Rosemount World Class 3000 O2 Analyzer with IFT 3000 Intelligent Field Transmitter-Rev 3.6 Manuals & Guides

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WORLD CLASS 3000 OXYGEN ANALYZER WITH IFT 3000 INTELLIGENT FIELD TRANSMITTER

Instruction Bulletin IB-106-300NH Rev. 3.6

World Class 3000 Probe

Part No. _______________ Serial No. _______________ Order No. _______________

IFT 3000

Part No. _______________ Serial No. _______________ Order No. _______________

HPS 3000

Part No. _______________ Serial No. _______________ Order No. _______________

MPS 3000

Part No. _______________ Serial No. _______________ Order No. _______________

PAGE SUMMARY

HIGHLIGHTS OF CHANGES

Effective May, 1996 Rev. 3

---

--2-2 3-3 4-1

PAGE SUMMARY

2-3 2-8

2-9

PAGE SUMMARY

1-3 3-21

General. Updated text and art to reflect new IFT version. General. Inserted new note regarding ambient air and high test gas. Updated Figure 2-1, Probe Ins tal la ti on (sheet 1 of 5) Updated system s t atu s codes . Updated system s t atu s codes .

Updated Figure 2-1, Probe Ins tal la ti on (sheet 2 of 5) Added Caution regarding n eed f or circu it break er on electrical power supply. Deleted Note on removin g

probe. Added instruction in Caution to change labeling.

Added description of th e pas s word protection feature for th e IFT. Added password prot ecti on i n f ormation.

Effective June, 1996 Rev. 3.1

Effective October, 1996 Rev. 3.2

4-1

PAGE SUMMARY

iii 2-1 2-8 2-10 2-15 2-19 2-21 2-22 4-1

Added new st atu s di s plays for password protection f eat u res .

Added "Safety instructions for the wiring and installation of this apparatus". Added WARNING to read new safety instructions. Added NOTE regarding IFT fuse locations an d s pecif ication s . Added NOTE regarding IFT fuse locations to Figure 2-7. Added NOTE regarding HPS fuse locations and s pecifi cation s. Added NOTE regarding HPS fuse locations to Figure 2-17. Added NOTE regarding MPS fuse locations and s pecifi cation s. Added NOTE regarding MPS fuse specifications to Figure 2-20. Added WARNING regardin g protect ive covers and grounds.

Effective January, 1997 Rev. 3.3

IB-106-300N H

HIGHLIGHTS OF CHANGES (continued)

Effective May, 1997 Rev. 3.4

PAGE SUMMARY

iii-xv Added foreign language safety sheets.

Effective February, 1998 Rev. 3.5

PAGE SUMMARY

2-2 3-17

PAGE SUMMARY

--1-3 3-7 3-21 through 3-26

Figure 2-1. Changed calibration gas tube dimensions. Added note on calibration gas flowmeter.

Changed test gas to calibration gas and reference gas to reference air throughout the instruction bulletin. Deleted paragraph 1-2.d.10. Figure 3-2 (Sheet 3 of 5). Deleted password protection in formation. Deleted paragraph 3-12 and Figures 3-7 though 3-10.

Effective July, 1998 Rev. 3.6

IB-106-300N H

ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount shall, upon prompt written notice fro m the purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IM PLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure of Rosemount to comply with th e warranty provisions, w h eth er claims by the purchaser are based in contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deterioration due to environment. Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the w a rran ty period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be subject to the same warranty as is ex tended to R osemount by the original man u f actu rer.

At the time of installation it is important that the required services are supplied to the system and that the electronic controller is set up at least to the point where it is controlling the sensor heater. This will ensure, that should there be a delay between installation and full commissioning that the sensor being supplied with ac power and reference air will not be subjected to component deterioration.

IB-106-300N H

NOTE

Only one probe can be calibrated at a time. Probe calibrations must be scheduled appropriately in multiple probe applications.

PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the World Class 3000

Oxygen Analyzer components, functions, installation, and maintenance.

This manual is designed to provide information about the World Class 3000 Oxygen Analyzer. We recommend that you thoroughly familiarize yourself with the Overview and Installation sections before installing your emissions monitor.

The overview presents the basic principles of the oxygen analyzer along with its performance characteristics and components . The remaining sections contain detailed procedures and information necessary to install and service the oxy g en an alyzer.

Before contacting Rosemount concerning any questions, first consult this manual. It describes most situations encountered in your equipment's operation and details necessary action.

DEFINITIONS

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

Highlights an operation or maintenance procedure, practice, condition, statement, etc., that if not strictly observed, could result in injury, death, or long-term health hazards of personnel.

NOTE

Highlights an essential operation procedure, condition, or statemen t.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

Highlights an operation or maintenance procedure, practice, conditions, statement, etc., that if not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE TO USERS

The number in the low er rig h t corn er of each illu stration in th is pu blication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

IB-106-300N H

IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING AND

INSTALLATION OF THIS APPARATUS

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. Non-EU 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.

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.

IB-106-300N H

iii

BELANGRIJK

Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.

De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften.

1. Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten, intern en extern.

2. Na installatie of controle moeten alle veiligheidsdeksels en -aardingen terug geplaatst worden. Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven.

3. Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.

4. Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen, hoger dan 75°C.

5. Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd is.

6. Om de veilige werking van dit toestel te verzekeren, moet de voeding door een stroomonderbreker gevoerd worden (min 10A) welke alle draden van de voeding moet onderbreken. De stroomonderbreker mag een mechanische schakelaar bevatten. Zoniet moet een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten onderworpen zijn aan een erkende standaard zoals IEC947.

7. Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning aanwezig. Deze deksels mogen enkel verwijderd worden nadat de voedingsspanning werd afgelegd en enkel door getraind onderhoudspersoneel.

8. Waar toestellen of deksels aangegeven staan met het symbool is er gevaar voor hete oppervlakken. Deze deksels mogen enkel verwijderd worden door getraind onderhoudspersoneel nadat de voedingsspanning verwijderd werd. Sommige opppervlakken kunnen 45 minuten later nog steeds heet aanvoelen.

9. Waar toestellen of deksels aangegeven staan met het symbool gelieve het handboek te raadplegen.

10. Alle grafische symbolen gebruikt in dit produkt, zijn afkomstig uit een of meer van devolgende standaards; EN61010-1, IEC417 en ISO3864.

IB-106-300N H

VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.

Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bør også følges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse forefindes.

2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og jordforbindelser reetableres.

3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.

4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur højere end 75° C.

5. Alle benyttede kabelforskruninger skal have en intern dimension, så passende kabelaflastning kan etableres.

6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse mod indirekte berøring gennem afbryder (min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsitua-tion. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og mærkes som sådan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947.

7. Hvor udstyr eller dæksler er mærket med dette symbol, er farlige spændinger normalt forekom-mende bagved. Disse dæksler bør kun afmonteres, når forsyningsspændingen er frakoblet - og da kun af instrueret servicepersonale.

8. Hvor udstyr eller dæksler er mærket med dette symbol, forefindes meget varme overflader bagved. Disse dæksler bør kun afmonteres af instrueret servicepersonale, når forsyningsspænding er frakoblet. Visse overflader vil stadig være for varme at berøre i op til 45 minutter efter frakobling.

9. Hvor udstyr eller dæksler er mærket med dette symbol, se da i betjeningsmanual for instruktion.

10. Alle benyttede grafiske symboler i dette udstyr findes i én eller flere af følgende standarder:- EN61010-1, IEC417 & ISO3864.

IB-106-300N H

BELANGRIJK

Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.

Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving anders voorschrijft.

1. Alle voorziene interne- en externe aardaansluitingen dienen op adequate wijze aangesloten te worden.

2. Na installatie,onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels /kappen en aardingen om reden van veiligheid weer aangebracht te worden.

3. Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of IEC 245.

4. Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven 75°C.

5. Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankering van de kabel wordt verkregen.

6. Om een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats te vinden via een meerpolige automatische zekering (min.10A) die foutconditie optreedt. Deze automatische zekering mag ook voorzien zijn van een mechanisch bediende schakelaar. Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars dienen te voldoen aan een erkende standaard zoals IEC 947.

spanningvoerende geleiders verbreekt indien een

alle

7. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder spanning voerende delen bevinden die gevaar op kunnen leveren. Deze beschermdeksels/kappen mogen uitsluitend verwijderd worden door getraind personeel als de spanning is afgeschakeld.

8. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder hete oppervlakken of onderdelen bevinden. Bepaalde delen kunnen mogelijk na 45 min. nog te heet zijn om aan te raken.

9. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, dient men de bedieningshandleiding te raadplegen.

10. Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende standaarden: EN 61010-1, IEC 417 & ISO 3864.

IB-106-300N H

TÄRKEÄÄ

Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa.

Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive) yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta, elleivät kansalliset standardit estä sitä.

1. Riittävät maadoituskytkennät on tehtävä kaikkiin maadoituspisteisiin, sisäisiin ja ulkoisiin.

2. Asennuksen ja vianetsinnän jälkeen on kaikki suojat ja suojamaat asennettava takaisin pai-koilleen. Maadoitusliittimen kunnollinen toiminta täytyy aina ylläpitää.

3. Jännitesyöttöjohtimien täytyy täyttää IEC227 ja IEC245 vaatimukset.

4. Kaikkien johdotuksien tulee toimia >75°C lämpötiloissa.

5. Kaikkien läpivientiholkkien sisähalkaisijan täytyy olla sellainen että kaapeli lukkiutuu kun-nolla kiinni.

6. Turvallisen toiminnan varmistamiseksi täytyy jännitesyöttö varustaa turvakytkimellä (min 10A), joka kytkee irti kaikki jännitesyöttöjohtimet vikatilanteessa. Suojaan täytyy myös sisältyä mekaaninen erotuskytkin. Jos ei, niin jännitesyöttö on pystyttävä katkaisemaan muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi. Turvakytkimien tai kat-kaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä.

7. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla hengenvaarallisen suuruinen jännite. Suojaa ei saa poistaa jänniteen ollessa kytkettynä laitteeseen ja poistamisen saa suorittaa vain alan asian-tuntija.

8. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla kuuma pinta. Suojan saa poistaa vain alan asiantuntija kun jännite-syöttö on katkaistu. Tällainen pinta voi säilyä kosketuskuumana jopa 45 mi-nuuttia.

9. Mikäli laite tai kosketussuoja on merkitty tällä merkillä katso lisäohjeita käyttöohjekirjasta

10. Kaikki tässä tuotteessa käytetyt graafiset symbolit ovat yhdestä tai useammasta seuraavis-ta standardeista: EN61010-1, IEC417 & ISO3864.

IB-106-300N H

vii

IMPORTANT

Consignes de sécurité concernant le raccordement et l’installation de cet appareil.

Les consignes de sécurité ci-dessous s’adressent particulièrement à tous les états membres de la communauté européenne. Elles doivent être strictement appliquées afin de satisfaire aux directives concernant la basse tension. Les états non membres de la communauté européenne doivent également appliquer ces consignes sauf si elles sont en contradiction avec les standards locaux ou nationaux.

1. Un raccordement adéquate à la terre doit être effectuée à chaque borne de mise à la terre, interne et externe.

2. Après installation ou dépannage, tous les capots de protection et toutes les prises de terre doivent être remis en place, toutes les prises de terre doivent être respectées en permanence.

3. Les câbles d’alimentation électrique doivent être conformes aux normes IEC227 ou IEC245

4. Tous les raccordements doivent pouvoir supporter une température ambiante supérieure à 75°C.

5. Tous les presse-étoupes utilisés doivent avoir un diamètre interne en rapport avec les câbles afin d’assurer un serrage correct sur ces derniers.

6. Afin de garantir la sécurité du fonctionnement de cet appareil, le raccordement à l’alimentation électrique doit être réalisé exclusivement au travers d’un disjoncteur (minimum 10A.) isolant tous les conducteurs en cas d’anomalie. Ce disjoncteur doit également pouvoir être actionné manuellement, de façon mécanique. Dans le cas contraire, un autre système doit être mis en place afin de pouvoir isoler l’appareil et doit être signalisé comme tel. Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telle IEC947.

7. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des tensions dangereuses sont présentes. Ces capots ne doivent être démontés que lorsque l’alimentation est coupée, et uniquement par un personnel compétent.

8. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des surfaces dangereusement chaudes sont présentes. Ces capots ne doivent être démontés que lorsque l’alimentation est coupée, et uniquement par un personnel compétent. Certaines surfaces peuvent rester chaudes jusqu’à 45 mn.

9. Lorsque les équipements ou les capots affichent le symbole suivant, se reporter au manuel d’instructions.

10. Tous les symboles graphiques utilisés dans ce produit sont conformes à un ou plusieurs des standards suivants: EN61010-1, IEC417 & ISO3864.

IB-106-300N H

viii

Wichtig

Sicherheitshinweise für den Anschluß und die Installation dieser Geräte.

Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der Niederspannungsrichtlinie zu genügen. Nichtmitgliedsstaaten der europäischen Gemeinschaft sollten die national gültigen Normen und Richtlinien einhalten.

1. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden.

2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerät müssen alle Sicherheitsabdeckungen und Erdungen wieder installiert werden. Die Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gestört sein.

3. Die Netzspannungsversorgung muß den Anforderungen der IEC227 oder IEC245 genügen.

4. Alle Verdrahtungen sollten mindestens bis 75 °C ihre Funktion dauerhaft erfüllen.

5. Alle Kabeldurchführungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so gewählt werden, daß diese eine sichere Verkabelung des Gerätes ermöglichen.

6. Um eine sichere Funktion des Gerätes zu gewährleisten, muß die Spannungsversorgung über mindestens 10 A abgesichert sein. Im Fehlerfall muß dadurch gewährleistet sein, daß die Spannungsversorgung zum Gerät bzw. zu den Geräten unterbrochen wird. Ein mechanischer Schutzschalter kann in dieses System integriert werden. Falls eine derartige Vorrichtung nicht vorhanden ist, muß eine andere Möglichkeit zur Unterbrechung der Spannungszufuhr gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden. Ein solcher Mechanismus zur Spannungsunterbrechung muß mit den Normen und Richtlinien für die allgemeine Installation von Elektrogeräten, wie zum Beispiel der IEC947, übereinstimmen.

7. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, die eine gefährliche (Netzspannung) Spannung führen. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen.

8. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, in bzw. unter denen heiße Teile vorhanden sind. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen. Bis 45 Minuten nach dem Unterbrechen der Netzzufuhr können derartig Teile noch über eine erhöhte Temperatur verfügen.

9. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, bei denen vor dem Eingriff die entsprechenden Kapitel im Handbuch sorgfältig durchgelesen werden müssen.

10. Alle in diesem Gerät verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgend aufgeführten Standards: EN61010-1, IEC417 & ISO3864.

IB-106-300N H

IMPORTANTE

Norme di sicurezza per il cablaggio e l’installazione dello strumento.

Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all’Unione Europea, salvo quanto disposto dalle vigenti normative l ocali o nazionali

1. Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra interni ed esterni, dove

2. Dopo l’installazione o la localizzazione dei guasti, assicurarsi che tutti i coperchi di protezione siano stati

3. I cavi di alimentazione della rete devono essere secondo disposizioni IEC227 o IEC245.

4. L’intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore a 75°C.

5. Le dimensioni di tutti i connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggio

previsti.

collocati e le messa a terra siano collegate. L’integrità di ciscun morsetto di terra deve essere costantemente garantita.

al cavo.

6. Per garantire un sicuro funzionamento dello strumento il collegamento alla rete di alimentazione principale dovrà essere eseguita tramite interruttore automatico (min.10A), in grado di disattivare tutti i conduttori di circuito in caso di guasto. Tale interruttore dovrà inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione dell’alimentazione, chiaramente identificabile. Gli interruttori dovranno essere conformi agli standard riconosciuti, quali IEC947.

7. Il simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza di elevati voltaggi. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento.

8. Il simbolo riportato sullo strumento o sui coperchi di protezione indica rischio di contatto con superfici ad alta temperatura. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento. Alcune superfici possono mantenere temperature elevate per oltre 45 minuti.

9. Se lo strumento o il coperchio di protezione riportano il simbolo, fare riferimento alle istruzioni del manuale Operatore.

10. Tutti i simboli grafici utilizzati in questo prodotto sono previsti da uno o più dei seguenti standard: EN61010-1, IEC417 e ISO3864.

IB-106-300N H

VIKTIG

Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret.

Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder.

1. Passende jordforbindelser må tilkobles alle jordingspunkter, interne og eksterne hvor disse forefinnes.

2. Etter installasjon eller feilsøking skal alle sikkerhetsdeksler og jordforbindelser reetableres. Jordingsforbindelsene må alltid holdes i god stand.

3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.

4. Alle ledningsforbindelser skal være konstruert for en omgivelsestemperatur høyere en 750C.

5. Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnåes.

6. For å oppnå sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom en strømbryter (minimum 10A) som vil bryte spenningsforsyningen til alle elektriske kretser ved en feilsituasjon. Strømbryteren kan også inneholde en mekanisk operert bryter for å isolere instrumentet fra spenningsforsyningen. Dersom det ikke er en mekanisk operert bryter installert, må det være en annen måte å isolere utstyret fra spenningsforsyningen, og denne måten må være tydelig merket. Kretsbrytere eller kontakter skal oppfylle kravene i en annerkjent standard av typen IEC947 eller tilsvarende.

7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell.

8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. Noen overflater kan være for varme til å berøres i opp til 45 minutter etter spenningsforsyning frakoblet.

9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til instruksjonsmanualen for instrukser.

10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av følgende standarder: EN61010-1, IEC417 & ISO3864.

IB-106-300N H

IMPORTANTE

Instruções de segurança para ligação e instalação deste aparelho.

As seguintes instruções de segurança aplicam-se especificamente a todos os estados membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tensão. Relativamente aos estados que não pertençam à UE, deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação local a tiver substituído.

1. Devem ser feitas ligações de terra apropriadas a todos os pontos de terra, internos ou externos.

2. Após a instalação ou eventual reparação, devem ser recolocadas todas as tampas de segurança e terras de protecção. Deve manter-se sempre a integridade de todos os terminais de terra.

3. Os cabos de alimentação eléctrica devem obedecer às exigências das normas IEC227 ou IEC245.

4. Os cabos e fios utilizados nas ligações eléctricas devem ser adequados para utilização a uma temperatura ambiente até 75º C.

5. As dimensões internas dos bucins dos cabos devem ser adequadas a uma boa fixação dos cabos.

6. Para assegurar um funcionamento seguro deste equipamento, a ligação ao cabo de alimentação eléctrica deve ser feita através de um disjuntor (min. 10A) que desligará todos os condutores de circuitos durante uma avaria. O disjuntor poderá também conter um interruptor de isolamento accionado manualmente. Caso contrário, deverá ser instalado qualquer outro meio para desligar o equipamento da energia eléctrica, devendo ser assinalado convenientemente. Os disjuntores ou interruptores devem obedecer a uma norma reconhecida, tipo IEC947.

7. Sempre que o equipamento ou as tampas contiverem o símbolo, é provável a existência de tensões perigosas. Estas tampas só devem ser retiradas quando a energia eléctrica tiver sido desligada e por Pessoal da Assistência devidamente treinado.

