Rosemount World Class 3000 O2 Analyzer DR Direct Replacement Probe-Rev 3.3 Manuals & Guides

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Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

Oxygen Analyzer Direct Replacement Probe for use with Existing Signal Conditioning Electronics

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, 1996 Rev. 3

Page Summary

--- General. Updated text and illustrations to reflect probe design changes.

Page 1-15 Added “Extended temperature by-pass arrangements” to Figure 1-15,

sheet 3 of 3.

Effective December, 1996 Rev. 3.1

Page Summary

Page P-2 Added "Safety instructions for the wiring and installation of this

apparatus".

Page 1-4 Corrected Figure 1-3 item listing.

Page 2-1 Added one WARNING to read new safety instructions and another

WARNING regarding protective covers and grounds.

Page 3-1 Added WARNING regarding protective covers and grounds.

Page 4-1 Added WARNING regarding protective covers and grounds.

Page 4-6 Added title block to Figure 4-6.

Page 5-1 Added WARNING regarding protective covers and grounds.

Page 7-1 Corrected cell replacement kit part numbers in Table 7-1.

Page 7-2 Corrected cell replacement kit part number in Table 7-1.

Effective May, 1997 Rev. 3.2

Page Summary

Page P-2 Added safety sheet.

Effective February, 1998 Rev. 3.3

Page Summary

Page 2-2 Figure 2-1. Changed calibration gas tube dimensions.

World Class 3000

PREFACE.........................................................................................................................P1

Definitions ......................................................................................................................... P1

Safety Instructions ........................................................................................................... P2

1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1

1-1 Component Checklist ..................................................................................................... 1-1

1-2 System Overview............................................................................................................ 1-1

1-3 Physical Description ....................................................................................................... 1-3

1-4 Probe Exterior................................................................................................................. 1-5

1-5 Probe Interior .................................................................................................................. 1-7

1-6 Junction Box .................................................................................................................... 1-8

1-7 Cable Assembly...............................................................................................................1-9

1-8 Probe Options................................................................................................................. 1-9

2-0 INSTALLATION .............................................................................................................. 2-1

2-1 Locating The Oxygen Analyzer Probe.......................................................................... 2-1

2-2 Service Required .............................................................................................................2-1

2-3 Mechanical Installation ................................................................................................... 2-6

2-4 Electrical Installation ........................................................................................................ 2-7

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

3-0 STARTUP........................................................................................................................ 3-1

3-1 Overview.......................................................................................................................... 3-1

3-2 Models 218, 225, And 132 (Analog) Electronics Setup............................................. 3-1

3-3 Model 218A Electronics Setup ..................................................................................... 3-2

3-4 Model TC200 Veritrim Electronics Setup ..................................................................... 3-3

3-5 Model 132 Digital Electronics Setup............................................................................ 3-4

3-6 The Yokogawa ZA8C And AV8C Converter Electronics Setup ................................ 3-4

4-0 MAINTENANCE AND SERVICE .................................................................................. 4-1

4-1 Overview.......................................................................................................................... 4-1

4-2 Probe Calibration ............................................................................................................. 4-1

4-3 Cell Replacement ........................................................................................................... 4-1

4-4 Optional Ceramic Diffusion Element Replacement ..................................................... 4-3

4-5 Replacement Of Contact And Thermocouple Assembly ............................................. 4-5

4-6 Replacement Of Heater, V-Strut And Backplate Assembly ..................................... 4-7

4-7 Calibration And Reference Gas Lines For High Temperature -

Corrosive Environment Operation ................................................................................... 4-9

5-0 TROUBLESHOOTING .................................................................................................... 5-1

5-1 Overview.......................................................................................................................... 5-1

5-2 Probe Troubleshooting ................................................................................................... 5-1

6-0 RETURN OF MATERIAL .............................................................................................. 6-1

7-0 REPLACEMENT PARTS ................................................................................................ 7-1

8-0 INDEX.............................................................................................................................. 8-1

Rosemount Analytical Inc. A Division of Emerson Process Management i

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

Figure 1-1. Typical System Package ....................................................................................... 1-1

Figure 1-2. Typical System Installation .................................................................................... 1-3

Figure 1-3. Oxygen Analyzer Probe - Exploded View.............................................................. 1-4

Figure 1-4. Main Probe Components ....................................................................................... 1-5

Figure 1-5. Cell and Tube Assemblies ..................................................................................... 1-5

Figure 1-6. Optional Ceramic Diffusor and Vee Deflector Assembly....................................... 1-7

Figure 1-7. Inner Probe Assembly............................................................................................ 1-8

Figure 1-8. Junction Box .......................................................................................................... 1-8

Figure 1-9. Abrasive Shield Assembly ................................................................................... 1-10

Figure 1-10. Ceramic Diffusion/Dust Seal Assembly ............................................................... 1-11

Figure 1-11. Flame Arrestor Diffusion/Dust Seal Assembly..................................................... 1-11

Figure 1-12. Ceramic Diffusion Assembly................................................................................ 1-11

Figure 1-13. Flame Arrestor Diffusion Assembly ..................................................................... 1-11

Figure 1-14. Snubber Diffusion/Dust Seal Assembly............................................................... 1-12

Figure 1-15. Bypass Probe Option (Sheet 1 of 3) .................................................................... 1-13

Figure 2-1. Probe Installation (Sheet 1 of 5) ............................................................................ 2-2

Figure 2-2. Orienting the Optional Vee Deflector ..................................................................... 2-7

Figure 2-3. Wiring the Direct Replacement Probe ................................................................... 2-8

Figure 3-1. Temperature Controller Card Calibration Points ................................................... 3-1

Figure 3-2. Main PCB (Model 218A) EPROM Replacement ................................................... 3-2

Figure 3-3. Main PCB (Model TC200) EPROM Replacement ................................................. 3-3

Figure 3-4. Main PCB (Model 132) EPROM Replacement...................................................... 3-4

Figure 3-5. DR Probe Wired to the ZA8C or A V8C Converter ................................................ 3-5

Figure 4-1. Cell Wiring Connection .......................................................................................... 4-2

Figure 4-2. Removal of Optional Ceramic Diffusor and Vee Deflector .................................... 4-3

Figure 4-3. Cell Replacement Kit ............................................................................................. 4-3

Figure 4-4. Junction Box Mechanical Connections.................................................................. 4-5

Figure 4-5. Inner Probe Replacement (Heater, V-Strut, and Backplate Assembly)................ 4-6

Figure 4-6. Heater, Strut, and Backplate Assembly (Inner Probe Assembly).......................... 4-6

Figure 4-7. Oxygen Analyzer Probe, Cross-Sectional View .................................................... 4-8

Figure 4-8. High Temperature – Corrosive Environment Kit .................................................... 4-9

World Class 3000

LIST OF ILLUSTRATIONS

LIST OF TABLES

Table 1-1. Specifications for Oxygen Analyzing Equipment

Table 5-1. Fault Finding .......................................................................................................... 5-2

Table 7-1. Replacement Parts for Probe ................................................................................ 7-1

ii Rosemount Analytical Inc. A Division of Emerson Process Management

1 2

............................................... 1-6

World Class 3000

The World Class 3000 Direct Replacement Probe can be used with any of the following model electronics: 218, 225, 218A, ZA8C, and TC200. Read the appropriate setpoint adjustment in this manual to prevent damage to the probe.

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of this particular probe.

Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

CAUTION

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.

NOTE

Highlights an essential operating procedure, condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

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 TO USERS

The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

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

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

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

DESCRIPTION AND SPECIFICATIONS

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

SECTION 1

1-1 COMPONENT CHECKLIST

The Direct Replacement (DR) Probe package of the World Class 3000 Oxygen Analyzer typically includes the probe, the instruction bulletin, and the mounting hardware. These three items are shown in Figure 1-1. Record the Part Number, Serial Number, and Order Number of your system on the first page of this manual.

1-2 SYSTEM OVERVIEW

a. Scope

This Instruction Bulletin has been designed to supply details needed to install, start up, and troubleshoot the Rosemount World Class 3000 Oxygen Analyzer. The Direct

Replacement Probe can be interfaced to a number of different and earlier model electronics packages. These electronic packages are not covered in this manual. For specific information concerning calibration and operation of the system, refer to the Instruction Bulletin applicable to your electronics package.

b. System Function

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. The sampling system is in situ rather than extractive.

1. Oxygen Analyzer Probe

2. Mounting Adapter Plate with Mounting Hardware and Gasket

3. Instruction Bulletin

19290001

Figure 1-1. Typical System Package

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

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 sensor cell is given by the following Nernst equation:

EMF = KT log

10(P1/P2

) + C

Where:

1. P

is the partial pressure of the oxygen

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.

NOTE

For best results, use clean, dry, instrument air (20.95% oxygen) as a reference gas.

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 DR probe is similar to the Exchange Probe (NE model) except that the DR uses a 115 V heater like most older systems. The DR does not require a separate power supply as does the NE. The DR probe (like the NE) is available in five lengths. The length of stack penetration depends on the size of the stack or duct. The length options are 18 in., 3 ft, 6 ft, 9 ft, and 12 ft (457 mm, 0.9 m, 1.8 m, 2.7 m, and 3.7 m).

d. Features

1. Output voltage and sensitivity increase as the oxygen concentration decreases.

When the cell is at operating temperature, oxygen ions will travel through the cell from high to low oxygen partial pressures. The resulting output voltage is about 50 mV per decade. The voltage varies with the ratio of oxygen partial pressures of the reference gas over the sample gas. Thus, the output signal increases as the sample oxygen level decreases. This property gives the analyzer high sensitivity at low oxygen levels.

