junction box.

d. Reinstall the cell per paragraph A-3, steps

f, g, h, i, j, and k.

e. Consult Safety Data Sheet 1M03226, then

power up system. Monitor thermocouple output. It should stabilize at setpoint mV ±0.2 mV. Recalibrate probe per Instruction Bulletin applicable to your electronics package.

A-18 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

Appendix AX Rev. 2.1

February 1998

REPLACEMENT PARTS

Table A-3. Replacement Parts for Probe

FIGURE and

INDEX No.

A-1, 13 3D39149G06 A-1, 13 3D39149G07 A-1, 13 3D39149G08 A-16, 2 3534B56G04 A-16, 2 3534B56G05 A-16, 2 3534B56G06

PART

NUMBER DESCRIPTION

1U03066G07V-Strut Assembly (18 in.) V-Strut Assembly (3 ft) V-Strut Assembly (6 ft) Contact and Thermocouple Assembly (18 in.) Contact and Thermocouple Assembly (3 ft)

Contact and Thermocouple Assembly (6 ft) 4847B61G19 Cell Replacement Kit (18 in.) 4847B61G20 Cell Replacement Kit (3 ft) 4847B61G21 Cell Replacement Kit (6ft) 4847B61G24 Cell Replacement Kit (No Inconel and Platinum Pad Assembly) 1U05677G01 Probe Disassembly Kit

A-11 1U05677G04 F/A Diffuser Hub Assembly (Snubber Diffuser)

1U05677G06 F/A Diffuser Hub Assembly (For use with Abrasive Shield) 6292A74G02 Ceramic Diffusion Element Replacement Kit 1N04966H02 Abrasive Shield Assembly (3 ft) 1N04966H03 Abrasive Shield Assembly (6 ft) 1M03241H01 90° Elbow for Bypass

A-7, 2 4507C26G07 Bypass Gas Pickup Tube (3 ft) A-7, 3 4507C26G08 Bypass Gas Pickup Tube (6 ft) A-7, 4 4507C26G09 Bypass Gas Pickup Tube (9 ft)

263C152G01 Reference Gas Air Set

771B635H01 Calibration Gas Rotameter

1L03650H01 F/A Diffusion Hub Setscrew IB-106-300NFX Instruction Bulletin (IFT) IB-106-300NCX Instruction Bulletin (CRE) IB-106-300NEX Instruction Bulletin (Upgrade - CENELEC Digital Electronics)

1U03066G07 EExd Barrier Gland Kit (one pair of glands per kit)

V-Strut assembly includes contact and thermocouple assembly.

Contact and thermocouple assembly includes platinum pad and inconel wire.

NOTE

The replacement parts listed above must be obtained only from the manufacturer or his agent.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-19

Instruction Manual

Appendix AX Rev. 2.1 February 1998

World Class 3000

A-20 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

HPS 3000 HEATER POWER SUPPLY FIELD MODULE

(CENELEC APPROVED VERSION)

Consult Safety Data Sheet 1M03243 for safety related information.

B-1 DESCRIPTION

The Rosemount CENELEC approved HPS 3000 Heater Power Supply Field Module (Figure B-1) acts as an interface between probe and electronics and supplies power to the probe heater. The unit allows the use of probes with a number of different electronics packages.

Instruction Manual

Appendix BX Rev. 1.2

January 1997

APPENDIX BX, REV. 1.2

DESCRIPTION

P00001B

Figure B-1. CENELEC Approved HPS 3000

Heater Power Supply Field Module

The CENELEC approved HPS 3000 is certified EExd IIC T6 to CENELEC standards EN50014 and EN50018.

The heater power supply, Figure B-2, consists of a motherboard, daughterboard, and a transformer for supplying correct voltage to the probe heater. The mother- and daughterboards contain terminal strips for connecting probe, electronics, and power supply.

The HPS is jumper configurable for 120, 220, or 240 Vac.

If you reconfigure the equipment for a line voltage other than the one marked on the serial label, then you should change the marking on the serial label to state the new line voltage.