8. Sempre que o equipamento ou as tampas contiverem o símbolo, há perigo de existência de superfícies quentes. Estas tampas só devem ser retiradas por Pessoal da Assistência devidamente treinado e depois de a energia eléctrica ter sido desligada. Algumas superfícies permanecem quentes até 45 minutos depois.

9. Sempre que o equipamento ou as tampas contiverem o símbolo, o Manual de Funcionamento deve ser consultado para obtenção das necessárias instruções.

10. Todos os símbolos gráficos utilizados neste produto baseiam-se em uma ou mais das seguintes normas: EN61010-1, IEC417 e ISO3864.

IB-106-300N H

xii

IMPORTANTE

Instrucciones de seguridad para el montaje y cableado de este aparato.

Las siguientes instrucciones de seguridad , son de aplicacion especifica a todos los miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension.

1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en aquellos terminales previstos al efecto.

2. Una vez finalizada las operaciones de mantenimiento del equipo, se deben volver a colocar las cubiertas de seguridad aasi como los terminales de tierra. Se debe comprobar la integridad de cada terminal.

3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245.

4. Todo el cableado sera adecuado para una temperatura ambiental de 75ºC.

5. Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables.

6. Para un manejo seguro del equipo, la alimentacion electrica se realizara a traves de un interruptor magnetotermico ( min 10 A ), el cual desconectara la alimentacion electrica al equipo en todas sus fases durante un fallo. Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio.

7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa, dicho alojamiento solamente se abrira una vez que se haya interrumpido la alimentacion electrica al equipo asimismo la intervencion sera llevada a cabo por personal entrenado para estas labores.

8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con alta temperatura, por tanto se abrira una vez que se haya interrumpido la alimentacion electrica al equipo por personal entrenado para estas labores, y al menos se esperara unos 45 minutos para enfriar las superficies calientes.

9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el manual de instrucciones.

10. Todos los simbolos graficos usados en esta hoja, estan de acuerdo a las siguientes normas EN61010-1, IEC417 & ISO 3864.

IB-106-300N H

xiii

VIKTIGT

Säkerhetsföreskrifter för kablage och installation av denna apparat.

Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varje avseende för att överensstämma med Lågspännings direktivet. Icke EU medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala eller nationella föreskrifter.

1. Tillämplig jordkontakt skall utföras till alla jordade punkter, såväl internt som externt där så erfordras.

2. Efter installation eller felsökning skall samtliga säkerhetshöljen och säkerhetsjord återplaceras. Samtliga jordterminaler måste hållas obrutna hela tiden.

3. Matningsspänningens kabel måste överensstämma med föreskrifterna i IEC227 eller IEC245.

4. Allt kablage skall vara lämpligt för användning i en omgivningstemperatur högre än 75ºC.

5. Alla kabelförskruvningar som används skall ha inre dimensioner som motsvarar adekvat kabelförankring.

6. För att säkerställa säker drift av denna utrustning skall anslutning till huvudströmmen endast göras genom en säkring (min 10A) som skall frånkoppla alla strömförande kretsar när något fel uppstår. Säkringen kan även ha en mekanisk frånskiljare. Om så inte är fallet, måste ett annat förfarande för att frånskilja utrustningen från strömförsörjning tillhandahållas och klart framgå genom markering. Säkring eller omkopplare måste överensstämma med en gällande standard såsom t ex IEC947.

7. Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för livsfarlig spänning i närheten. Dessa höljen får endast avlägsnas när strömmen ej är ansluten till utrustningen - och då endast av utbildad servicepersonal.

8. När utrustning eller hölje är markerad med vidstående symbol föreligger risk för brännskada vid kontakt med uppvärmd yta. Dessa höljen får endast avlägsnas av utbildad servicepersonal, när strömmen kopplats från utrustningen. Vissa ytor kan vara mycket varma att vidröra även upp till 45 minuter efter avstängning av strömmen.

9. När utrustning eller hölje markerats med vidstående symbol bör instruktionsmanualen studeras för information.

10.

Samtliga grafiska symboler som förekommer i denna produkt finns angivna i en eller flera av följande föreskrifter:- EN61010-1, IEC417 & ISO3864.

IB-106-300N H

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IB-106-300N H

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Section Page

Rosemount Warranty.......................................................................................................................................... i

I. DESCRIPTION

................................................................................................................................................. 1-1

1-1. Component Check list of Typical System (Package Cont en ts )............................................................... 1-1

1-2. System Overv iew.................................................................................................................................... 1-2

II. INSTALLATION

.............................................................................................................................................. 2-1

2-1. Oxygen An alyzer (Probe) Installation.................................................................................................... 2-1

2-2. Intelligent Field Transmitter (IFT) Installation ...................................................................................... 2-8

2-3. Heater Power Supply Installation........................................................................................................... 2-12

2-4. Multiprobe Calibration Gas Sequencer Installation............................................................................... 2-20

III. GENERAL USER INTERFACE (GUI) OPERATION

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

3-2. Deluxe Version IFT Displays and C ont rols ............................................................................................ 3-2

3-3. Help Key................................................................................................................................................. 3-3

3-4. Status Line............................................................................................................................................... 3-3

3-5 Quick Reference Chart............................................................................................................................ 3-3

3-6. Main Menu.............................................................................................................................................. 3-3

3-7 PROBE DATA Sub-Menu.................................................................................................................... 3-4

3-8. CALIBRA TE O

Sub-Menu................................................................................................................... 3-14

3-9. SETUP Sub-Menu.................................................................................................................................. 3-14

3-10. Analog Output Calibration...................................................................................................................... 3-14

3-11. System Calibration.................................................................................................................................. 3-14

IV. SYSTEM TROUBLESHOOTING

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

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

4-2. Special Troubleshooting Notes............................................................................................................... 4-1

4-3. System Troubleshootin g......................................................................................................................... 4-1

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

V. RETURNING EQUIPMENT TO THE FACTORY

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

APPENDIX A. WORLD CLASS 3000 OXYGEN ANALYZER (PROBE)

APPENDIX B. HPS 3000 HEATER POWER SUPPLY FIELD MODULE

APPENDIX D. MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER

APPENDIX E. IFT 3000 INTELLIGENT FIELD TRANSMITTER

APPENDIX J. HART

COMMUNICATOR, MODEL 275D9E IFT APPLICATIONS

IB-106-300N H

xvii

LIST OF ILLUSTRATIONS

Figure Page

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

1-2 Typical System Installation................................................................................................................................. 1-5

1-3 World Class 3000 Typical Application with Intelligen t Field Transmitters...................................................... 1-6

2-1 Probe Installation ................................................................................................................................................ 2-2

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

2-3 Air Set, Plant Air Connection............................................................................................................................. 2-7

2-4 Outline of Intelligent Field Transmitter.............................................................................................................. 2-8

2-5 Power Supply Board Jumper Configuration....................................................................................................... 2-9

2-6 Signal Wire Routing............................................................................................................................................ 2-9

2-7 IFT Power Supply Board Jumpers...................................................................................................................... 2-10

2-8 Wiring Layout for IFT 3000 System without HPS............................................................................................. 2-11

2-9 Microprocessor Board Jumper Configuration.................................................................................................... 2-12

2-10 IFT Microprocessor Board ................................................................................................................................. 2-13

2-11 Interconnect Board Jumper Conf ig u ration......................................................................................................... 2-14

2-12 IFT Interconnect Board Output Connection s..................................................................................................... 2-14

2-13 Outline of Heater Power Supply......................................................................................................................... 2-15

2-14 Wiring Layout f or C omplete IFT 3000 System wi th HPS................................................................................. 2-16

2-15 Heater Power Supply Wiring C on n ection s......................................................................................................... 2-18

2-16 Jumper Selection Label....................................................................................................................................... 2-19

2-17 Jumpers on HPS Mother Board.......................................................................................................................... 2-19

2-18 MPS Module....................................................................................................................................................... 2-20

2-19 MPS Gas Connections........................................................................................................................................ 2- 21

2-20 MPS Probe Wiring.............................................................................................................................................. 2-22

3-1 Deluxe Version IFT Displays and Controls........................................................................................................ 3- 2

3-2 Quick Reference Chart........................................................................................................................................ 3-5

3-3 Typical Calibration Setup .................................................................................................................................. 3-17

3-4 Portable Rosemount Oxygen Calibration Gas Kit.............................................................................................. 3-18

3-5 Typical Portable Calibration Setup..................................................................................................................... 3-18

3-6 Typical Automatic Calibration System............................................................................................................... 3-20

LIST OF TABLES

Table Page

3-1 Sample HELP Messages..................................................................................................................................... 3-3

3-2 MAIN Menu....................................................................................................................................................... 3-3

3-3 PROBE DATA Sub-Menu ............................................................................................................................... 3-4

3-4 CALIBRATE O

3-5 SETUP Sub-Menu ............................................................................................................................................. 3-11

3-6 Efficiency Constants........................................................................................................................................... 3-14

Sub-Menu.............................................................................................................................. 3-10

IB-106-300N H

xviii

SECTION I. DESCRIPTION

1-1. COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS) A typical

Rosemount World Class 3000 Oxygen Analyzer with IFT 3000 Intelligent Field Transmitter should contain the items shown in Figure 1-1. Record the part number, serial number, and order nu mber for each component of your system in the table located on the first page of this manual.

ITEM DESCRIPTION

1 Intelligent Field Transmitter 2 Instruction Bulletin 3 Multiprobe Calibration Gas Sequencer

(Optional) 4 Heater Power Supply (Optional) 5 Oxygen Analyzer (Probe) 6System Cable 7 Adapter Plate with moun ting

hardware and gask et 8 Reference Air Set

(If MPS not supplied) 9HART

Communicator Packag e (Option al)

MAN4275A00

October1994

HART Communicator

FISHER-ROSEMOUNT

English

21190001

Figure 1-1. Typical System Package

IB-106-300NH

1-1

1-2. SYSTEM OVERVIEW.

a. S cope.