Oxygen analyzer equipment measures net oxygen concentration in the presence of all the products of combustion, including water

2. In situ, non-sampling analyzer.

3. Field replaceable cell.

4. Analyzer constructed of rugged 316 LSS for all wetted parts.

5. Suitable for use in temperatures up to 1300°F (700°C).

6. The DR probe uses a 115 V heater and does not require a separate heater power supply.

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

e. Handling the Oxygen Analyzer

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

GASES

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.

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

Prior to installation of your Rosemount World Class 3000 Oxygen Analyzer, make sure you have all of the components necessary to make the system installation. Ensure all components are properly integrated to make the system functional.

STACK

CALIBRATION

INSTRUMENT

AIR SUPPLY

(REF. GAS)

GAS

PRESSURE

REGULATOR

FLOWMETER

EXISTING

ELECTRONICS

Figure 1-2. Typical System Installation

connecting test gas tanks to the oxygen analyzer when the probe is to be calibrated.

NOTE

Ambient air is not recommended for use as high test gas. An 8% O balance in nitrogen is recommended for high test gas.

DUCT

ADAPTER

OXYGEN

ANALYZER

(PROBE)

PLATE

VOLTAGE

19290002

LINE

Once you have verified 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 installation is illustrated in Figure 1-2.

If test gas bottles will be hooked up permanently, an optional check valve is recommended next to the calibration fittings on the probe head. This is to prevent breathing of calibration gas line and subsequent flue 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. After selecting the probe mounting location, provision should be made for a platform

1-3 PHYSICAL DESCRIPTION

where the probe can be easily serviced.

The Oxygen Analyzer Probe, Figure 1-3 conA source of instrument air is required at the probe for reference gas use. Since the

sists of three component groups: probe exterior,

inner probe, and junction box, Figure 1-4. probe is equipped with an in place calibration feature, provision should be made for

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FOR

PURCHASE SEPARATELY. FOR LIST OF AVAILABLE PARTS, SEE TABLE 7-1.

World Class 3000

NOTE: ITEM , CALIBRATION GAS TUBE,

FITS INTO HOLES WHEN PROBE IS

ASSEMBLED.

1. Heater, Strut, and Backplate 11. Probe Junction Box Cover 22. Gas Connection Assembly 12. Cover Gasket 23. Seal Cap

2. Diffusion Assembly 13. Insulating Sheet 24. Label

3. Retainer Screw 14. O-Ring 25. Probe Junction Box

4. Cell and Flange 15. Terminal Block Screw 26. Ground Wires

5. Corrugated Seal 16. Terminal Block 27. Insulating Gasket

6. Probe Tube Assembly 17. Terminal Block Marker 28. Washer

7. Cover Screw 18. Terminal Block Mounting Plate 29. Screw

8. Washer 19. Probe Junction Box Screws 30. Tag

9. Cover Chain Screw 20. Hose Clamp

10. Cover Chain 21. Hose

35900002

Figure 1-3. Oxygen Analyzer Probe - Exploded View

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

PROBE EXTERIOR (SENSING CELL INSTALLED)

PROBE INTERIOR

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

PROBE

JUNCTION

BOX

Figure 1-4. Main Probe Components

1-4 PROBE EXTERIOR

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

a. Cell and Flange Assembly

The primary component in the cell and flange assembly, Figure 1-5, is a yttria-stabilized zirconium oxide cell. The cell creates an electrical signal when the oxygen 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

21240006

The tube assembly includes a flange which mates with a stack-mounted flange (shown attached to the probe flange in Figure 1-4). Studs on the stack flange make installation easy. There is also a tube to carry calibration gas from the junction box to the process side of the cell during calibration.

PROBE TUBE

CORRUGATED

SEAL

CELL AND

FLANGE

ASSEMBLY

Four screws secure the cell and flange assembly, Figure 1-5, to the probe tube assembly. When in place, the cell is inside the tube.

21240007

Figure 1-5. Cell and Tube Assemblies

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

Table 1-1. Specifications for Oxygen Analyzing Equipment

1 2

Probe lengths, nominal ...................................................................... 18 in. (457 mm), 3 ft (0.91 m),

6 ft (1.83 m), 9 ft (2.74 m), or 12 ft (3.66 m), depending on duct dimensions

Temperature limits in process

measurement area ....................................................................... 50° to 1300°F (10° to 704°C)

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

indication (Digital display

and analog output)........................................................................ 0.1% O

or ±3% of reading, whichever is greater

using Rosemount test gases

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

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

transmitted signal

Probe reference air flow .................................................................... 2 scfh (56.6 L/hr) clean, dry, instrument

quality air (20.95% O

), regulated to

5 psi (34 kPa)

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

6296A27G01 contains 0.4% O

and 8% O

Nominal

2N2

Nominal

2N2

Calibration gas flow ........................................................................... 5 scfh (141.6 L/hr)

Power supply ..................................................................................... 115 ±10% Vac at 50/60 Hz

Power requirement ............................................................................ 200 VA

Ambient operating temperature (Junction Box)................................. 300°F (149°C) [160°F (71°C) max for YEW

replacement] Approximate shipping weights:

18 in. (457 mm) package ....................................................... 55 lbs (24.97 kg)

3 ft (0.91 m) package ............................................................. 60 lbs (27.24 kg)

6 ft (1.83 m) package ............................................................. 65 lbs (29.51 kg)

9 ft (2.74 m) package ............................................................. 72 lbs (32.66 kg)

12 ft (3.66 m) package ........................................................... 78 lbs (35.38 kg)

All static performance characteristics are with operating variables constant.

Equipment ordered utilizing this document as reference will be supplied to the USA standard design. Customers requiring the EEC standard design should request the EEC documentation and utilize its ordering data. Temperatures over 1000°F (537°C) may affect the ease of field cell replaceability.

c. Snubber Diffusion Assembly

The snubber diffusion assembly protects the cell from heavy particles and isolates the cell from changes in temperature. The snubber assembly threads onto the cell and flange assembly. Pin spanner wrenches

An optional ceramic diffusor element and vee deflector shown in Figure 1-6, is available. The ceramic diffusor assembly is also available in a flame arresting version to keep heat from the cell from igniting flue gases.

(probe disassembly kit 3535B42G01) are applied to holes in the diffusion element hub to remove or install the snubber assembly.

1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

is noted in the calibration data sheet supplied with each probe.

DIFFUSION

ELEMENT

HUB

WRENCH

VEE

DEFLECTOR

21240024

Figure 1-6. Optional Ceramic Diffusor and Vee

Deflector Assembly

Systems that use an abrasive shield require a special diffusor assembly with a hub that is grooved to accept two dust seal gaskets. This special diffusor is available in both snubber and ceramic versions. See Probe Options, paragraph 1-8.

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.

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

There are two styles of the heater/strut inner probe assembly. P/Ns 3D39441G06 through G10 identify the 44 V heater design. P/Ns 3D39441G01 through G05 and G11 through G15 identify the 115 V heater design. Both styles look the same. When replacing a strut, be sure the replacement has the same part number as the original. A stainless steel tag is attached to the inner probe assembly to identify the 115V design. Operating a probe on the wrong heater voltage can cause injury or severe damage to equipment.

1-5 PROBE INTERIOR

The inner probe assembly, Figure 1-7, 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.

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

c. A chromel-alumel thermocouple which acts

as the sensing element for the temperature controller. (Not visible in Figure 1-7; located within ceramic support rod.)

carefully.

d. A platinum screen pad which forms electri-

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 and +15 mV. The cell constant

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7

cal contact with the inner electrode of the electrochemical cell. (Not visible in Figure 1-7; located at end of ceramic support rod.) The pad is attached to an inconel/stainless steel wire which carries the signal to the terminal strip.

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

inner probe assembly.

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

HEATER

INSULATING

GASKET

V-STRUT

CERAMIC SUPPORT

ROD

Figure 1-7. Inner Probe Assembly

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

Refer to Section 4, Maintenance and Service, for repair procedures for probe components.

1-6 JUNCTION BOX

The junction box, Figure 1-8, 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 on American units, and 6 mm tubing on European units. 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, a manual block valve is required at the probe (between the calibration fitting and the gas line) to prevent condensation of flue gas down the calibration gas line.

During operation and calibration, reference gas is supplied through the reference gas fitting to the reference side of the cell. This gives the

REFERENCE

GAS TUBE

TAG

21220004

PROBE

JUNCTION BOX

COVER

TERMINAL

STRIP

CALIBRATION

GAS FITTING

REFERENCE GAS FITTING

21240029

Figure 1-8. Junction Box

system a known quantity of oxygen with which to compare the oxygen level in the process gas. Though ambient air can be used for this purpose, accuracy can only be assured if a reference gas air set is used.

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.

1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

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

1-7 CABLE ASSEMBLY

The Westinghouse and Rosemount systems use a 7-conductor cable to connect the probe to the electronics package. Standard length for this cable is 20 ft (6 m), but lengths up to 150 ft (45 m) are available. The seven conductors include one shielded pair of wires for the cell millivolt signal, one shielded pair of type K wires for the thermocouple, and three individual 16-gauge wires for the heater and for ground. The assembled conductors are wrapped by a

Teflon

jacket and braided stainless steel

Instruction Manual

IB-106-300DR Rev. 3.3

shield. The Teflon ing is suitable for high temperature use. All metal shields are isolated at the probe end and connect by drain wires to ground at the electronics.

1-8 PROBE OPTIONS

a. Abrasive Shield Assembly

The abrasive shield assembly, Figure 1-9, is a stainless-steel 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 diffusion and vee deflector assembly fitted with dual dust seal packing.

and stainless steel jacket-

February 2000

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-9

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

0.187

03.584

03.554

ON INSIDE BREAK FOR SMOOTH

0.45 MIN

125

SKIN CUT FACE FOR 90

ROUNDED EDGE ON BOTH ENDS OF CHAMFER.

6.00

0.187

NOTES:

VIEW A

0.75 THRU 4 PLS.

EQ SP ON 4.75 B.C.