B-2 THEORY OF OPERATION

The HPS 3000 Heater Power Supply may perform slightly different functions, depending upon which electronics package with which it is used. Figure B-3 shows a functional block diagram of the unit. The HPS contains a transformer for converting line voltage to 44 volts needed to power the probe heater. The relay can be used to remotely turn the probe on or off manually.

A triac module is used to turn the heater on or off, depending on probe temperature.

When used with the CRE 3000 Control Room Electronics or IFT 3000 Intelligent Field Transmitter, the HPS uses a cold junction temperature compensation feature. This allows for the use of a less expensive cable between the HPS and CRE or HPS and IFT. The HPS and electronics package can be located up to 364 m (1200 ft) apart.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-1

Instruction Manual

Appendix BX Rev. 1.2 January 1997

World Class 3000

TERMINAL

COVERS

(PROVIDED)

INTERNAL

EARTHING

HARDWARE

EXTERNAL

EARTHING

HARDWARE

SCREW

(2 PER COVER)

FRONT VIEW SIDE VIEW

TRANSFORMER

JM8

JM7

JM4

JM5

JM2

1 JM

Figure B-2. Heater Power Supply, Interior

TERMINAL STRIP (FROM ELECTRONICS)

TERMINAL STRIP (FROM PROBE)

P00002B

Table B-1. Specifications for Heater Power Supply

Power Supply .............................................................................. 110/115/220 VAC ± 10% at 50/60 Hz

Power Requirement .................................................................... 200 VA

Humidity Range........................................................................... 95% Relative Humidity

Ambient Temperature Range...................................................... 0° to 60°C (32° to 140°F)

Vibration ...................................................................................... 5 m/sec

, 10 to 500 xyz plane

External Electrical Noise ............................................................. Minimum Interference

Installation Category (Overvoltage Category)............................. IEC 664 Category II

Cabling Distance Between HPS 3000 and Probe....................... Maximum 45 m (150 ft)

Cabling Distance Between HPS 3000 and CRE 3000................ Maximum 364 m (1200 ft)

Cabling Distance Between HPS 3000 and IFT 3000.................. Maximum 364 m (1200 ft)

Approximate Shipping Weight..................................................... 20 kg (44 lbs)

B-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

LINE

RELAY

TRIAC

TRANSFORMER

ZERO

CROSSING

DETECTOR

Instruction Manual

Appendix BX Rev. 1.2

January 1997

TRIACRELAY

TO HEATER

FROM

IFT OR

CRE

AD590

PROBE TC

STACK TC

CELL MV

COLD

JUNCTION

TEMP.

Figure B-3. Heater Power Supply Block Diagram

The standard cable, between probe and HPS, is thermocouple compensated. This prevents the additional junctions between thermocouple and cablefrom producing a voltage which would affect the thermocouple output signal. A temperature sensor in the HPS monitors the temperature at the junction and sends a voltage signal to the CRE and IFT. The CRE and IFT uses this signal to compensate the probe thermocouple reading for the temperature at the junction between the compensated and uncompensated cables.

In operation, when connected to the CRE 3000 Control Room Electronics, line voltage passes through the relay (when on) and is converted into 44 volts by the transformer. If the probe thermocouple indicates that the probe has dropped below operating temperature, a signal from the CRE triggers the triac. The triac then supplies voltage to the probe heater, warming the cell. Conversely, if the probe thermocouple indicates that the probe heater has reached the upper limit of operating temperature, the CRE deactivates the triac, shutting off power to the heater.

B-3 CONNECTIONS TO NEW GENERATION

ELECTRONICS (IFT 3000 AND CRE 3000)

Use the following information about input and output connections if your system includes CENELEC approved new generation electronics.