This Instruction Bulletin has been designed to supply details needed to install, startup, operate, and maintain the Rosemount World Class 3000 Oxygen Analyzer with IFT 3000 Intelligent Field Transmitter. The Intelligent Field Transmitter (IFT) can be interfaced with one World Class 3000 probe. The IFT provides all necessary intelligence for controlling the probe and optional MPS 3000 Multiprobe Calibration Gas Sequencer. Appendices at the back of this manual detail each component and option from the standpoint of trouble-shooting, repair, and spare parts.

Operator/Technician interface to the IFT can be provided from the displays and keypads on the front panel, and remotely through HART communications protocol, utilizing the 4-20 mA output signal from the IFT interconnect board. HART Communicator IFT applications are detailed in Appendix J.

b. System Description.

The Rosemount Oxygen Analyzer (Probe) is designed to measure the net concentration of oxygen in an industrial process; i.e., the oxygen remaining after all fuels have been oxidized. The probe is permanently positioned within an exhaust duct or stack and performs its task without the use of a sampling system.

The equipment measures oxygen percentage by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output voltage of the cell is given by the following Nernst equation:

EMF = KT log

10(P1/P2

Where:

1. P

is the partial pressure of the oxygen in the

measured gas on on e s ide of the cell,

2. P

is the partial pressure of the oxygen in the

reference air 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 air.

) + C

When the cell is at operating temperature and there are unequal oxygen concentrations across the cell, oxygen ions will travel from the high partial pressure of oxygen side to the low partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade. Because the magnitude of the output is proportional to the logarithm of the inverse of the sample of the oxygen partial pressure, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the oxygen analyzer to provide exceptional sensitivity at low oxygen concentrations.

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

may be considered an analysis on a "wet" basis. In comparison with older methods, such as the Orsat apparatus, which provides an analysis on a "dry" gas basis, the "wet" analysis will, in general, indicate a lower percentage of oxygen. The difference will be proportional to the water content of the sampled gas stream.

c. System Configuration.

The equipment covered in this manual consists of three major components: the oxygen analyzer (probe), the intelligent field transmitter (IFT), and an optional heater power supply (HPS). The HPS is required where the cable run between the probe and the electronics is greater than 150 ft (45 m). There is also an optional multiprobe calibration gas sequencer (MPS) to facilitate automatic calibration of the probe.

Probes are available in five length op tions, giving the user the flexibility to use an in situ penetration appropriate to the size of the stack or duct. The options on length are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), 9 ft (2.7 m), or 12 ft (3.66 m).

The IFT contains electronics that control probe temperature (in conjunction with the optional HPS), supply power, and provide isolated outputs that are proportional to the measured oxygen concentration. The oxygen sensing cell is maintained at a constant temperature by modulating the duty cycle of the probe heater. The IFT accepts millivolt signals generated by the sensing cell and produces outputs to be used by remotely connected devices. The IFT output is isolated and selectable to provide linearized voltage or current.

IB-106-300NH

1-2

The heater power supply (HPS) can provide an interface between the IFT and the probe. The HPS contains a transformer for supplying proper voltage to the probe heater. The enclosure has been designed to meet NEMA 4X (IP56) specifications for water tightness; an optional enclosure to meet Class 1, Division 1, Group B (IP56) explosion proof is also available.

8. Five languages may be selected for use with the Intelligent Field Transmitter:

English Italian French Spanish German

9. An operator can set up, calibrate, or troubleshoot the IFT in on e of t wo ways:

Systems with multiprobe and multiple IFT applications may employ an optional MPS 3000 Multiprobe Calibration Gas Sequencer. The MPS 3000 provides automatic calibration gas sequencing for up to four probes and IFTs to accommodate autom atic calibration .

d. System Features.

1. Unique and patented electronic cell protection action that automatically protects sensor cell when the analyzer detects reducing atmospheres.

2. Output voltage and sensitivity increase as the oxygen concentration decreas es .

3. User friendly, menu driven operator interface with context-sensitive on-line help.

4. Field replaceable cell.

5. Analyzer constructed of rugge d 316 LSS for all wetted parts.

Optional General User Interface

(a)

(GUI).

The GUI is housed within the IFT electronics enclosure and makes use of an LCD and keypad.

Optional HART Interface.

(b)

4-20 mA output line transmits an analog signal proportional to oxygen level. The line also carries all information normally accessed by use of the General User Interface LCD and keypad. This information can be accessed through the following:

1 Rosemount Model 275 Handheld

Communicator - The handheld communicator requires Device Descriptor (DD) software specific to the World Class 3000 product. The DD software will be supplied with many model 275 units, but can also be programmed into existing units at most Fisher-Rosemount service offices.

The IFT's

6. The intelligent field transmitter (IFT) can be located up to 150 ft (45 m) from the probe when used without optional heater power supply (HPS). When the system includes the optional HPS, the HPS can be located up to 150 ft (45 m) from the probe and the IFT may be located up to 1200 ft (364 m) from the HPS.

7. All electronic modules are adaptable to 100, 120, 220, and 240 line voltag es .

2 Personal Computer (PC) - The use

of a personal computer requires Cornerstone software with Module Library (ModLib) specific to the World Class 3000 product.

3 Selected Distributed Control Sys-

tems - The use of distributed control systems requires input/output (I/O) hardware and software which permit HART communications.

IB-106-300NH

1-3

e. Handling the Oxygen Analyzer.

It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to prevent possible equipment damage.

The oxygen analyzer is designed for industrial application. Treat each component of the system with care to avoid physical damage. The probe contains components made from ceramics, which are susceptible to shock when mishandled.

terms of available power supply, ambient temperatures, environmental considerations, convenience, and serviceability. A typical system installation is illustrated in Figure 1-2. Figure 1-3 shows a typical system wiring. For details on installing the individual components of the system, refer to Section II, Installation.

After selecting the probe mounting location, provision should be made for a platform where the probe can be easily serviced. The intelligent field transmitter (IFT) can be located up to 150 ft (45 m) cabling distance from the probe when used without optional heater power supply (HPS). When the system includes the optional HPS, the HPS can be located up to 150 ft (45 m) cabling distance from the probe and the IFT may be located up to 1200 ft (364 m) cabling distance from the HPS.

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 with Intelligent Field Transmitter make sure that you have all of the components necessary to make the system installation. Ensure that all the components are properly integrated to make the system functional.

Once you have verified that you have all the components, select mounting locations and determine how each component will be placed in

A source of instrument air is required at the probe for reference air use. Since the probe is equipped with an in-place calibration feature, provision should be made for connecting calibration gas tanks to the oxygen analyzer when the probe is to be calibrated.

If the calibration gas bottles will be permanently hooked up, a check valve is required next to the calibration fittings on the probe junction box. T his 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 calibration gas kit or the solenoid valve in the multiprobe calibration gas sequencer units.

An optional Z-purge arrangement is available for applications where hazardous area classification may be required (See Application Data Bulletin AD 106-300B).

IB-106-300NH

1-4

GASES

STACK

STANDARD

DUCT

CALIBRATION

INSTRUMENT

AIR SUPPLY

(REF. AIR)

GAS

PRESSURE

REGULATOR

FLOWMETER

OXYGEN ANALYZER (PROBE)

INTELLIGENT FIELD TRANSMITTER

MULTIPROBE

CALIBRATION GAS

SEQUENCER

}

ADAPTER PLATE

LINE VOLTAGE

INST. AIR

CAL GAS 1

CAL GAS 2

GASES

STACK

ADAPTER

PLATE

CALIBRATION

GAS

SUPPLY

REFERENCE AIR

OPTIONS

DUCT

OXYGEN ANALYZER (PROBE)

HEATER POWER SUPPLY

Figure 1-2. Typical System I n s tall ation

IB-106-300NH

1-5

INTELLIGENT FIELD TRANSMITTER

}

LINE VOLTAGE

27270001

Stack Thermocouple

(optional)

2-Conductor T/C

Wire [150 Ft (45 m) Max]

(optional)

(OPTIONAL)

Line Voltage

4 Twisted Pair Plus 2 Twisted Pair for Options [1200 Ft (364 m) Max]

Line Voltage

World Class 3000

Probe

2-Calibration Gas Lines

World Class 3000

Probe

Stack Thermocouple

(optional)

7-Conductor Cable

[150 Ft (45 m) Max]

by Customer

[300 Ft (90 m) Max]

HPS 3000

Explosion Proof Required only for Hazardous Area Applications, otherwise use NEMA 4X. Lengths Exceeding 150 ft (45 m).

(OPTIONAL)

MPS 3000

CALIBRATION GAS

SEQUENCER

Modular Design Up to 4 Probes

(HPS not required for lengths of less than 150 feet)

7-Conductor Cable

[150 Feet (45 m) Max]

2-Conductor T/C

Wire [150 Feet (45 m) Max]

(optional)

Line Voltage

Calibration Gas

Customer

IFT 3000

Intelligent Field Transmitter

NEMA 4X Enclosure

Line Voltage 100 to 120 Volt 220 to 240 Volt

5 Conductor

[1000 Ft (309 m) Max]

Line Voltage

IFT 3000

Intelligent Field Transmitter

NEMA 4X Enclosure

Line Voltage 100 to 120 Volt 220 to 240 Volt

World Class 3000

Probe

7-Conductor Cable

[150 Ft (45 m) Max]

2-Calibration Gas Lines by Customer [300 Ft (90 m) Max]

4-20 mA Output

Line Voltage

HPS 3000

Heater Power Supply

Required for > 150 Ft (45 m)]

[Optional,

4 Twisted Pair, plus 2 Twisted Pair for Options [1200 Ft (364 m) Max]

Line Voltage

IFT 3000

Intelligent Field Transmitter

NEMA 4X Enclosure

Line Voltage 100 to 120 Volt 220 to 240 Volt

(Twisted Pair)

Termination in Control Room

Customer's Laptop with

Cornerstone Software

Customer's Distributed

Control System

with HART

Interface Capability

Figure 1-3. World Class 3000 Typical Application with Intelligent Field Transmitters

IB-106-300NH

1-6

HART Model 275

Hand Held

Interface

27270002

SECTION II. INSTALLATION

2-1. OXYGEN ANALYZER (PROBE)

INSTALLATION.