WELD ON BOTH SIDES WITH EXPANDING CHILL BLOCK.

BEFORE WELDING, BUTT ITEM 2 WITH ITEM 1 AS SHOWN.

Figure 1-9. Abrasive Shield Assembly

VIEW B

22.5

0.745 DIA ON A 7.50 DIA B.C. (REF)

0.755

P0009

1-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

P0010

Figure 1-10. Ceramic Diffusion/Dust Seal

Assembly

These modified diffusion and vee deflector assemblies are available in standard, Figure 1-10, and flame arrestor version, Figure 1-11.

b. Ceramic Diffusion Assembly

The ceramic diffusion assembly, Figure 1-12, is the traditional design for the probe. Used for over 25 years, the ceramic diffusion assembly provides a greater filter surface area for the probe.

19280010

Figure 1-12. Ceramic Diffusion Assembly

c. Flame Arrestor Diffusion Assembly

Where a high concentration of unburned fuel is present in the exhaust gases, a flame arrestor diffusion assembly, Figure 1-11 and Figure 1-13 is recommended.

The flame diffusion assembly includes a set of baffles between the cell and the stack gases. This keeps 1500°F (816°C) cell temperatures from igniting unburned fuel in the stack.

P0011

P0012

Figure 1-13. Flame Arrestor Diffusion Assembly

Figure 1-11. Flame Arrestor Diffusion/Dust Seal

Assembly

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-11

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

P0014

Figure 1-14. Snubber Diffusion/Dust Seal

Assembly

d. Snubber Diffusion/Dust Seal Assembly

The snubber diffusion/dust seal assembly, Figure 1-14, is used in applications where an abrasive shield is to be used with a snubber type diffusion element. The dust seal consists of two rings of packing to prevent abrasive dust from collecting inside the abrasive shield.

World Class 3000

can be employed. The bypass system uses an 18 inch (457 mm) or 3 foot (0.92 m) probe mounted externally on the stack or duct. The process or exhaust gases are directed out to the probe through a passive sampling system using inconel tubes. Flue gas flow induces the movement of gases into, through, and out of the bypass unit. 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 1300°F (704°C) to 2000°F (1094°C). A higher temperature version of the bypass provides for operation at temperatures up to 2500°F (1372°C). In this version the pick up tubes are made of a special high-temperature alloy.

Overall dimensions and mounting details of the American and European bypass systems are shown in Figure 1-15.

f. Probe Mounting Jacket Options

e. Bypass Probe Options

For processes where the flue gas exceeds the maximum allowable temperature of 1300°F (704°C) a bypass sensor package

A probe mounting jacket option is available to allow the probe to operate at temperatures of up to 2000°F (1095°C). A separate instruction bulletin is available for this option.

1-12 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

C).

A - A

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

19290005

OF FLOW

DIRECTION

TO 980

POINT OR

F (650

DEW

Y AIR REQUIRED. FITTING

TO 1800

ARDS DIRECTION ONLY.

AX. CLEAN DR

TION GAS REQUIRED.

AX. CALIBRA

CALIBRATION AND PURGE GAS CONNECTION. BITE TYPE FITTING (PARKER CPI)

REFERENCE AIR SUPPLY CONNECTION BITE TYPE FITTING (PARKER CPI) FOR

NOTES:

10 SCFH AT 32 PSIG M

0.250 O.D. TUBING. 2 SCFH AT 3 PSIG M

IS LOCATED ON FAR SIDE.

TURE RANGE 1200

TURE DOES NOT GO BELOW

PERA

YZER IN A VERTICALLY DOW

ITH ANAL

FLUE GAS OPERATING TEM

LAG TO ENSURE GAS TEM

EXCEED 500

INSTALL W

GROUP NOTE

ARENTHESES.

AL CONDUCTIVITY K

ETERS IN P

TION. THERM

ILLIM

ITH M

O INCH THK INSULA

ENDED TW M

ENSIONS ARE IN INCHES W

RECOM

EQUALS 0.5 FOR INSULATION.

DIM

A 3 FT (914.4) GAS TUBE PICK-UP

B 6 FT (1828.8) GAS TUBE PICK-UP

GASKET AND HARDWARE

FLANGE

CAL

GAS

VIEW

REF

GAS

4.026 (102.26)

04 03 02

I.D.

ELECT CABLE

C 9 FT (2743.2) GAS TUBE PICK-UP

BY CUSTOMER

OPTIONAL MOUNTING

ARRANGEMENT, 4 IN.

150# FLANGE SUPPLIED

HARDWARE

GASKET AND

30.62 (777.75) REF (4507C26G01)

62.50 (1587.5) REF (4507C26G03)

26.50 (673.1) REF (4507C26G01 AND G02)

37.00 (939.8) REF (4507C26G01)

73.00 (1854.2) REF (4507C26G02)

109.00 (2768.6) REF (4507C26G03)

6.0

(152.4) REF

6.50

(165.1) REF

DRAIN

STD 20 FT

(6.1 M) CABLE

FOR

INSERTION

FOR PROBE

27.31 (693.67)

AND REMOVAL

CLEARANCE REQ

3D3947G01

19.80 (502.92) SQUARE TO GAS FLOW.

BE ORIENTED SO THAT VEE SHIELD IS

IF EQUIPPED WITH THE OPTIONAL CERAMIC

DIFFUSOR ASSEMBLY, PROBE ASSEMBLY MUST

Figure 1-15. Bypass Probe Option (Sheet 1 of 3)

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-13

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

POINT OR

DEW

ARDS DIRECTION ONLY.

YZER IN A VERTICALLY DOW

ITH ANAL

ARENTHESES.

ITH MILLIMETERS IN P

GROUP NOTE

A 3 FT (914.4) GAS TUBE PICK-UP

ELECT

B 6 FT (1828.8) GAS TUBE PICK-UP

C 9 FT (2743.2) GAS TUBE PICK-UP

CAL

GAS

CABLE

OMER

REF

GAS

A - A

VIEW

OF FLOW

DIRECTION

I.D.

4.026 (102.26)

19290006

PICKUP (3D390004G07 OR G08)

26.5 (673.1) ON 3 FT (914.4) OR 6 FT (1828.8)

62.5 (1587.5) ON 9 FT (2743.2) PICKUP (3D390004G09)

37.0 (939.8) ON 3 FT (914.4) PICKUP (3D390004G07)

73.0 (1854.2) ON 6 FT (1828.8) PICKUP (3D390004G08)

109.0 (2768.6) ON 9 FT (2743.2) PICKUP (3D390004G09)

CALIBRATION AND PURGE GAS CONNECTION. BITE TYPE FITTING (PARKER CPI)

10 SCFH AT 32 PSIG (220.64 kPa GAUGE) MAX. CALIBRATION GAS REQUIRED.

LAG TO ENSURE GAS TEMPERATURE DOES NOT GO BELOW

REFERENCE AIR SUPPLY CONNECTION BITE TYPE FITTING (PARKER CPI) FOR

0.250 O.D. TUBING. 2 SCFH AT 3 PSIG (20.69 kPa GAUGE) MAX. CLEAN DRY AIR

REQUIRED. FITTING IS LOCATED ON FAR SIDE.

NOTES:

EXCEED 932 F (500 C).

STD CABLE

20 FT (6.1 M)

RECOMMENDED 2.0 INCH (50.8) THK INSULATION. THERMAL CONDUCTIVITY K EQUAL

0.5 FOR INSULATION.

DIMENSIONS ARE IN INCHES W

FLUE GAS OPERATING TEMPERATURE RANGE 1200 TO 1800 F (650 TO 980 C).

INSTALL W

INSERTION

FOR PROBE

27.31 (693.67) CLEARANCE REQ

FLANGE

AND REMOVAL

AND

GASKET

HARDWARE

Figure 1-15. Bypass Probe Option (Sheet 2 of 3)

ELD BY CUST W

FOR

19.80 (502.92)

3D3947G01

PLATE

ELDED W

TO STACK

6.50 (165.1) REF

DRAIN

ITH THE OPTIONAL CERAMIC

SQUARE TO GAS FLOW.

BE ORIENTED SO THAT VEE SHIELD IS

IF EQUIPPED W

DIFFUSOR ASSEMBLY, PROBE ASSEMBLY MUST

1-14 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

PARTS LIST

NOTE DEFINER

ITEM

01 WORLD CLASS

02 GAS PICK-UP DWG

03 GAS PICK-UP DWG

04 GAS PICK-UP DWG

05 ANALYZER

06 MTG HARDWARE DWG

07 MTG HARDWARE DWG

08 MTG HARDWARE DWG

09 ANALYZER

10 ANALYZER

11 GAS PICK-UP DWG

12 GAS PICK-UP DWG

13 GAS PICK-UP DWG

14 GAS PICK-UP DWG

15 GAS PICK-UP DWG

16 GAS PICK-UP DWG

PART NAME

3000

HOUSING

PARTS LIST UNITS: INCHES GROUP NOTE A B C A B C A B C

SIZEREFERENCE INFORMATION

DWG

PROBE 18 IN.

3 FT

6 FT

9 FT

FOR WORLD CLASS

3000 ANSI

FOR ANSI FLANGE

FOR JIS

FOR DIN

FOR JIS

FOR DIN

FOR JIS 3 FT

FOR JIS 6 FT

FOR JIS 9 FT

FOR DIN 3 FT

FOR DIN 6 FT

FOR DIN 9 FT

Instruction Manual

IB-106-300DR Rev. 3.3

FLANGE

STYLE ANSI JIS DIN

MAIL CODE

PART NUMBER

OR REF DWG

ORDER FROM

MATRIX

4507C26G01

4507C26G02

4507C26G03

3D39005G01

3535B58G01

3535B58G03

3535B58G05

3D39005G02

3D39005G03

4507C26G04

4507C26G05

4507C26G06

4507C26G07

4507C26G08

4507C26G09

G01 G02 G03 G04 G05 G06 G07 G08 G09

111

3D39004 GROUP

111

February 2000

111

Extended Temperature By-Pass Arrangements (2400°°°°F; 1300°°°°C)

GROUP

PART NO.