PROBE TC

STACK TC

CELL

a. Probe Thermocouple

PBTC+ and PBTC- (J3 pins 4 and 5, J8 pins 3 and 4). This thermocouple provides feedback from the probe heater to the electronics.

b. Stack Thermocouple (Optional)

STTC+ and STTC- (J2 pins 1 and 2, J9 pins 5 and 6). The stack thermocouple is a thermocouple separate from the CENELEC approved World Class 3000 Probe. It is used to measure stack temperature.

c. AD590

AD590+ and AD590- (J8 pin 5, J8 pin 6). The AD590 is a temperature measuring device used to measure temperature inside the CENELEC approved Heater Power Supply HPS 3000.

d. Zirconium Cell

PBMV+ and PBMV- (J3 pins 1 and 2, J8 pins 1 and 2). The voltage signal from the zirconium cell.

e. Probe Heater

44 Vac output (J2 pins 4, 5, and 6). The 44 Vac output to power the probe heater.

TO PROBE

730004

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-3

Instruction Manual

Appendix BX Rev. 1.2 January 1997

World Class 3000

f. TRIAC

TRIAC+ and TRIAC- (J9 pins 1 and 2). The signal by which the new generation electronics controls the triac of Heater Power Supply HPS 3000. By controlling this triac, the new generation electronics modulates the 44 V waveform to the probe heater.

g. Relay

Relay+ and Relay- (J9 pins 3 and 4). By activating or deactivating this relay, the new generation electronics can switch off or switch on the 44 Vac from the Heater Power Supply HPS 3000 to the probe heater. This feature is jumper selectable (JM2).

h. Line Voltage

(J1 pins 1, 2, and 3). Jumper selectable (JM1, JM4, and JM5) for 120 Vac or 220/240 Vac.

i. Shield (Cable Armour)

a. Probe Thermocouple

PBTC+ and PBTC- (J3 pins 4 and 5, J8 pins 3 and 4). This thermocouple provides feedback from the probe heater to the electronics.

b. Stack Thermocouple

(Optional) STTC+ and STTC- (J2 pins 1 and 2, J9 pins 5 and 6). The stack thermocouple is a thermocouple separate from the WC3000 probe. It is used to measure stack temperature.

c. Zirconium Cell

PBMV+ and PBMV- (J3 pins 1 and 2, J8 pins 1 and 2). The voltage signal from the zirconium cell.

d. Probe Heater

44 Vac out (J2 pins 4, 5, and 6). This is the 44 Vac output to power the probe heater.

The cable armour, as well as providing mechanical protection, acts as a shield. This shield is directly connected to the Heater Power Supply HPS 3000 housing through the cable gland.

NOTE

When using the HPS 3000 with an existing electronics package, such as Models 218, 218A, or 225, the electronics will not have the input/output capacity to support all of the functions mentioned in this section. Refer to Instruction Bulletin IB-106-300NEX.

B-4 CONNECTION TO OLD GENERATION

ELECTRONICS

Use the following information about input and output connections if your system does not include CENELEC approved new generation digital electronics:

e. Line Voltage Pins

This is a modulated 115 Vac from the old generation electronics. Bridge rectifier (BR1) converts this modulated 115 Vac to the TRIAC+ and TRIAC- low voltage signal. This signal controls the triac of the Heater Power Supply HPS 3000. A modulated 44 Vac is thus sent to the probe heater.

f. Shield (Optional)

(J8 pin 7.) The PBMV+/PBMV- and the PBTC+/PBTC- lines to the old generation electronics may be shielded against electrical noise through these connections.

g. Shield (Cable Armour)

The cable armour, as well as providing mechanical protection, acts as a shield. This shield is directly connected to the Heater Power Supply HPS 3000 housing through the cable gland.

B-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

Appendix BX Rev. 1.2

January 1997

TROUBLESHOOTING

B-5 OVERVIEW

Before carrying out any work on the CENELEC approved HPS 3000, consult Safety Data Sheet 1M03243.

Install all protective equipment covers and safety ground leads after troubleshooting. Failure to replace covers and ground leads could result in serious injury or death.

The HPS 3000 troubleshooting section describes how to identify and isolate faults which may develop in the HPS 3000 assembly.

B-6 HPS 3000 TROUBLESHOOTING

The HPS 3000 troubleshooting may overlap with the probe in use in the system. Faults in either system may cause an error to be displayed in the electronics package. Figure B-4 and Figure B-5 provide troubleshooting information.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-5

Instruction Manual

Appendix BX Rev. 1.2 January 1997

SYMPTOM

World Class 3000

HEATER DOES NOT HEAT UP (DOES NOT INCREASE IN OUTPUT).