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.

a. Selecting Location.

1. The location of the probe in the stack or flue is most important for maximum accuracy in the oxygen analyzing process. The probe must be positioned so that the gas it measures is representative of the process. Best results are normally obtained if the probe is positioned near the center of the duct (40 to 60% insertion). A point too near the edge or wall of the duct may not provide a representative sample because of the possibility of gas stratification. In addition, the sensing point should be selected so that the process gas temperature falls within a range of 50° to 1300°F (10° to 704°C). Figure 2-1 provides mechanical installation referen ces.

4. If the probe is to be mounted outside, subject to rain and snow conditions, make sure the back of the probe (outside of the duct) is insulated to prevent the formation of flue gas condensate in the calibration gas lines.

Do not allow the temperature of the probe junction box to exceed 300°F (149°C) or damage to the unit may result. If the probe junction box temperature exceeds 300°F (149°C), the user must fabricate a heat shield or provide adequate cooling air to the probe junction box.

b. Mechanical Installati on .

1. Ensure that all components are available for installation of the probe. Ensure that the system cable is the required length. If equipped with the optional ceramic diffusor element, ensure that it is not damaged.

2. The probe may be installed intact as it is received. It is recommended that you disassemble the adapter plate for each installation.

NOTE

2. Check the flue or stack for holes and air leakage. The presence of this condition will substantially affect the accuracy of the oxygen reading. Therefore, either make necessary repairs or install the probe upstream of any leakage.

3. Ensure that the area is clear of obstructions internal and external that will interfere with installation. Allow adequate clearance for removal of probe (Fig u re 2- 1).

IB-106-300N H

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.

3. Weld or bolt adapter plate (Figure 2-1) onto the duct.

2-1

TO AMBIENT

REF AIR

CAL GAS

1/4 IN. TUBE

ANSI

ELEC

CONN

6 MM TUBE

DIN

JIS

1/2"

CONDUIT

27270009

1.88 (48)

FURNISHED IN - XIT

ADAPTER & ACCESSORY

0.062 THK GASKET

INSULATE IF EXPOSED

WEATHER CONDITIONS

4512C34

4512C35

4512C36

3535B18H02

3635B48H01

3535B45H01

ANSI

JIS

DIN

2.27 (58)

DIA MAX

ROSEMOUNT

3.80 (96.5) ADD TO DIM "A"

FOR PROBE

WITH CERAMIC

5.85 (148.6)DIM "A"

WITH STANDARD

DIFFUSER

4.90 (124.5)

7.58 (192)

SNUBBER

DIFFUSER

ADD TO DIM "A" FOR

DIFFUSER AND FLAME

PROBE WITH CERAMIC

DIM "B" REMOVAL ENVELOPE

ARRESTOR

GAS CAL

JIS

6.10

4512C18H01

DIN

7.28

4512C19H01

ANSI

6.00

4512C17H01

(155)

(185)

(153)

0.59

0.71

0.75

AIR REF

(15)

(18)

(20)

AT THE BOTTOM

BOTTOM VIEW

INSTALL WITH CONNECTIONS

5.12

(130)

5.71

(145)

4.75

(121)

THESE FLAT FACED FLANGES ARE MANUFACTURED

DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN

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

PARENTHESES.

NOTES: 1.

DIM "B"

27.3 (694)

45.3 (1151)

16 (406)

34 (864)

DIM "A"

PRESSURE RATED.

81.3 (2065)6FT

70 (1778)

117.3 (2980)

153.3 (3894)

142 (3607)

106 (2692)

TABLE I MOUNTING FLANGE

FLANGE

DIA.

HOLE

PROCESS FLOW MUST

BE IN THIS DIRECTION

WITH RESPECT TO

DEFLECTOR 3534848G01

Figure 2-1. Probe Installation (Sh eet 1 of 5)

IB-106-300N H

2-2

DIA.

(4) HOLES

EQ SP ON BC

TABLE II INSTALLATION/REMOVAL

18 IN.

PROBE

3FT

9FT

12 FT

TABLE IV. FLANGE SIZE

7.50

BOLT

CIRCLE

0.75

(8) HOLES

DIAMETER

FLANGE

9.00 (153)

DIAMETER

ANSI

7.48

0.75

9.25 (235)

JIS

7.48

0.945

9.25 (235)

DIN

DIN, AND JIS BOLT PATTERNS AND ARE

* FLANGES ARE MANUFACTURED TO ANSI,

FLAT FACED. THESE FLANGES ARE NOT

PRESSURE RATED.

5.7 (145)

14.5

(369)

DIM "D" REMOVAL ENVELOPE

7.00

(178)

SEE TABLE IV

FOR FLANGE

SIZES

REF AIR AND

CAL GAS

CONNECTOR

ELECTRICAL

CONNECTOR

CAL GAS LINES

CHECK VALVE FOR

INSULATE IF

EXPOSED TO

AMBIENT WEATHER

27270010

CONDITIONS

31.1

(790)

45.3 (1151)

DIM "D" DIM "E"

(686)

DIM "C"

NOMINAL MEASUREMENTS

TABLE III. REMOVAL / INSTALLATION

3FT

67.1

81.3

6FT

(1704)

(2065)

(1600)

103.1

(2619)

117.3

(2980)

(2515)

9FT

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 (Sh eet 2 of 5)

3.6

NOMINAL

(P/N 4843B38G02)

SNUBBER DIFFUSION/

DUST SEAL ASSEMBLY

DIMENSIONS ARE IN INCHES WITH

MILLIMETERS IN PARENTHESES.

NOTE:

IB-106-300N H

2-3

16860021

TABLE VI. ADAPTOR PLATE DIMENSIONS FOR ABRASIVE SHIELD

JIS

(P/N 3535B58G04)

DIN

(P/N 3535B58G06)

ANSI

(P/N 3535B58G02)

IN.

(mm)

"A"

DIMENSIONS

9.25

(235)

9.25

(235)

9.00

(229)

4.92

3.94

4.75

"B"

(125)

(100)

(121)

DIA

(M-20 x 2.5)

(M-16 x 2)

0.625-11

"C"

THREAD

(200)

7.894

7.48

(190)

7.50

(191)

"D"

DIA

ATTACHING HARDWARE.

NOTE: PART NUMBERS FOR ADAPTOR PLATES INCLUDE

8 THREADED HOLES

EQUALLY SPACED ON

D DIA B.C.

ABRASIVE SHIELD

FLANGE O.D.

22.5

OUTSIDE WALL SURFACE.

CROSSHATCHED AREA IN 4

CORNERS MAY BE USED TO

FIELD BOLTING OF PLATE TO

TABLE V. ADAPTOR PLATE DIMENSIONS FOR PROBE

JIS

(P/N 4512C35G01)

DIN

(P/N 4512C36G01)

ANSI

(P/N 4512C34G01)

IN.

(mm)

DIMENSIONS

6.50

(165)

7.5 (191)

6.00

(153)

"A"

(M-12 x 1.75)

(M-16 x 2)

0.625-11

"B"

THREAD

(130)

5.118

(145)

5.708

4.75

(121)

"C"

DIA

ATTACHING HARDWARE.

NOTE: PART NUMBERS FOR ADAPTOR PLATES INCLUDE

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

C DIA B.C.

2.500 DIA

ADAPTOR PLATE FOR

STD WORLD CLASS 3000

PROBE INSTALLATION.

SEE SHEET 1.

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

IB-106-300N H

2-4

INSTALLATION FOR METAL

WALL STACK OR DUCT

CONSTRUCTION

INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION

MTG HOLES SHOWN ROTATED

OUT OF

TRUE POSITION

WELD OR BOLT ADAPTOR PLATE TO METAL WALL OF STACK OR DUCT. JOINT MUST BE AIR TIGHT.

0.50 [13]

3.75 [95] MIN DIA HOLE

IN WALL

STACK OR DUCT METAL WALL

0.50 [13]

BOLT ADAPTOR

PLATE TO OUTSIDE

WALL SURFACE

FIELD WELD

PIPE TO

ADAPTOR PLATE

MTG HOLES

SHOWN ROTATED

TRUE POSITION

OUT OF

JOINT MUST

BE AIRTIGHT

OUTSIDE WALL

SURFACE

NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPT

ADAPTOR PLATE NOT FURNISHED BY ROSEMOUNT.

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 ADAPTOR

PLATE TO METAL WALL

OF STACK OR DUCT.

JOINT MUST BE AIR TIGHT.

2.50 [63.5] MIN DIA HOLE

IN WALL

STACK OR DUCT METAL WALL

BOLT ADAPTOR

PLATE TO OUTSIDE

WALL SURFACE

JOINT MUST

BE AIRTIGHT

OUTSIDE WALL

SURFACE

NOTE: DIMENSIONS IN INCHES WITH

MILLIMETERS IN PARENTHESES.