CODE DESCRIPTION

1U0571 G01 3’ By-pass Package with ANSI bolt pattern.

1U0571 G02 6’ By-pass Package with ANSI bolt pattern.

1U0571 G03 9’ By-pass Package with ANSI bolt pattern.

1U0571 G04 3’ By-pass Package with JIS bolt pattern.

1U0571 G05 6’ By-pass Package with JIS bolt pattern.

1U0571 G06 9’ By-pass Package with JIS bolt pattern.

1U0571 G07 3’ By-pass Package with DIN bolt pattern.

1U0571 G08 6’ By-pass Package with DIN bolt pattern.

1U0571 G09 9’ By-pass Package with DIN bolt pattern.

Figure 1-15. Bypass Probe Option (Sheet 3 of 3)

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-15

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

1-16 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Before starting to install this equipment, read the "Safety instructions for the wiring and installation of this apparatus" at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury or death.

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.

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

SECTION 2

INSTALLATION

b. 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).

The junction box temperature must not exceed 300°°°°F (149°°°°C). If used with the Yokogawa ZA8C electronics, junction box temperature is limited to 160°°°°F (71°°°°C). To meet these limits, the user may need to make a heat shield or provide cooling air to the junction box. The temperature limit is due to the thermocouple "cold reference" device.

2-1 LOCATING THE OXYGEN ANALYZER

PROBE

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 50° to 1300°F (10° to 704°C). Figure 2-1 provides mechanical installation references.

a. 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.

2-2 SERVICE REQUIRED

a. Power input: 115 ±10% Vac single phase,

50 to 60 Hz, 3 amp minimum. (See label.)

b. Compressed air: 10 psig (69 kPa gauge)

minimum, 225 psig (1551 kPa gauge) maximum at 2 scfh (56.6 L/hr) maximum; supplied by one of the following (less than 40 parts-per-million total hydrocarbons). Regulator outlet pressure should be set at 5 psi (35 kPa).

1. Instrument air - clean, dry.

2. Bottled standard air with step-down regulator.

3. Bottled compressed gas mixture (20.95% oxygen in nitrogen).

4. Other equivalent clean, dry, oil-free air supply.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

FURNISHED IN - XIT

4512C34

ADAPTER & ACCESSORY

TO AMBIENT

INSULATE IF EXPOSED

WEATHER CONDITIONS

4512C35

4512C36

2.27 (58)

DIA MAX

ROSEMOUNT

5.85 (148.6)

DIM "A"

WITH STANDARD

REF GAS

CAL GAS

7.58 (192)

SNUBBER

DIFFUSER

ELEC

DIM "B" REMOVAL ENVELOPE

1/4 IN. TUBE

6 MM TUBE

ANSI

DIN

JIS

1/2"

CONN

CONDUIT

GAS CAL

JIS

4512C18H01

6.10

(155)

1.88 (48)

0.59

GAS REF

(15)

AT THE BOTTOM

BOTTOM VIEW

INSTALL WITH CONNECTIONS

5.12

(130)

THESE FLAT FACED FLANGES ARE MANUFACTURED

TO ANSI, DIN, AND JIS BOLT PATTERNS AND ARE NOT

DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN

PARENTHESES.

PRESSURE RATED.

NOTES: 1.

24610001

3.80 (96.5)

DIFFUSER

FOR PROBE

WITH CERAMIC

4.90 (124.5)

ADD TO DIM "A" FOR

ARRESTOR

DIFFUSER AND FLAME

PROBE WITH CERAMIC

DIN

7.28

4512C19H01

ANSI

6.00

4512C17H01

(185)

(153)

0.71

0.75

(18)

(20)

5.71

4.75

(145)

(121)

DIM "B"

DIM "A"

27.3 (694)

16 (406)

45.3 (1151)

34 (864)

81.3 (2065)

117.3 (2980)

70 (1778)

106 (2692)

153.3 (3894)

142 (3607)

3535B18H02

ANSI

0.062 THK GASKET

3635B48H01

3535B45H01

JIS

DIN

ADD TO DIM "A"

TABLE I MOUNTING FLANGE

3FT

6FT

9FT

12 FT

PROCESS FLOW MUST

BE IN THIS DIRECTION

WITH RESPECT TO

DEFLECTOR 3534848G01

FLANGE

DIA.

HOLE

DIA.

(4) HOLES

EQ SP ON BC

TABLE II INSTALLATION/REMOVAL

18 IN.

PROBE

Figure 2-1. Probe Installation (Sheet 1 of 5)

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

World Class 3000

7.50

7.48

BOLT

CIRCLE

0.75

(8) HOLES

DIAMETER

FLANGE

9.00 (153)

DIAMETER

TABLE IV. FLANGE SIZE

ANSI

7.48

0.75

0.945

9.25 (235)

JIS

DIN

FLANGES ARE MANUFACTURED TO ANSI,

5.7 (145)

14.5

(369)

DIM "D" REMOVAL ENVELOPE

PRESSURE RATED.

FLAT FACED. THESE FLANGES ARE NOT

DIN, AND JIS BOLT PATTERNS AND ARE

7.00

(178)

SEE TABLE IV

FOR FLANGE

SIZES

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

21190008

REF AND

CAL GAS

CONNECTOR

ELECTRICAL

CONNECTOR

CAL GAS LINES

CHECK VALVE FOR

INSULATE IF

CONDITIONS

EXPOSED TO

AMBIENT WEATHER

31.1

(790)

DIM "E"

45.3 (1151)

DIM "D"

(686)

DIM "C"

NOMINAL MEASUREMENTS

TABLE III. REMOVAL / INSTALLATION

3 FT

67.1

81.3

6 FT

(1704)

(2065)

(1600)

103.1

(2619)

117.3

(2980)

(2515)

9 FT

139.1

(3533)

153.3

(3894)

(P/N 3535B58G04 - JIS)

135

12 FT

(3429)

DIM "C"

0.06 THK GASKET FURNISHED

DIM "E" (WITH FLAME ARRESTOR)

(P/N 3535B58G06 - DIN)

(P/N 3535B58G02 - ANSI)

IN HARDWARE PACKAGE

Figure 2-1. Probe Installation (Sheet 2 of 5)

3.6

NOMINAL

(P/N 4843B38G02)

SNUBBER DIFFUSION/

DUST SEAL ASSEMBLY

DIMENSIONS ARE IN INCHES WITH

MILLIMETERS IN PARENTHESES.

NOTE:

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

JIS

(P/N 3535B58G04)

9.25

(235)

4.92

(125)

(200)

7.894

(M-20 x 2.5)

World Class 3000

16860021

8 THREADED HOLES

EQUALLY SPACED ON

D DIA B.C.

ABRASIVE SHIELD

FLANGE O.D.

DIN

(P/N 3535B58G06)

ANSI

(P/N 3535B58G02)

IN.

TABLE VI. ADAPTOR PLATE DIMENSIONS FOR ABRASIVE SHIELD

(mm)

DIMENSIONS

JIS

(P/N 4512C35G01)

9.25

9.00

"A"

6.50

(235)

(229)

(165)

3.94

(100)

4.75

(121)

"B"

DIA

(M-12 x 1.75)

7.48

(M-16 x 2)

7.50

0.625-11

"C"

"D"

THREAD

(130)

5.118

(190)

(191)

DIA

NOTE: PART NUMBERS FOR ADAPTOR PLATES INCLUDE

ATTACHING HARDWARE.

22.5

OUTSIDE WALL SURFACE.

CROSSHATCHED AREA IN 4

CORNERS MAY BE USED TO

FIELD BOLTING OF PLATE TO

PROVIDE ADDITIONAL HOLES FOR

AND 12 FT ABRASIVE SHIELD

ADAPTOR PLATE FOR 3, 6, 9,

INSTALLATIONS. SEE SHEET 2.

4 STUDS,

LOCKWASHERS AND

NUTS EQUALLY

SPACED ON

DIN

ANSI

TABLE V. ADAPTOR PLATE DIMENSIONS FOR PROBE

IN.

DIMENSIONS

7.5 (191)

(M-16 x 2)

(P/N 4512C36G01)

6.00

(153)

0.625-11

(P/N 4512C34G01)

"B"

"A"

(mm)

THREAD

(145)

5.708

4.75

(121)

"C"

DIA

ATTACHING HARDWARE.

2.500 DIA

NOTE: PART NUMBERS FOR ADAPTOR PLATES INCLUDE

C DIA B.C.

ADAPTOR PLATE FOR

STD WORLD CLASS 3000

PROBE INSTALLATION.

SEE SHEET 1.

Figure 2-1. Probe Installation (Sheet 3 of 5)

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

World Class 3000

INSTALLATION FOR METAL

WALL STACK OR DUCT

CONSTRUCTION

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION

MTG HOLES

SHOWN ROTATED

OUT OF

22.5

TRUE POSITION

WELD OR BOLT MOUNTING

PLATE TO METAL WALL

OF STACK OR DUCT.

JOINT MUST BE AIRTIGHT.

0.50 (13)

3.75 (95) 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

OUT OF

22.5

TRUE POSITION

JOINT MUST

BE AIRTIGHT

OUTSIDE WALL

SURFACE

NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPT

ADAPTOR PLATE NOT FURNISHED BY ROSEMOUNT.

ABRASIVE SHIELD MOUNTING

0.50 (13)

4.50 (114) 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 AIRTIGHT.