SET METER* FOR 50 VAC. PLACE PROBES ON TERMINAL BLOCK J2, “FROM PROBE”, PROBE HEATER.

METER INDICATES PULSATING NOMINAL 44 VAC.

YES

DISCONNECT POWER FROM HPS & PROBE ELECT. SET METER ON RX1.

MEASURE RESISTANCE OF HEATER BY PLACING PROBES ON TERMINAL BLOCK J2, “FROM PROBE”, PROBE HEATER.

SET METER TO 250 VAC. PLACE METER PROBES ON J9, “FROM ELECTRONICS”, ANALOG HEATER.

METER SHOULD REGISTER A PULSATING NOMINAL 115 VAC.

YES

DISCONNECT POWER TO HPS AND PROBE ELECTRONICS. CHECK ALL FOUR FUSES IN HPS.

FUSES BLOWN IN HPS.

YES YES

CHECK THAT LINE VOLTAGE IS CORRECT BY SELECTING CORRECT JUMPERS ACCORDING TO CHART ON INSIDE OF HPS COVER.

CHECK FUSES IN PROBE ELECTRONICS.

IF FUSES OK, POSSIBLE PROBE ELECTRONICS TRIAC FAILURE.

CHECK JUMPER JM2 IS INSTALLED.

POSSIBLE TRIAC FAILURE. REPLACE HPS MOTHERBOARD.

RESISTANCE MEASURED SHOULD BE NOMINALLY 12 OHMS.

*SIMPSON MODEL 260 OR EQUIVALENT MULTIMETER.

REPLACE BLOWN FUSES.

HEATER IS OPEN. REPLACE HEATER.

34990015

Figure B-4. HPS Troubleshooting Flowchart, #1

B-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

SYMPTOM

HEATER OVERHEATS. NOTE: ON INITIAL STARTUP THE

TEMPERATURE OF THE PROBE MAY OVERHEAT TO A NOMINAL TEMP OF 800°C(480°F).

Instruction Manual

Appendix BX Rev. 1.2

January 1997

CHECK IF THE YELLOW WIRE IS CONNECTED TO POSITIVE AND THE RED TO NEGATIVE ON BOTH “FROM ELECTRONICS” AND “FROM PROBE” TERMINAL BLOCKS. (MODELS 218 AND 225 ONLY)

YES

SET METER* ON 250 VAC SCALE.

CHECK “FROM ELECTRONIC”, ANALOG HEATER TERMINALS IF THERE IS A PULSATING NOMINAL 115 VAC ON J9.

YES

SET METER* ON 50 VAC SCALE.

CONNECT THE WIRING ACCORDING TO THE DECALS ON THE TERMINAL COVERS.

IF THE VOLTAGE IS CONSTANTLY ON, THEN THE TRIAC IN THE PROBE ELECTRONICS IS SHORTED.

CHECK “FROM PROBE”, TERMINALS AT PROBE HEATER IF THERE IS A PULSATING NOMINAL 44 VOLTS ON J2.

YES

CHECK PROBE ELECTRONICS SETPOINT HAS BEEN CHANGED ACCORDING TO APPLICABLE ELECTRONICS PACKAGE IB.

YES

CHECK IF PROBE HEATER VOLTAGE SELECTION JUMPER JM7 INSTALLED (REMOVE JM8).

*SIMPSON MODEL 260 OR EQUIVALENT MULTIMETER.

IF THE VOLTAGE IS CONSTANTLY ON, THEN THE TRIAC MODULE IN THE HPS IS SHORTED.

34990014

Figure B-5. HPS Troubleshooting Flowchart, #2

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-7

Instruction Manual

Appendix BX Rev. 1.2 January 1997

MAINTENANCE AND SERVICE

Consult Safety Data Sheet 1M03243 before performing any work on the CENELEC approved HPS 3000.

Install all protective equipment covers and safety ground leads after equipment repair or service. Failure to install covers and ground leads could result in serious injury or death.