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

FIELD WELD PIPE TO ADAPTOR PLATE

3.50 [89] O.D. REF

PIPE 3.00 SCHED 40 PIPE SLEEVE (NOT BY ROSEMOUNT) LENGTH BY CUSTOMER

MASONRY STACK WALL

624038

IB-106-300N H

2-5

60 MAX.

BRACE BARS (NOT BY ROSEMOUNT)

2.00 (51)

1.00 (25)

NOTE: DIMENSIONS IN INCHES WITH

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.)

BY ROSEMOUNT

}

30 MIN.

4.12

(105)

4.12

(105)

2 HOLES - 0.625 (16) DIA. FOR

0.50 (12) DIA. BOLT

0.375 (10)

1.00 (25) MAX.

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.

5.62

(143)

5.62

(143)

36.00 (914)

ABRASIVE SHIELD

Figure 2-1. Probe Installation (Sh eet 5 of 5)

27270008

4. If using the optional ceramic diffusor element, the vee deflector must be correctly oriented. Before inserting the probe, check the direction of flow of the gas in the duct. Orient the vee deflector on the probe so that the apex points upstream toward the flow (Figure 2-2). This may be done by loosening the setscrews, and rotating the vee deflector to the desired position. Retighten the setscrews.

5. In horizontal installations, the probe junction box should be oriented so that the system cable drops vertically from the probe junction box. In a vertical installation, the system cable can be oriented in any direction.

6. If the system has an abrasive shield, check the dust seal packings. The joints in the two packings must be staggered 180°. Also, make sure that the packings are in the hub grooves

IB-106-300N H

as the probe slides into the 15° fo rcing cone in the abrasive shield.

NOTE

If process temperatures will exceed 392°F (200°C), use anti-seize compound on stud threads to ease future removal of probe.

7. Insert 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.

NOTE

Probe Installation To maintain CE compliance, ensure there is a good connection between the chassis of the probe and earth.

2-6

APEX

6240

TO PROBE HEAD

REF AIR SET

263C152G01

1 FLOWMETER 0.2-2.0 SCFH 771B635H02

2 2" PRESSURE GAGE 0-15 PSIG 275431-006

3 COMBINATION FILTER-REG. 0-30 PSIG 4505C21G01

NOTE: DIMENSIONS ARE IN INCHES WITH

MILLIMETERS IN PARENTHESES.

4.81 (122.17)

FLOW SET

POINT KNOB

0.125-27 NPT FEMALE

OUTLET CONNECTION

1.19 (30.22)

10.0 REF (254)

DRAIN VALVE

3.12 (79.25) MAX

8.50 MAX (215.90)

2.0

(50.80)

2 MOUNTING HOLES

3.19 (81.03) LG

THROUGH BODY FOR

0.312 (7.92) DIA BOLTS

1.50

(38.10)

2.250 (57.15)

SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYGEN ANALYZER PROBE HEAD.

OUTLET

0.25-18 NPT FEMALE INLET CONNECTION

COMPRESSED AIR SUPPLY 10-225 PSIG MAX PRESSURE

27270003

0.250 OR 6 MM OD TUBING (SUPPLIED BY CUSTOMER)

0.250 OR 6 MM OD

TUBE COMPRESSION

FITTING (SUPPLIED BY WECO)

FILTER

GAS FLOW DIRECTION

VEE

DEFLECTOR

DIFFUSION

ELEMENT

SETSCREW

c. Reference Air Package. After the oxygen

analyzing (probe) unit is installed, connect the reference air set to the probe junction box. The reference air set should be installed in accordance with Fig u re 2- 3.

d. Service Required.

1. Power input: 100, 115 or 220 Vac single phase, 50 to 60 Hz, 3 amp minimum. (See label.)

Figure 2-2. Orienting the Optional Vee Defl ector

VEE

DEFLECTOR

2. Compressed air: 10 psig (68.95 kPa) minimum, 225 psig (1551.38 kPa) maximum at 2 scfh (56.6 L/hr) maximum; supplied by one of the following (less than 40 parts-permillion total hydrocarbons). Regulator outlet pressure should be se t at 5 ps i (35 k Pa).

(a) Instrument air - clean, dry.

Figure 2-3. Air Set, Plant Air Connection

IB-106-300N H

2-7

(b) Bottled standard air with step-down

5.76 (146.3)

9.00 (228.6)

1.25

(31.75)

21190002

6.0

(152.4)

DESIGN DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.

NOTE:

8.00 (203.2)

11.24 (285.5)

0.31 (7.9)

13.24

(336.3)

15.00

(381.0)

16.00

(406.4)

2.00

(50.8)

1.62

(41.1)

2.25

(57.15)

0.867

(22.00)

11.5 (292.1) MINIMUM DOOR SWING CLEARANCE

3.36

(85.3)

regulator.

(20.95% oxygen in n i trogen).

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

supply.

2-2. INTELLIGENT FIELD TRANSMITTER (IFT)

INSTALLATION. a. Mechanical Installation. The outline drawing of

the IFT module in Figure 2-4 shows mounting centers and clearances. The NEMA 4X enclosure is designed to be mounted on a wall or bulkhead. The IFT should be installed no more than 1200 feet (364 m) from the optional HPS or 150 feet (45 m) from the probe if HPS is not installed in the system.

b. Electrical Connections.

To meet the Safety Requirements of IEC 1010 (EC requirement), and ensure safe operation of this equipment, connection to the main electrical power supply must be made through a circuit breaker (min 10A) which will disconnect all current carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IE C 947.

NOTE

Refer to Figure 2-7 for fuse locations and specifications.

1. The IFT can be configured for 100, 120, 220, or 240 line voltages. For 120 Vac usage, install JM8, JM7, and JM1 on the power supply board. For 220 Vac usage, install jumpers JM6, JM5, JM2 (refer to Figures 2-5 and 2-7).

2. For installations where the cable run is less than 150 feet (45 m), the IFT can be configured to connect directly to a probe. An optional HPS is available for cable runs o ver

Figure 2-4. Outline of Intelligent Field Transmitter

150 feet (45 m). The electrical connections for a non-HPS equipped system should be made as described in the electrical installation diagram, Figure 2-8. Refer to Figure 2-14 for connections for an HPS equipped system.

Do not install jumper JM6 on the microprocessor board, or JM1 on the interconnect board, if an HPS is installed in the system. This will result in system failure.

3. The IFT must have JM6 on the microprocessor board (Figures 2-9 and 2-10) and JM1 on the interconnect board (Figures 2-11 and 2-12) installed if an HPS is not installed in the system.

IB-106-300N H

2-8

4. If an MPS is not used in the system, wire jumper between CAL RET and NO GAS must be installed on the interconnect board. Remove wire jumper if MPS is installed in the system. Refer to Figure 2-8, note 6.

5. The power cable should comply with the safety regulations in the user's country and should not be sm al l er th an 16 gauge, 3 amp.

JUMPER

CONFIGURATION

LINE VOLTAGE

SELECTION

100 V.A.C.

120 V.A.C.

220 V.A.C.

240 V.A.C.

JUMPER

(INSTALL)

JM3, JM7, JM2

JM8, JM7, JM1

JM6, JM5, JM2

JM6, JM5, JM1

6. Before supplying power to the IFT, verify that the jumpers have been properly set in the IFT (Figures 2-5, 2-9, an d 2-11).

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

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

PROBE HEATER

VOLTAGE SELECTION

WORLD CLASS PROBE (44V)

218 PROBE (115V)

WORLD CLASS "DIRECT

REPLACEMENT" PROBE (115V)

JUMPER

(INSTALL)

JM10

JM9

21190012

If incorrect heater voltage is selected, damage to the probe may occur. For HPS voltage selection jumper, refer to Figure 2-15. Always update the relevant labeling to reflect the set voltage.

Figure 2-5. Power Supply Board Jumper Configuration

NOTE

General Wiring Recommendations To maintain CE compliance and ensure proper EMC performance, all signal wires to the Interconnect Board, with the exception of the probe cable, should be looped through the ferrite beads provided as shown in Figure 2-6 (P/N 1L04253H01). Signal wires may be grouped together and looped through before exiting the enclosure. Ferrite beads should be placed as close as possible to the exit point. Ferrite beads are provided for European Common Market applications only.

Figure 2-6. Signal Wire Routing

IB-106-300N H

2-9

Figure 2-7. IFT Power Supply Board Jumpers

IB-106-300N H

2-10

PROBE JUNCTION

BOX WIRING

GN CELL -VE

OR CELL +VE

YE CHROMEL

RD ALUMEL

123456 78

BLPROBE MV -

GNE

HEATER

CURRENT/VOLTAGE SELECTOR SWITCH

3D39513G

MICROPROCESSOR

BOARD

}

3D39122G REV

POWER SUPPLYBOARD

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

JM7

JM6

PROBE MV +

PROBE TC +

PROBE TC -

WORLD CLASS

PROBE

NOTES:

STACK TC WIRING AS REQUIRED.

SPECIAL PROBE CABLE BETWEEN PROBE AND IFT BY ROSEMOUNT.

INSTALL JM1 ON INTERCONNECT BOARD.

INSTALL JM6 ON MICROPROCESSOR BOARD.

IF STACK TEMPERATURE NOT USED.

IF MPS 3000 NOT USED.

1 RELAY PER PROBE AVAILABLE FOR CALIBRATION STATUS INDICATION. (48 V max, 100 mA max)

CURRENT/VOLTAGE SELECTOR SWITCH MUST BE SELECTED TO CURRENT (I) FOR HART COMMUNICATIONS APPLICATIONS.

JUMPER JM7 INFORMATION APPEARS IN FIGURE 2-9.