3.25 (82.5)

MIN DIA HOLE IN WALL

STACK OR DUCT METAL WALL

BOLT MOUNTING

PLATE TO OUTSIDE

WALL SURFACE

OUTSIDE WALL

PROBE MOUNTING

JOINT MUST

BE AIRTIGHT

SURFACE

NOTE: DIMENSIONS IN INCHES WITH

MILLIMETERS IN PARENTHESES.

FIELD WELD PIPE TO ADAPTOR PLATE

4.0 (102) O.D. REF

PIPE 3.5 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH BY CUSTOMER

MASONRY STACK WALL

P0038

Figure 2-1. Probe Installation (Sheet 4 of 5)

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

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

60 MAX.

30 MIN.

4.12

(105)

4.12

(105)

BRACE BARS (NOT BY ROSEMOUNT)

2.00 (51)

1.00 (25)

2 HOLES - 0.625 (16) DIA. FOR

0.50 (12) DIA. BOLT

1.00 (25) MAX.

0.375 (10)

NOTE: DIMENSIONS IN INCHES WITH

5.62

(143)

5.62

(143)

MILLIMETERS IN PARETHESES.

VERTICAL BRACE CLAMP ASSY. HORIZONTAL BRACE CLAMP ASSY.

(BOTH BRACE CLAMP ASSEMBLIES ARE THE SAME. INSTALLATION AND LOCATION OF CLAMP ASSEMBLIES AND BRACE BARS TO BE DONE IN FIELD.)

ABRASIVE SHIELD

BY ROSEMOUNT

}

NOTE: BRACING IS FOR VERTICAL AND HORIZONTAL PROBE INSTALLATION.

EXTERNAL BRACING REQUIRED FOR 9 FT AND 12 FT (2.75 M AND 3.66 M) PROBES AS SHOWN ABOVE.

Figure 2-1. Probe Installation (Sheet 5 of 5)

2-3 MECHANICAL INSTALLATION

a. Ensure that all components are available for

installation of the probe. If equipped with the optional ceramic diffusor, check to ensure that it is not damaged. Ensure that the system cable is the required length.

b. The probe may be installed intact as it is re-

ceived. It is recommended that you disassemble the adapter plate for each installation.

36.00 (914)

P0039

NOTE

An abrasive shield is recommended for high velocity particulate in the flue stream (such as those in coal fired boilers, kilns, and recovery boilers). Vertical and horizontal brace clamps are provided for 9 ft and 12 ft (2.75 m and 3.66 m) probes to provide mechanical support of the probe. Refer to Figure 2-1, sheet 5.

c. Weld or bolt adapter plate (Figure 2-1) onto

the duct. Existing stack penetration and mounting hardware may be revised, or new mounting flanges may be installed (see Figure 2-1, sheets 3 and 4).

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

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

d. If using the optional ceramic diffusor ele-

ment, the vee deflector must be correctly oriented. Before inserting the probe, check the direction of gas flow 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.

GAS FLOW DIRECTION

VEE

APEX

FILTER

DEFLECTOR

DIFFUSION

ELEMENT

SETSCREW

VEE

DEFLECTOR

e. In horizontal installations, the probe cover

should be oriented so the system cable drops vertically from the probe cover. In a vertical installation, the system cable can be oriented in any direction.

f. 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.

g. Insert the probe through the opening in the

mounting flange and bolt the unit to the flange When probe lengths selected are 9 or 12 ft (2.74 or 3.66 m), special brackets are supplied to provide additional support for the probe inside the flue or stack. See Figure 2-1, sheet 5.

2-4 ELECTRICAL INSTALLATION

Figure 2-3 shows the junction box wiring for the direct replacement probe including the 115 V hookup. Consult the electronics manual for the connections to power and the existing signal conditioning electronics.

P0017

Figure 2-2. Orienting the Optional Vee Deflector

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

NOTE: FOR YOKOGAWA (YEW) ZA8C,

115V

HEATER

}

YE CHROMEL

RD ALUMEL

OR CELL +VE

BL CELL -VE

1234567

JUNCTION BOX

WIRING

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.

WHT

Figure 2-3. Wiring the Direct Replacement Probe

NOTE

PROBE

REFER TO SECTION 3-6.

TEST GAS INPUT

AT 2-3 L/MIN

(4-7 SCFH)

CHECK

VALV E

REF. GAS SUPPLY

INPUT AIR AT

1 L/MIN (2 SCFH)

19290007

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.

2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

SECTION 3

STARTUP

3-1 OVERVIEW

This section covers the setup procedures for the World Class 3000 Oxygen Analyzer. The DR probe can be used with several electronics packages including: Models 218, 218A, 225, 132 (analog and digital), TC200, and ZA8C.

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

For Models 218, 225, and 132 (analog), refer to paragraph 3-2. Additional information can be found in IB-106-101.

For Model 218A, refer to paragraph 3-3. Additional information can be found in IB-106-101A.

For Model TC200, refer to paragraph 3-4. Additional information can be found in IB-107-020.

d. Attach voltmeter with positive (+) lead on

TP1 and negative (-) on either Pin 2 or 7.

NOTE

The voltage given above is for an ambient (machinery space) temperature of 77°F (25°C). For each degree of ambient temperature above or below 77°F (25°C), add or subtract 0.242 mV from the nominal. Example: at 87°F (31°C), the nominal voltage of -322.3 Mv should be increased (made less negative) by 10 x 0.242 or 2.42 mV, making the adjusted nominal -319.9 Mv.

e. Adjust potentiometer M110-1 to read -322.3

millivolts nominal.

f. Remove voltmeter leads.

g. Remove jumper wire.

TP1

M110-1

For Model 132 (digital), refer to paragraph 3-5. Additional information can be found in IB-106106A.

For Yokogawa Model ZA8C, refer to paragraph 3-6.

3-2 MODELS 218, 225, AND 132 (ANALOG)

ELECTRONICS SETUP

Before beginning operation, it is important that the probe heater setpoint of the existing electronics be changed to support the World Class 3000 probe. The setpoint adjustment procedure required for Models 218, 225, and 132 analog electronics is as follows:

a. Open electronics enclosure.

b. On temperature controller card, Figure 3-1,

connect jumper wire from TP3 to either Pin 2 or Pin 7.

c. Set voltmeter to read DC millivolts (MV).

TP3

PIN 2 (PSC)

Figure 3-1. Temperature Controller Card

23 567 1012

PIN 7 (PSC)

Calibration Points

P0019

Rosemount Analytical Inc. A Division of Emerson Process Management Startup 3-1

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

3-3 MODEL 218A ELECTRONICS SETUP

Before beginning operation, it is important that the probe heater setpoint of the existing electronics be changed to support the World Class 3000 probe. To convert the Model 218A Digital Electronics Package for use with the DR probe, an EPROM change is necessary. Remove Main PCB and check back of board to identify unit as G02 or G04. The replacement EPROM needed is as identified below:

G02 G04

United States 1M03192G01 1M02982G01 United Kingdom 1M03192G02 1M02982G02 Germany 1M03192G03 1M02982G03 France 1M03192G04 1M02982G04 Italy 1M03192G05 1M02982G05

NOTE

The replacement EPROM when using a multiprobe averager unit is 1M02982G10.

To replace the EPROM, proceed as follows:

a. Shut off and lock out power to the electron-

ics package.

b. Open electronics enclosure.

c. On the Main PCB, Figure 3-2, locate and

remove old EPROM.

d. Replace with new EPROM.

e. Close electronics enclosure and power up

system.

EPROM

MAIN PCB

Figure 3-2. Main PCB (Model 218A) EPROM Replacement

3-2 Startup Rosemount Analytical Inc. A Division of Emerson Process Management

P0020

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

3-4 MODEL TC200 VERITRIM ELECTRONICS

SETUP

Before beginning operation, it is important that the probe heater setpoint of the existing electronics be changed to support the World Class 3000 Probe. To convert the Model TC200 Electronics Package for use with the DR probe, an EPROM change is necessary. The replacement EPROM needed is part number 1M03154G02.

a. EPROM Replacement

To replace the EPROM, proceed as follows:

1. Shut off and lock out power to the electronics package.

2. Open electronics enclosure.

3. On the main PCB, Figure 3-3, locate and remove old EPROMs U11 and U12.

b. Heater SetPoint Adjustment

EPROMS

U11 AND U12

4. Replace with new EPROMs (part number 1M03154G02) being careful to install U11 and U12 in their proper locations.

5. Close electronics enclosure and power up system.

The adjustment procedure required for the Model TC200 Electronics Package is as follows:

1. Open keylocked enclosure to access membrane keyboard.

2. Put controller in PAR (parameter) mode by depressing "LOCK" "▲"

"%O

" "INC" "ACK" in sequence.

3. Depress "ACK" pushbutton to clear display.

DIS A/M

U12

U11

Figure 3-3. Main PCB (Model TC200) EPROM Replacement

P0021

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

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

4. Press "NUM" pushbutton.

5. Using "INC", "DEC" buttons, display parameter 125.

6. Press "VAL" button.

7. Using "INC", "DEC" buttons, change parameter 125 value to 15.4.

8. Press "ENT" to save new value.

3-5 MODEL 132 DIGITAL

ELECTRONICS SETUP

Before beginning operation, it is important that the probe heater setpoint of the existing electronics be changed to support the World Class 3000 Probe. To convert the Model 132 Digital Electronics Package for use with the DR probe, an EPROM change is necessary. The replacement EPROM needed is as identified below:

United States IM03222G01 United Kingdom Germany France Italy

EPROM

MAIN PCB

To replace the EPROM, proceed as follows:

a. Shut off and lock out power to the

electronics package.

b. Open electronics enclosure.

c. On the Main PCB, Figure 3-4, locate and

remove old EPROM.

d. Replace with new EPROM.

e. Close electronics enclosure and power up

system.

3-6 THE YOKOGAWA ZA8C AND AV8C CON-

VERTER ELECTRONICS SETUP

The DR probe can be wired to work with the Yokogawa® ZA8C and AV8C Converters.