B-7 OVERVIEW

This section describes service and routine maintenance of the HPS 3000 Heater Power Supply Field Module. Replacement parts referred to are available from Rosemount. Refer to Replacement Parts of this appendix for part numbers and ordering information.

World Class 3000

b. Loosen setscrew (13, Figure B-6) retaining

HPS cover (14). Remove HPS cover.

c. Remove hex nut (2), flat washer (3), and

hex head bolt (4) that retain transformer to mounting bracket.

d. Disconnect the 6-pin transformer wiring

harness connector from J7 on the HPS motherboard (25). Disconnect the 2-pin wiring harness connector from the jumper that was selected to configure the HPS for the proper voltage.

NOTE

The transformer connector is keyed making connection possible in only one direction.

e. Remove old toroidal transformer (11). Place

new transformer in position and reconnect wiring harness connectors as noted in step d.

B-8 FUSE REPLACEMENT

The heater power supply's motherboard (25, Figure B-6) contains four identical 5 amp fuses (24) (5 amp anti-surge, Type T to IEC127, ROSEMOUNT Part No. IL01293H02). To check or replace a fuse, simply unscrew the fuse holder cap (23) with a flat head screwdriver and remove fuse. After checking or replacing a fuse, reinstall fuse holder cap.

B-9 TRANSFORMER REPLACEMENT

Consult Safety Data Sheet 1M03243 before performing any work on the CENELEC approved HPS 3000.

a. Follow the power down procedure outlined

in safety data sheet 1M03243 and the official "Codes of Practice" for your country of installation.

f. Place insulating disc (10) (one on either

side of transformer) and metal disc (12) on transformer.

g. Tighten hex nut (2) and hex head bolt (4)

only enough to firmly hold transformer in place.

h. Reinstall HPS cover (14) and secure with

setscrew (13).

B-10 MOTHERBOARD REPLACEMENT.

Consult Safety Data Sheet 1M03243 before performing any work on the CENELEC approved HPS 3000.

a. Follow the power down procedure outlined

in safety data sheet 1M03243 and the official "Codes of Practice" for your country of installation.

B-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

Appendix BX Rev. 1.2

January 1997

NOTE:

NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASE SEPARATELY. FOR A LIST OF AVAILABLE PARTS, SEE TABLE B-2.

2 3

1. HPS Housing

2. Hex Nut

3. Flat Washer

4. Hex Head Bolt

5. Transformer Mounting Bracket

6. Screw

7. Lockwasher

8. Flat Washer

9. Hex Standoff

10. Insulating Disc

11. Toroidal Transformer

12. Metal Disc

2-PIN CONNECTOR

6-PIN CONNECTOR

13. Setscrew

14. HPS Cover

15. O-Ring Seal

16. Slotted Screw

17. Lockwasher

18. Flat Washer

19. Terminal Strip Cover (Probe)

20. Terminal Strip Cover (Electronics)

21. HPS Daughterboard PCB

22. Hex Stand Off

23. Fuse Holder Cap

24. Fuse

25. HPS Motherboard PCB

26. Hex Nut

27. Hex Standoff

28. Earthing Hardware

P00007

Figure B-6. Heater Power Supply, Exploded View

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-9

Instruction Manual

Appendix BX Rev. 1.2 January 1997

World Class 3000

b. Loosen setscrew (13) retaining HPS cover

(14). Remove cover.

c. Disconnect transformer wiring harness con-

nectors as described in the previous paragraph from motherboard (25).

d. Remove slotted screw (16), lockwasher

(17), and flat washer (18) attaching terminal strip covers (19) and (20). Remove terminal strip covers.

e. Unplug ribbon cable from the receptacle on

the daughterboard (21). Take note of location of black and white wires connected to pin 8 and pin 9 of terminal strip J8. Disconnect these wires from J8.

f. Unscrew stand offs (22) on either side of

the daughterboard. Remove daughterboard (21).

g. Unscrew four stand offs (22) that support

the daughterboard.

h. Making a note of the location and color of

each wire, disconnect wires from terminal strip on HPS motherboard (25).

i. Remove hex nut (26), lockwasher (17), and

flat washer (18) securing the HPS motherboard to the enclosure and transformer mounting bracket (5).

j. Remove motherboard (25).

n. Plug ribbon cable back into receptacle on

daughterboard and reconnect black and white wires. The black wire goes to pin 8 and the white to pin 9 of terminal block J8 on daughter board. Reinstall terminal covers.

o. Reconnect transformer wiring harness con-

nectors to motherboard. Note that in any case, the transformer's connector is keyed so that it can only be inserted one way.

p. Reinstall HPS cover (14) and secure with

setscrew (12).