LINE VOLTAGE SECTION

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

JUMPER CONFIGURATION

JUMPER

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

PROBE HEATER

VOLTAGE SECTION

WORLD CLASS PROBE

218 PROBE

WORLD CLASS "DIRECT REPLACEMENT" PROBE

JUMPER

(INSTALL)

JM10

JM9 JM9

J2 J3 J4

3D39120G REV

INTERCONNECT BOARD

CAL RET

J5 J6

LINE

VOLTAGE

BK WH

GN PU

BL YE

INTELLIGENT FIELD TRANSMITTER IFT 3000

PROBE 1

LINE OUT LINE IN

J10

HI GAS

IN CAL

CAL RET

NO GAS

LOW GAS

NO GAS

LO GAS HI GAS IN GAS

SHIELD

PROBE 2 PROBE 3 PROBE 4

IN CAL

HI GAS

NO GAS

CAL RET

LOW GAS

NC C NO NC C NO NC C NO NC C NO

J11

PROBE 1

PROBE 2 PROBE 3 PROBE 4

MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER (OPTIONAL)

MPS TERMINATION BOARD

SHIELD STACK TC STACK TC +

J8 J9

SHIELD

PROBE TC -

RD YE

PROBE TC +

SHIELD BL OR

5 CONDUCTOR SHIELDED CABLE PER PROBE #16 AWG BY CUSTOMER

IN CAL

HI GAS

CAL RET

PROBE 1

SOLENOID

J13 J14 J15 J16 J17 J18

PROBE MV

PROBE

NO GAS

LOW GAS

PROBE 2

SOLENOID

MV+

HI GAS

PROBE 3

SOLENOID

IN CAL

PROBE 4

SOLENOID

NO GAS

CAL RET

HIGH GAS

SOLENOID

LOW GAS

JM1

LOW GAS

SOLENOID

SWITCH

PRESSURE

J12

LINE

VOLTAGE

27270011

Figure 2-8. Wiring Layout for IFT 3000 Sys tem without HPS

IB-106-300N H

2-11

OUTPUT JUMPER

HPS Probe (No HPS)

Remove JM6 Install JM6

ANALOG OUTPUT (Condition during microcontroller failure) JUMPER

Output = zero

Output = maximum

Install JM7

Remove JM7

analog output is typically sent to recording equipment such as chart recorders. Relay outputs are typically sent to annunciators.

3. Relays K1 and K2 are user configurable from the probe SETUP sub-menu (Table 3-5). Typically these are used to indicate O

values

above or below specified tolerances . OK relay is energized when unit is functioning properly.

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

(See Figure 2-10 for jumper locations .)

Figure 2-9. Microprocessor Board Jump er Con figu ration

c. Analog Output and Relay Output Connections.

1. The microprocessor board has a selector for voltage or current operations. Figure 2-10 shows switch orientation. In voltage mode, output is 0-10 V. In the current mode, the output can be configured from the SETUP menu to be 0- 20 mA or 4-20 mA.

2. The analog output and relay outputs are programmed by the user as needed. The

5. Connect the analog output and relay outputs as shown i n Fi g u re 2-12.

2-3. HEATER POWER SUPPLY INSTALLATION.

a. Mechanical Installation.

The outline drawing of the heater power supply enclosure in Figure 2-13 shows mounting centers and clearances. The NEMA 4X enclosure is designed to be mounted on a wall or bulkhead. The heater power supply should be installed no further than 150 feet (45 m) from the probe. The heater power supply must be located in a location free from significant ambient temperature changes and electrical noise. Ambient temperature must be between -20° and 140°F (-30° and 60°C).

IB-106-300N H

2-12

Figure 2-10. IFT Microprocessor Board

IB-106-300N H

2-13

OUTPUT JUMPER

OK-COM OK-NO

K1-COM K1-NO K2-COM K2-NO

ANOUT

ANOUT+

STACK T/C STACK T/C

PROBE T/C PROBE T/C

PROBE MV

PROBE MV+

OK-NC

K1-NC

K2-NC

CALINIT-2

CAL INIT-1

CALRET

NOGAS

LOGAS

HIGAS

INCAL

RELAY

RELAY+

AD590

AD590+

TRIAC

TRIAC+

JM1 (UNDER SHIELD)

NOTES:

DENOTES SHIELD CONNECTION.

OK RELAY IS ENERGIZED WHEN UNIT IS FUNCTIONING PROPERLY.

16860010

HPS Probe (No HPS)

Remove JM1 Install JM1

Figure 2-11. Interconnect Board Jumper Configuration

Figure 2-12. IFT Interconnect Board Output Connections

IB-106-300N H

2-14

3.25

(82.6)

NOTE: DIMENSIONS IN INCHES

WITH MILLIMETERS IN PARENTHESES.

7.00

(177.8)

3.63

(92.2)

(NON-HAZARDOUS)

NEMA 4X

10.39 (264)

0.31

(7.9)

6.00

#0.31

(152.4)

(124)

6.75

(171.5)

4.88

4.00

(101.6)

(215.9)

8.50

b. Electrical Connections.

1. Electrical connections should be made as described in the electrical installation diagram, Figure 2-14. The wiring terminals are divided into two layers; the bottom (FROM PROBE) terminals should be connected first, the top (FROM ELECTRONICS) terminals should be connected last (Figure 2-15). Each terminal strip has a protective cover which must be removed when making connections. To remove the terminal covers, remove two slotted screws holding cover in place. Always reinstall terminal covers after making connections. All wiring must conform to local and national codes.

0.13" (3.3) THK U. L. APPROVED GASKET

4.38

1.81 (46)

11.00

(279.4)

8.00

(203.2)

#10-32 UNF 2A THREADED INSERT (0.31 x 0.31 FROM CORNER OF PLATE)

(111.3)

Figure 2-13. Outline of Heater Power Supply

9.96

(253)

0.38 (9.7)

1.00 (25.4) MINIMUM CLEARANCE

4.72

(120)

CLASS 1, DIVISION 1, GROUP B ENCLOSURE

FOR REMOVING COVER

9.17

(233)

2. Power Input: 120, 220 or 240 Vac. For 120 Vac usage, install jumpers JM4 and JM1. For 220 or 240 Vac usage, install jumper JM5 (see label, Figure 2-16).

NOTE

For 100 Vac usage, the heater power supply is factory-supplied with a different transformer. When using the HPS with 100 Vac transformer, instal l ju mpers JM1 and JM4.

3. The power cable should comply with safety regulations in the user's country and should not be smaller th an 16 g auge, 3 amp.

8.50

(215.9)

6.18

(156.9)

0.56 (14) DIA (2) MOUNTING HOLES

686029

NOTE

Refer to Figure 2-17 for fuse locations and specifications.

IB-106-300N H

2-15

Figure 2-14. Wiring Layout for Com p le te I FT 3000 Sys tem with HPS (Sheet 1 of 2)

IB-106-300N H

2-16

URRENT/VOLTAGE

SELECTOR SWITCH

LINE VOLTAGE SECTION

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

JUMPER

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

J5 J6

LINE

VOLTAGE

POWER SUPPLYBOARD

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

JUMPER CONFIGURATION

PROBE HEATER

VOLTAGE SECTION

NOT USED REMOVE

NOT USED

3D39122G REV

(INSTALL)

JUMPER

JM9, JM10

3D39513G

MICROPROCESSOR

BOARD

CAL RET NO GAS

LO GAS HI GAS IN CAL

SHIELD RELAY – RELAY + SHIELD AD590 –

AD590 + SHIELD TRIAC –

TRIAC +

J2 J3

J5 J6 J7 J8 J9

SHIELD STACK TC – STACK TC +

SHIELD

PROBE TC – PROBE TC +

SHIELD

PROBE MV – PROBE MV +

3D39120G REV

INTERCONNECT BOARD

JM7

JM6

JM1

INTELLIGENT FIELD TRANSMITTER IFT 3000

PROBE 1

LINE OUT LINE IN

IN CAL

HI GAS

NO GAS

CAL RET

J10

NC C NO NC C NO NC C NO NC C NO

J11

PROBE 1

PROBE 2 PROBE 3 PROBE 4

IN CAL

HI GAS

LOW GAS

CAL RET

5 CONDUCTOR SHIELDED CABLE PER PROBE #16 AWG BY CUSTOMER

NO GAS

LOW GAS

IN CAL

HI GAS

NO GAS

CAL RET

PROBE 2

PROBE 1

SOLENOID

J13 J14 J15 J16 J17 J18

LOW GAS

SOLENOID

PROBE 3

HI GAS

SOLENOID

IN CAL

PROBE 4

CAL RET

SOLENOID

HIGH GAS

NO GAS

SOLENOID

LOW GAS

SOLENOID

SWITCH

PRESSURE

J12

LINE VOLTAGE

MPS TERMINATION BOARD

MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER (OPTIONAL)

27270012

Figure 2-14. Wiring Layout for Com p le te I FT 3000 Sys tem with HPS (Sheet 2 of 2)

IB-106-300N H

2-17

Figure 2-15. Heater Power Supply Wiring Connections

IB-106-300N H

2-18

0310

NOTES:

100 V.A.C. OPERATION REQUIRES TRANSFORMER PART NUMBER 1M02961G02.

REFER TO TABLE 3-5 FOR PROPER SET POINT SELECTION.

Figure 2-16. Jumper Selecti on L ab el

NOTE

Before supplying power to the hea ter power supply, verify that jumpers JM3, JM6 are removed and JM7 is installed. If relay wire (Figure 2-14, note 1) is installed, JM2 must be removed from HPS Mother Board (Figure 2-17).

4. Before supplying power to the heater power supply, verify that the jumpers on the mother board, Figure 2-17, are properly configured. Jumpers JM3 and JM6 should be removed and JM7 should be inst all ed.