Connect the cabling from the ZA8C or AV8C terminal to the probe terminal in the junction box as shown in Figure 3-5.

TX2

C34

M55

CR18

P61

C44

C48

C37

LM8

R38

TP1

R27

XT1

C26

C27

R12

C38

R38

C29

C28

C30

C29

R26

P25

P36

CR25

C13

D12

P28

O18

LED1

R63

R62

R54

R41

R48

RP1

C46

TP2

C24

D14

C21

C23

D13

C12

C14

C16

CR17

R48

C39

C31

U10

C43

C42

R53

U13

C22

C13

C10

C41

R42

CR15

CR16

CR24

R36

CR13

CR14

CR12

CR11

R37

BR1

C30

R44

R49

R47

U14

R43

R38

R86

CR18

R68

P29

P22

R64

C86

C10

U12

R61

C16

C32

TR1

TX1

C38

R56

CR19

C36

C11

R46

R48

P62

U11

C48

C3 C8

C47

2001A

CK1

R58

R57

R59

P68

U19

U17

R18

R16

R17

U16

R11

R18

CR3

CR4

U18

CR1

CR2

R16

C46

CR7

CR6

R19

CR8

CR5

LK2

R14

R23

R28

LK1

CR21

CR20

C17

R21

R13

R24

CR23

CR22

FIL1

CR9

R81

ALARM

MTR-T/C CELL SKG STK-T/C ML-O/P

T83

C11

T82

OFF

HEATER

MAIN INPUT

T81

SW1

MOV1

MOV2

P0022

Figure 3-4. Main PCB (Model 132) EPROM Replacement

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

World Class 3000

ZA8C

AV8C

CONVERTER

WORLD CLASS 3000

REPLACEMENT PROBE

WITH ADAPTER FLANGE

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

STACK WALL

TEST GAS

IF AVAILABLE

CELL

THERMOCOUPLE

COLD

JUNCTION

HEATER AND SIGNAL CABLE

REFERENCE AIR

IF AVAILABLE

SIGNAL

CABLE

ZA8C

AV8C

TERMINAL

}

4–

}

6–

}

8–

EXISTING

MOUNTING

COLD

JUNCTION

DEVICE

+–

GN OR YE RD BK BK GN

12345678

SHIELD

PROBE

PROBE TERMINAL

ZA8C OR AV8C

NOTES: 1. HEATER TEMPERATURE SET TO 1380

GND SHIELD

THE GREATER MASS OF THE WORLD CLASS DIRECT REPLACEMENT PROBE REQUIRES

2. LONGER TIME TO HEAT UP. UPON STARTUP, THE YOKOGAWA ELECTRONICS MAY INDICATE AN ERROR BECAUSE THE PROBE HAS NOT REACHED TEMPERATURE SETPOINT

IN THE NORMAL TIME. REMOVE POWER FROM THE YOKOGAWA ELECTRONICS OR PROBE MODULE TO CLEAR THE ERROR, AND RESTORE POWER. THIS PROCEDURE MAY HAVE TO BE REPEATED A COUPLE OF TIMES BEFORE PROBE OPERATING TEMPERATURE IS REACHED.

PROBE

HEATER

F (750oC)

624023

Figure 3-5. DR Probe Wired to the ZA8C or A V8C Converter

Rosemount Analytical Inc. A Division of Emerson Process Management Startup 3-5

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

3-6 Startup Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

IB-106-300DR Rev. 3.3

World Class 3000

SECTION 4

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.

February 2000

4-1 OVERVIEW

This section describes routine maintenance of the oxygen analyzer probe. Spare parts referred to are avail-able from Rosemount. Probe disassembly kit 3535B42G01 contains the required spanner and hex wrenches. Refer to Section 7 for part numbers and ordering information.

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.

4-2 PROBE CALIBRATION

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.

The cell replacement kit contains a cell and flange assembly, corrugated seal, 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 7-1.

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

Disconnect and lock out power before working on any electrical components. There is voltage up to 115 Vac.

4-3 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 7-1.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-1

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

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

BOMB TAIL

CONNECTOR

CELL EXTENSION

WIRE (ORANGE)

INCONEL

CELL WIRE

(CLEAR

SLEEVING)

CALIBRATION

GAS FITTING

CABLE

HEATER

WIRES

(BLACK

SLEEVING)

THERMOCOUPLE -

(RED ALUMEL)

(YELLOW CHROMEL)

REFERENCE GAS FITTING

THERMOCOUPLE +

PROBE JUNCTION

BOX COVER

21220001

Figure 4-1. Cell Wiring Connection

a. Disconnect and lock out power to electron-

ics. Shut off and disconnect reference gas and calibration gas supplies from junction box, Figure 4-1. 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. If the probe uses the standard diffusion

element, use a spanner wrench to remove the diffusion element.

c. If equipped with the optional ceramic diffu-

sor assembly, remove and discard setscrews, Figure 4-2, and remove vee deflector. Use spanner wrenches from probe disassembly kit, Table 7-1, to turn hub free from retainer. Inspect diffusion element. If damaged, replace element.

d. Loosen four socket head cap screws from

the cell and flange assembly and remove the assembly and the corrugated seal. The cell flange has a notch which may be used to gently pry the flange away from the probe. Note that the contact pad inside the probe will sometimes fuse to the oxygen sensing cell. If the cell is fused to the contact pad, push the cell assembly back into the probe (against spring pressure), and quickly twist the cell assembly. The cell and contact pad should separate. If the contact pad stays fused to the cell, a new contact/thermocouple assembly must be installed. Disconnect the cell and the thermocouple wires at the probe junction box, and withdraw the cell with the wires still attached (see paragraph 4-5).

4-2 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

WRENCH

OPTIONAL CERAMIC

DIFFUSION ELEMENT

SETSCREW

FILLET

VEE

DEFLECTOR

21240026

CEMENT

PORT

RETAINER

HUB

CEMENT

Figure 4-2. Removal of Optional Ceramic Diffusor

and Vee Deflector

e. If contact assembly is damaged, replace

contact and thermocouple according to paragraph 4-5, Replacement of Contact and Thermocouple Assembly.

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. Clean threads on retainer and hub.

g. Rub a small amount of anti-seize on both

sides of corrugated seal.

h. Assemble cell and flange assembly, corru-

gated seal, and probe tube. Make sure the calibration tube lines up with the calibration gas passage in each component. Apply a small amount of anti-seize compound to screw threads and use screws to secure assembly. Torque to 35 in-lbs (4 N·m).

i. Apply anti-seize compound to threads of

cell assembly, hub, and setscrews. Reinstall hub on cell assembly. Using pin spanner wrenches, torque to 10 ft-lbs (14 N·m). If applicable, reinstall vee deflector, orienting apex toward gas flow. Secure with setscrews and anti-seize compound. Torque to 25 in-lbs (2.8 N·m).

PROBE TUBE

(NOT INCLUDED

IN KIT)

CORRUGATED

SEAL

CELL AND

FLANGE

ASSEMBLY

SOCKET HEAD

CAP SCREWS

CALIBRATION GAS

PASSAGE

Figure 4-3. Cell Replacement Kit

j. On systems equipped with an abrasive

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

k. 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.

l. Turn power on to electronics and monitor

thermocouple output. It should stabilize at

29.3 ±0.2 mV. Set reference air flow at 2 scfh (56.6 L/hr). 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.

4-4 OPTIONAL CERAMIC DIFFUSION

ELEMENT REPLACEMENT

a. General

The optional ceramic 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 diffusion element whenever removing the probe for any purpose. Replace if damaged.

21240009

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-3

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

Damage to the 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 special tool kit, Table 7-1.

Wear heat resistant gloves and clothing to remove probe from stack. Normal operating temperatures of diffusor and vee deflector are approximately 600°°°° to 800°°°°F (300°°°° to 425°°°°C). These high temperatures can cause severe burns.

Disconnect and lock out power before working on any electrical component. There is voltage up to 115 Vac.

with M-6 x 6 stainless setscrews coated with anti-seize compound.

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

4. Use spanner wrenches from special tool kit, Table 7-1, to turn hub free from retainer.

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

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

7. Replace diffusion element, using replacement kit listed in Table 7-1. This consists of a diffusion element, cement, setscrews, anti-seize compound and instructions.

Do not remove the cell unless it is certain that replacement is necessary. Cell cannot be removed for inspection without damaging it. Refer to paragraph 4-3, Cell Replacement.

b. Replacement Procedure.

1. Shut off power to electronics. Disconnect cable conductors and remove cable, Figure 4-1. Shut off and disconnect reference gas and calibration gas supplies from probe head. Wearing heat resistant gloves and clothing, carefully remove probe assembly from stack and allow to cool to room temperature. Do not attempt to work on unit until it has cooled to a comfortable working temperature.

2. Loosen setscrews, Figure 4-2, using hex wrench from special tools kit, Table 7-1, and remove vee deflector. Inspect setscrews. If damaged, replace

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

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

9. Thoroughly mix cement and insert tip of squeeze bottle into cement port. Tilt bottle and squeeze while simultaneously turning diffusion element into seat. Do not get any cement on upper part of diffusion element. Ensure complete penetration of cement around three 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.

4-4 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

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

11. Wipe a heavy layer of anti-seize compound onto the threads and mating surfaces of the diffusion hub and retainer.

12. Assemble retainer and diffusion hub with two pin spanner wrenches. Torque to 10 ft-lbs (14 N·m).

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.

16. Turn power on to electronics and monitor thermocouple output. It should stabilize at 29.3 ±0.2 mV. Calibrate probe per Instruction Bulletin applicable to your electronics package.