B-11 DAUGHTERBOARD REPLACEMENT

Consult Safety Data Sheet 1M03243 before performing any work on the CENELEC approved HPS 3000.

a. Follow the power down procedure outlined

in safety data sheet 1M03243 and the official "Codes of Practice" for your country of installation.

b. Loosen setscrew (13, Figure B-6) retaining

HPS cover (14). Remove cover.

c. Remove slotted screw (16), lockwasher

(17), and flat washer (18) securing terminal strip covers (19) and (20). Remove terminal strip covers.

k. Position new motherboard on stand offs and

reinstall hex nut, lockwasher, and flat washer removed in step i.

l. Reconnect wires to terminal strip in posi-

tions noted in step h. Cross check with wiring diagram shown on Figure 2-4 of the main text (IB-106-300NX Series).

m. Reinstall four stand offs removed in step g.

Position daughterboard (21) on stand offs and reinstall stand offs removed in step f.

B-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

d. Making a note of the location and color of

each wire, disconnect wires from the terminal strip on the daughterboard (21).

e. Unplug ribbon cable from receptacle on

daughterboard. Take note of location of black and white wires connected to pin 8 and pin 9 of terminal strip J8. Disconnect these wires from J8.

f. Unscrew two stand offs (22) from daughter-

board. Remove daughterboard (21).

World Class 3000

Instruction Manual

Appendix BX Rev. 1.2

January 1997

g. Position new daughterboard on four stand

offs (22) on motherboard (25). Reinstall the stand offs removed in step f.

h. Plug ribbon cable back into receptacle on

daughterboard and reconnect black and white wires. The black wire goes to pin 8 and the white wire to pin 9 of terminal block J8 on daughterboard. Reinstall terminal covers.

i. Reconnect wires to terminal strip in posi-

tions noted in step d. Cross check with wiring diagram shown on Figure 2-4 of the main text (IB-106-300NX Series). Reinstall terminal covers.

j. Reinstall HPS cover (14) and secure with

setscrew (13).

REPLACEMENT PARTS

Table B-2. Replacement Parts for Heater Power Supply

FIGURE and

INDEX No.

B-1 1U05667G01 CENELEC HPS 3000 (120V) B-1 1U05667G03 CENELEC HPS 3000 (220V/240V)

B-6, 24 1L01293H02 Fuse 5A @ 250 Vac, anti-surge, case size; 5 x 20 mm, type T

B-6, 25 3D39080G02 Motherboard B-6, 21 3D39078G01 Daughterboard B-6, 11 1M02961G05 Toroidal Transformer (120V/240V)

PART

NUMBER DESCRIPTION

to IEC127, Schurter

IB-106-300NEX Instruction Bulletin Upgrade and Digital Electronics IB-106-300NFX Instruction Bulletin (IFT) IB-106-300NCX Instruction Bulletin (CRE)

NOTE

The replacement parts listed above must be obtained only from the manufacturer or his agent.

Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-11

Instruction Manual

Appendix BX Rev. 1.2 January 1997

World Class 3000

B-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management

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

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

SAFETY INSTRUCTIONS

DESCRIPTION

INSTALLATION

2-3 HEATER POWER SUPPLY INSTALLATION

SETUP AND OPERATION

3-4 STATUS LINE

3-5 QUICK REFERENCE CHART

3-6 MAIN MENU

3-7 PROBE DATA SUB-MENU

LDP OPERATION

4-3 LDP DISPLAYS

4-4 LDP DEFAULTS

TROUBLESHOOTING

5-2 SPECIAL TROUBLESHOOTING NOTES

RETURN OF MATERIAL

APPENDICES