4-5 REPLACEMENT OF CONTACT AND

THERMOCOUPLE ASSEMBLY

a. Disconnect and lock out power to electron-

ics. Using heat resistant gloves and clothing, remove junction box cover. Squeezing tabs on hose clamps, remove hoses from junction box, Figure 4-4. Remove four screws in corners of the junction box. Pull junction box and inner probe assembly free from probe tube. Set on bench and allow to cool to room temperature.

b. Disconnect cell extension wire (orange),

thermocouple wire (red alumel), and thermocouple wire (yellow chromel) by cutting bomb tail connections from the terminal strip, Figure 4-1.

c. Remove two screws, Figure 4-4, lockwash-

ers, and flat washers that connect junction box to inner probe assembly. Pull heater, V-strut and backplate assembly away from junction box. Inspect all O-rings and insulating gasket; replace if worn or damaged.

PROBE JUNCTION BOX TO HEATER,

STRUT, AND BACKPLATE

ASSEMBLY SCREW

PROBE JUNCTION BOX

INNER PROBE ASSEMBLY

TO PROBE TUBE SCREWS

PROBE

JUNCTION

BOX

HOSE

CLAMP

Use heat resistant gloves and clothing when removing junction box and inner probe assembly. Do not attempt to

HOSE

work on these components until they have cooled to room temperature. Probe components can be as hot as 800°°°°F (427°°°°C), and can cause severe burns.

Disconnect and lock out power before

21240027

working on any electrical components. There is voltage up to 115 Vac.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-5

Figure 4-4. Junction Box Mechanical Connections

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

HEATER SCREWS

(NOT SHOWN)

HEATER

CERAMIC ROD

35900001

MOUNTING SCREW

(REAR VIEW)

CONTACT AND

THERMOCOUPLER

ASSEMBLY

SPRING

INSULATING

GASKET

CLIP

V-STRUT

Figure 4-5. Inner Probe Replacement (Heater,

V-Strut, and Backplate Assembly)

d. Use a pencil to mark locations of spring clip

on ceramic rod, Figure 4-5.

e. Pry or squeeze tabs on spring clips, and

pull contact and thermocouple assembly out of probe assembly. Retain spring clips and spring; replace if damaged.

Be very careful when handling contact and thermocouple assembly. The ceramic rod in this assembly is fragile.

f. While very carefully handling new contact

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

g. Note wire lengths of old assembly as an aid

for trimming new lengths in step (j). Trimming of wires will not always be necessary. Throw away old contact and thermocouple assembly.

h. Carefully guide new contact and thermo-

couple assembly through V-strut assembly leaf spring (4, Figure 4-6), spring (9), spring clip (10) (held open by squeezing tabs), and tube supports (11, 13) until spring clip reaches pencil mark.

i. Reinstall insulating gasket on backplate, re-

place two screws, O-rings, lockwashers and flat washers connecting junction box to inner probe assembly.

Do not trim new wiring shorter than existing (old) wiring. Excessive wire trim will prevent connections from being properly made and will require new replacement kit.

j. Trim wires, if necessary, as noted in step

(g).

1. Heater Ceramic Rod

2. Contact and Thermocouple Assembly

3. Strut

4. Leaf Spring

1011

5. Ring Lug

6. Butt Connector

7. Extension Wire

8. Backplate

10. Spring Clip Assembly

11. Common Tube Support

12. Heater

13. Short Tube Support

9. Spring

21240011

Figure 4-6. Heater, Strut, and Backplate Assembly (Inner Probe Assembly)

4-6 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

k. Connect color coded wires to proper termi-

nals as shown in Figure 4-1. 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 1/4 in. (6.4 mm) from end of ceramic rod. Dress wires so they do not touch sides of junction box.

l. Slide assembled junction box and inner

probe assembly into probe tube. To align calibration gas tube with corresponding hole in backplate (A, B, Figure 1-3), insert scriber through hole in backplate and into calibration gas tube. Secure with screws. Reinstall hoses and probe cover.

m. 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.

4-6 REPLACEMENT OF HEATER, V-STRUT

AND BACKPLATE ASSEMBLY (Inner ProbeAssembly; Includes Contact And Thermocouple Assembly).

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

NOTE

This replacement may be done without removing the probe from the duct.

a. Disconnect and lock out power to electron-

ics. Using heat resistant gloves and clothing, remove probe cover. Squeeze tabs on hose clamps and remove hoses from junction box, Figure 4-4. Remove four screws and lockwashers (7 and 10, Figure 4-7) that hold junction box and inner probe assembly to probe tube. Pull junction box and inner probe assembly free from probe tube. Set on bench and allow to cool to room temperature.

b. Disconnect cell extension wire (orange),

thermocouple wire (red alumel), and ther-

Wear heat resistant gloves and clothing when remove probe head 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°°°°F (427°°°°C). This can cause severe burns.

Disconnect and lock out power before working on any electrical components. There is voltage up to 115 Vac.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-7

mocouple wire (yellow chromel) by cutting bomb tail connections from the terminal strip, Figure 4-1.

c. Remove two screws, lockwashers, and flat

washers that connect junction box to inner probe assembly. Remove and discard inner probe assembly (heater, V-strut, and backplate assembly). Replace with new inner probe assembly. Reinstall screws, lockwashers and flat washers.

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

124

World Class 3000

678 9

21240012

1. Snubber Diffusion Element

2. Socket Hd Cap Screw (0.25 in.-28 x 0.63 (16 mm)

3. Cell and Flange assembly

4. Corrugated Seal

5. Probe Tube Assembly

6. Gasket

7. Fillister Hd Screw

8. Cover Head Assembly

Figure 4-7. Oxygen Analyzer Probe, Cross-Sectional View

d. Connect color coded wires to proper termi-

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

4.0 in. (102 mm) x 4.0 in. x 0.12 in. (3 mm)

8-32 x 0.5 in. (12.7 mm)

e. Slide assembled junction box and inner

f. Power up system. Monitor thermocouple

9. Hose Clamp

10. Lockwasher, #8 Split

11. Heater Strut Assembly

probe assembly into probe tube. To align calibration gas tube with corresponding hole in backplate (A, B, Figure 1-3), insert aligning tool (included in probe disassembly kit, P/N 3535B42G01) through hole in backplate and into calibration gas tube, while sliding the heater strut into the probe tube. Secure with screws. Reinstall hoses and probe cover.

output. It should stabilize at set point ±0.2 mV. Recalibrate probe per Instruction Bulletin applicable to your electronics package.

4-8 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

4-7 CALIBRATION AND REFERENCE GAS

LINES FOR HIGH TEMPERATURE CORROSIVE ENVIRONMENT OPERATION

A high temperature, corrosive environment kit is available when the probe is exposed to these types of operating conditions. The kit includes stainless steel tubing and teflon fittings for inside the junction box. The kit part number is 4843B93G01.

a. Installation Procedure

Use heat resistant gloves and clothing when removing 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°°°°F (427°°°°C). This can cause severe burns.

Disconnect and lock out power before working on any electrical components. There is voltage up to 115 Vac.

1. Disconnect and lock out power to digital electronics. Using heat resistant gloves and clothing, remove probe cover. Squeezing tabs on hose clamps, remove hoses from junction box (Figure 4-4).

2. First install the stainless steel tubing on the fitting at the bottom of the junction box. Install the other end of the stainless steel tube onto the tube going to the probe (Figure 4-8).

NOTE

If abrasive conditions of high ash content and high velocity exist, an abrasive shield is recommended. To balance out the wear on the shield, rotate the shield 90° every time the probe is powered down for service.

TEFLON

SLEEVES

STAINLESS

STEEL

TUBING

21240028

Do not use sealant when installing the stainless steel tubes. Gas samples

Figure 4-8. High Temperature – Corrosive

Environment Kit

may become contaminated.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-9

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

4-10 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

SECTION 5

TROUBLESHOOTING

5-1 OVERVIEW

Troubleshooting for the oxygen analyzer system is broken down to the main component level. In addition to the information in this section, instruction bulletins for individual models also discuss troubleshooting.

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.

For Models 218, 225, and 132 (analog), refer to IB-106-101.

For Model 218A, refer to IB-106-101A.

For Model TC200, refer to IB-107-020.

For Model 132 (digital), refer to IB-106-106A.

For Yokogawa (YEW) ZA8C Converter, refer to original converter documentation.

5-2 PROBE TROUBLESHOOTING

a. Probe Faults

Listed below are the five symptoms of probe failure.

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.

4. The probe takes a long time to return to flue gas value after the calibration gas is turned off.

5. The probe heater temperature is unstable.

b. Table 5-1 provides a guide to fault finding

for the above symptoms.

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

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

SYMPTOM CHECK FAULT REMEDY

1. No response to oxygen concentration change when:

World Class 3000

Table 5-1. Fault Finding

Heater is cold and TC mV output is less than setpoint

Heater is hot and T/C mV output is at set point ±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 should be 67 ohm to 77 ohm

Triac O/P to heater Failure of electronics Check electronics package.

Recorder chart Recorder failure See Recorder Instruction

Cell mV input to electronics and cell mV at probe head

Heater failure Replace heater or return

probe to Rosemount.

Manual.

No cell mV at probe when test gas applied

Probe cell mV OK but no input to electronics

Cell mV satisfactory both at 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 indicationof applied test gas

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

Recorder or remote indicator

System calibration Calibration error Recalibrate system.

Probe mounting and condition of duct

Cell mV input to electronics Failure of electronics Check electronics package.

Test gas input port Blocked port Clean port. If the flue gas is

Ceramic diffusion element Blocked port

Calibration error Recalibrate recorder or in-

dicator. Reference Recorder Instruction Manual.

Air ingress into duct Stop air leaks or resite

probe.

condensing in the test gas line, insulate the back of the probe. Make sure that the test gas line is capped between calibrations, or a check valve is installed.

Diffusion element cracked, broken, or missing

Replace diffusion element.

World Class 3000

SYMPTOM CHECK FAULT REMEDY

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

Table 5-1. Fault Finding (continued)

4. Probe takes a long time to return to flue gas value after calibration gas is turned off

5. Probe heater temperature unstable

Plugged diffusion element Plugged diffusion element Change diffusion element or

snubber diffusion element.

Proper voltage heater is installed

Wrong heater Change heater to proper

voltage.

Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-3

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

5-4 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

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.).

3. Site from which equipment was removed.

5. Complete shipping instructions for return of equipment.

6. Reference the return authorization number.

d. Enclose a cover letter and purchase order

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

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

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

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

4. Whether warranty or nonwarranty service is requested.

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

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

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

World Class 3000

SECTION 7

REPLACEMENT PARTS

Table 7-1. Replacement Parts for Probe

FIGURE and

INDEX No. PART NUMBER DESCRIPTION

4-5 3D39441G01 4-5 3D39441G02 4-5 3D39441G03 4-5 3D39441G04 4-5 3D39441G05 4-5 3D39441G11

4-5 3D39441G12

4-5 3D39441G13

4-5 3D39441G14

4-5 3D39441G15

4-6, 2 3534B56G04 4-6, 2 3534B56G05 4-6, 2 3534B56G06 4-6, 2 3534B56G07 4-6, 2 3534B56G08 4-6, 2 4513C61G01

4-6, 2 4513C61G02

4-6, 2 4513C61G03

4-6, 2 4513C61G04

4-6, 2 4513C61G05

4-6, 2 3D39003G01 4-6, 2 3D39003G02 1-9 3D39003G07 1-9 3D39003G08 1-9 4847B61G01 Cell Replacement Kit, ANSI w/No lead wire 1-9 4847B61G02 Cell Replacement Kit, ANSI 18 in. (45.6 cm) 4-3 4847B61G03 Cell Replacement Kit, ANSI 3 ft (0.9 m) 4-3 4847B61G04 Cell Replacement Kit, ANSI 6 ft (1.8 m) 4-3 4847B61G05 Cell Replacement Kit, ANSI 9 ft (2.7 m) 4-3 4847B61G06 Cell Replacement Kit, ANSI 12 ft (3.6 m)

Heater, V-Strut, and Backplate Assembly (115 V), 18 in. (45.6 cm) Heater, V-Strut, and Backplate Assembly (115 V), 3 ft (0.9 m) Heater, V-Strut, and Backplate Assembly (115 V), 6 ft (1.8 m) Heater, V-Strut, and Backplate Assembly (115 V), 9 ft (2.7 m) Heater, V-Strut, and Backplate Assembly (115 V), 12 ft (3.6 m) Heater, V-Strut, and Backplate Assembly, 18 in. (45.6 cm)

(For use with YEW electronics)

Heater, V-Strut, and Backplate Assembly, 3 ft (0.9 m) (For use with YEW electronics)

Heater, V-Strut, and Backplate Assembly, 6 ft (1.8 m) (For use with YEW electronics)

Heater, V-Strut, and Backplate Assembly, 9 ft (2.7 m) (For use with YEW electronics)

Heater, V-Strut, and Backplate Assembly, 12 ft (3.6 m) (For use with YEW electronics)

Contact and Thermocouple Assembly, 18 in. (45.6 cm) Contact and Thermocouple Assembly, 3 ft (0.9 m) Contact and Thermocouple Assembly, 6 ft (1.8 m) Contact and Thermocouple Assembly, 9 ft (2.7 m) Contact and Thermocouple Assembly, 12 ft (3.6 m) Contact and Thermocouple Assembly, 18 in. (45.6 cm)

(For use with YEW electronics)

Contact and Thermocouple Assembly, 3 ft (0.9 m) (For use with YEW electronics)

Contact and Thermocouple Assembly, 6 ft (1.8 m) (For use with YEW electronics)

Contact and Thermocouple Assembly, 9 ft (2.7 m) (For use with YEW electronics)

Contact and Thermocouple Assembly, 12 ft (3.6 m) (For use with YEW electronics)

Abrasive Shield Assembly, 3 ft (0.9 m) Abrasive Shield Assembly, 6 ft (1.8 m) Abrasive Shield Assembly, 9 ft (2.7 m) Abrasive Shield Assembly, 12 ft (3.6 m)

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

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

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

Table 7-1. Replacement Parts for Probe (continued)

FIGURE and

INDEX No. PART NUMBER DESCRIPTION

4-3 4847B61G07 Cell Replacement Kit, JIS, w/No lead wire 4-3 4847B61G08 Cell Replacement Kit, JIS 18 in. (45.6 cm) 4-3 4847B61G09 Cell Replacement Kit, JIS 3 ft (0.9 m) 4-3 4847B61G10 Cell Replacement Kit, JIS 6 ft (1.8 m) 4-3 4847B61G11 Cell Replacement Kit, JIS 9 ft (2.7 m) 4-3 4847B61G12 Cell Replacement Kit, JIS 12 ft (3.6 m) 4-3 4847B61G13 Cell Replacement Kit, DIN w/No lead wire 4-3 4847B61G14 Cell Replacement Kit, DIN 18 in. (45.6 cm) 4-3 4847B61G15 Cell Replacement Kit, DIN 3 ft (0.9 m) 4-3 4847B61G16 Cell Replacement Kit, DIN 6 ft (1.8 m) 4-3 4847B61G17 Cell Replacement Kit, DIN 9 ft (2.7 m) 4-3 4847B61G18 Cell Replacement Kit, DIN 12 ft (3.6 m) 4-3 3535B42G01 Probe Disassembly Kit 1-13 3535B18G01 Ceramic Diffusor Assembly 1-11 3535B60G01

Ceramic Diffusor Dust Seal Hub Assembly

(For use with Abrasive Shield) 1-13 4841B03G02 Stainless Steel Diffusor Assembly 1-12 3535B63G01 Flame Arrestor Diffusor Dust Seal 1-14 3535B62G01 Flame Arrestor Diffusor 4-2 3535B48G01

Vee Deflector Assembly

(For use with standard ceramic or dust seal type diffusors) 4-2 6292A74G02 Diffusion Element Replacement Kit 2-1 1537B70G03 Horizontal and Vertical Brace Clamp Assembly, 9 and 12 foot

(2.7 and 3.6 m) probe 4-8 4843B93G01 High Temperature - Corrosive Environment Kit

4843B37G01 Snubber Diffusion Assembly

1-10 4843B38G01 Dust Seal/Snubber Diffusion Assembly

Heater, V-strut, and backplate assembly includes contact and thermocouple assembly.

Contact and thermocouple assembly includes platinum pad and inconel wire.

Abrasive shield assembly includes accessories necessary for its use and a mounting plate and gasket.

World Class 3000

7-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

This index is an alphabetized listing of parts, terms, and procedures having to do with the Hazardous Area Oxygen/Combustibles Transmitter. Every item listed in this index refers to a location in the manual by one or more page numbers.

Instruction Manual

IB-106-300DR Rev. 3.3

February 2000

SECTION 8

INDEX

Abrasive Shield, 1-7, 1-9, 2-8 Absolute Temperature, 1-2 Adapter Plate, 2-2 Ambient Temperature, 1-6 Arithmetic Constant, 1-2

Bypass Probe Option, 1-12

Calibration, 4-1 Cell Constant, 1-2 Check Valve, 1-3

Diffusion Element, 1-6, 1-12, 4-3 Diffusor Element, 1-6

Electrochemical Cell, 1-2 Electronic Packages, 1-1, 3-1, 4-1 EPROM, 3-2, 3-3, 3-4

Junction Box, 1-3, 1-8

Model 218A Digital Electronic Package, 3-2 Model 132 Digital Electronics Package, 3-4 Model 225 Electronics Package, 3-1 Model TC200 VERITRIM Electronics Package, 3-3 Models 218 Electronics Package, 3-1 Mounting Adapter Plate, 1-1

Nernst Equation, 1-2

Orsat Apparatus, 1-2 Oxygen Analyzer, 1-1

Probe Heater Setpoint, 3-3

Reference Gas, 1-3

Flame Arrestor, 1-11

Gas Stratification, 2-1

Sampling System, 1-1 Sensing Point, 2-1 Sensor Cell, 1-2, 1-4 Snubber, 1-12 Solenoid Valve, 1-3

Heater, 1-8, 3-1, 4-7, 5-2 Hub Grooves, 2-8

In Situ, 1-1, 1-2 Instrument Air, 1-2, 2-1

Rosemount Analytical Inc. A Division of Emerson Process Management Index 8-1

Thermocouple, 4-2, 4-5

Vee Deflector, 1-7, 2-8 V-Strut, 1-7, 4-6

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

Water Vapor, 1-2

Zirconia Disc, 1-2

8-2 Index Rosemount Analytical Inc. A Division of Emerson Process Management

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.

Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller's direct control.

2461

3267/2-00

Instruction Manual

IB-106-300DR Rev. 3.3 February 2000

World Class 3000

World Class 3000 Probe

Pa rt n o. __ __ ____________ Se ria l n o._ ______________ Ord er no._______________

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 gas.csc@emersonprocess.com

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd.

1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947

http://www.processanalytic.com

Fisher-Rosemount GmbH & Co.

Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd.

Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount

Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

Rosemount World Class 3000 O2 Analyzer DR Direct Replacement Probe-Rev 3.3 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

PREFACE

1-1 COMPONENT CHECKLIST

1-2 SYSTEM OVERVIEW

1-3 PHYSICAL DESCRIPTION

1-4 PROBE EXTERIOR

1-5 PROBE INTERIOR

JUNCTION BOX

1-8 PROBE OPTIONS

3-3 MODEL 218A ELECTRONICS SETUP

4-3 CELL REPLACEMENT

5-2 PROBE TROUBLESHOOTING

WARRANTY