Additionally, make sure that the proper jumper for your line voltage is installed, Figure 2-16. If relay wire (Figure 2-14, note

1) is not installed, JM 2 should be installed on the HPS Mother Board (Figure 2-17).

JM1

JM2 JM4

JM5

JM7

122

JM3 JM6

3D3 080G REV

NOTE

Refer to Figure 2-9 and 2-11 for proper IFT jumper configuration. IFT microprocessor and interconnect board jumper configurations must be set correctly in order for HPS to work properly.

Figure 2-17. Jumpers on HPS Mother Board.

IB-106-300N H

2-19

2-4. MULTIPROBE CALIBRATION GAS SEQUEN-

HIGHCAL

GASIN

LOWCAL

GASIN

CALGAS

OUT

REFAIR

OUT

INSTR

AIR

REFAIR

OUT

REFAIR

OUT

REFAIR

OUT

CALGAS

OUT

CALGAS

OUT

CALGAS

OUT

PROBE1 PROBE2 PROBE3 PROBE4

0.84 (21.34)

27270013

1.96 (49.78)

4.21 (106.93)

3.09 (78.49)

5.25 (133.35)

5.54 (140.72)

14.00 (355.60) REF

12.00

(304.80)

12.00

(304.80)

10.00

(254.00)

NOTE: DIMENSIONS ARE IN INCHES

WITH MILLIMETERS IN PARENTHESES.

CER INSTALLATION. a. Mechanical Installation.

The outline drawing of the MPS module in Figure 2-18 shows mounting centers and clearances. The box is designed to be mounted on a wall or bulkhead. The MPS module should be installed no further than 300 feet (91 m) piping distance from the probe, and no more than 1000 feet (303 m) cabling distance from the IFT. Install the MPS module in a location where the ambient temperature is between -20° and 160°F (-30° and 71°C).

b. Gas Connections

. Figure 2-19 shows the bottom of the MPS where the gas connections are made. 1/4 inch threaded fittings are used.

1. Connect the reference air supply to INSTR. AIR IN. The air pressure regulator valve is set at the factory to 20 psi (138 kPa). If the reference air pressure should need readjustment, turn the knob on the top of the valve until the desired pressure is obtained.

2. Connect the high O

calibration gas to HIGH

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

Figure 2-18. MPS Module

IB-106-300N H

2-20

3. Connect the low O2 calibration gas to LOW

HIGH CAL

GAS IN

LOW CAL

GAS IN

CAL GAS

OUT

REF AIR

OUT

INSTR

AIR

REF AIR

OUT

REF AIR

OUT

REF AIR

OUT

CAL GAS

OUT

CAL GAS

OUT

CAL GAS

OUT

PROBE 1 PROBE 2 PROBE 3 PROBE4

LINE IN

SIGNAL IN

27270014

DRAIN

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

system is being used, the additional probes and electric packages would be wired similar to the first probe.

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

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

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

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

c. Electrical Connections.

Electrical connections should be made as described in the electrical installation diagram, Figure 2-20. All wiring must conform to local and national codes. The electrical connections will exist only between the electronics package and the MPS to enable automatic and semiautomatic calibration. If more than one probe

NOTE

Refer to Figure 2-20 for fuse locations and specifications.

1. Run the line voltage through the bulkhead fitting on the bottom of the MPS where marked LINE IN, Figure 2-19. Connect the line voltage as shown in Figure 2-20 to the LINE IN terminal on the MPS termination board located inside the unit. Tighten the cord grips to provide strain relief.

2. The MPS can accommodate up to four probes. The terminal strips on the MPS termination board are marked PROBE 1, PROBE 2, PROBE 3, and PROBE 4. Select PROBE 1 if this is the first probe and electronic package installed on the MPS.

3. Make the connections from the MPS to the IFT as shown in Figure 2-20. Run wires from the MPS Termination Board inside the unit through the bulkhead fitting on the bottom o f the unit where marked SIGNAL IN, Figure 2-19. After the connections are made, tighten the cord grips to provide strain relief.

Figure 2-19. MPS Gas Connections

IB-106-300N H

2-21

INTERCONNECT

IFT

BOARD

CAL RET

NO GAS

LO GAS

HI GAS

IN CAL

MH1

J2 J3 J4 J5 J6 J7 J8 J9

MH2

MH3

MH4

PROBE 1 PROBE 2 PROBE 3 PROBE 4

LINE OUT LINE IN

IN CAL

HI GAS

NO GAS

CAL RET

LOW GAS

IN CAL

HI GAS

NO GAS

CAL RET

LOW GAS

HI GAS

IN CAL

NO GAS

CAL RET

LOW GAS

HI GAS

IN CAL

NO GAS

CAL RET

LOW GAS

J10

NC C NO NC C NO NC C NO NC C NO

J11

PROBE 1

PROBE 2 PROBE 3 PROBE 4

J13 J14 J15 J16 J17 J18

J12

MPS TERMINATION BOARD

Figure 2-20. MPS Probe Wiring

L E N

LINE VOLTAGE

686032

IB-106-300N H

2-22

NOTE

Upon completing installation, make sure that the probe is turned on and operating prior to firing u p 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.

IB-106-300N H

2-23/2-24

SECTION III. GENERAL USER INTERFACE (GUI) OPERATION

3-1. OVERVIEW.

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

The following five languages are can be selected within the IFT:

English Italian French Spanish German

Support the keypad with the free hand to prevent bounce back of the IFT door.

a. Intelligent Field Transmitter (IFT). The

Intelligent Field Transmitter may be supplied with either of two configurations. These are the blind version and the deluxe ve rsion. The two versions differ as follows:

Ensure that the oxygen analyzer, heater

NOTE

b. HART Communicator Interface Devices. The

HART communi cations protocol can in terf ace w ith any of the above IFT versions. To interface a HART communicator with an IFT, one of three interface devices is required. The interface devices are as follows:

1. Rosemount Model 275 Handheld Communicator. The handheld communicator requires Device Descriptor (DD) software specific to the World Class 3000 product. The DD software will be supplied with many model 275 units, but can also be programmed into existing units at most Fisher-Rosemount service offices.

2. Personal Computer (PC). The use of a personal computer requires Cornerstone software with Module Library (ModLib) specific to the World Clas s 3000 produ ct .

3. Selected Distributed Control Systems. The use of distributed control systems requires input/output (I/O) hardware and software which permit HART communications.

1. Blind Version. The blind version has no display and no keypad. With this version an external HART communications device is required.

2. Deluxe Version (GUI). The deluxe version is also known as the General User Interface (GUI) version. This IFT contains an LED display, liquid crystal display panel, and an eight-key pad from which the probe and electronics can be configured, calibrated and troubleshooted.

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

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

IB-106-300N H

3-1

3-2. DELUXE VERSION IFT DISPLAYS AND CONTROLS.

(Figure 3-1)

HELP

DATA

CAL

ESC

SETUP

ENTER

INTERNAL VIEW

IFT COVER DOOR

NOTE:

SHOWN FOR REFERENCE.

EXTERNAL VIEW

CAL TGH TGL

2119000

Figure 3-1. Deluxe Version IFT Disp lays an d Con trols

Fig. 3-1 Index No. Control/LED

Description

1 LCD Display Top line displays s ystem status, menu, and probe number. 2 HELP Context sensitive HELP is displayed when this key is pressed. 3 DATA DATA k ey is used to access DATA menu. 4 CAL CAL key u s ed to acces s CALIBRATE menu. 5 SETUP SETUP key used to access SETUP menu. 6 ESC The escape key is used to exit to a hi g h lev el menu or to abort a parameter change.

The decrease key is used to move the c urso r ( aste risk) when scro lling thro ugh lists or to decrease a parameter value.

The increase key is used to move the curso r (a sterisk) when scro lling thro ugh lists or to increase a parameter value.

9 ENTER The ENTER key is used to select a lower level menu, initiate calibration, or select a

parameter to change.

10 LED Display Indicates current O

or calibration gas value.

11 CAL Calibration in progress indicator light. 12 TGH High calibration gas indicator light. High calibration gas is being used in calibration

process.

13 TGL Low calibration gas indicator light. Low calibration gas is being used in calibration

process.

IB-106-300N H

3-2

Table 3-1. Sample HELP Messages.

MENU, SUB-MENU, HELP OR PARAMETER NAME MESSAGE

PROBE DATA

CALIBRATE O2

SETUP

Press ENTER key to access DATA m en u.

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

The SETUP menu is us ed t o con f i g u re the IFT 3000.

3-3. HELP KEY. The HELP key will display explanatory

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

3-4. STATUS LINE. The top line of the LCD display (3,

Figure 3-1) is a status line that always displays system status, menu name, and O

level. System status displays

will be displayed one at a time in priority sequence, as follows:

a. Off - The probe has been turned off because the

IFT cannot control the heater temperature.

b. PrbEr - The probe is disconnected, cold, or leads

are reversed.

i. ResHi - Resistance is above the high lim it.

j. OK - System is functioning correctly.

3-5. QUICK REFERENCE CHART. The quick

reference chart ( Figure 3 -2) is d esigned to help you get where you want to be in the menu system. The chart shows all the available menu and sub-menu options for the IFT. Follow the lines to determine which menu choices to make. Moving down a level on the chart is accomplished by the use of the ENTER key. To move up a level on the chart, press the ESCA PE key.

Table 3-2. MAIN Menu.

MENU SELECTION DESCRIPTION

PROBE DATA

Refer to Table 3-3.

c. HtrEr - Heater error.

d. InCAL - Calibration in progress.

e. LowO2 - O2 value is below the low alarm limit.

f. HiO2 - O2 value is above the high alarm limit.

g. NoGas - Calibration gas pressure is low.

h. CalEr - Calibration error.

CALIBRATE O2

SETUP

Refer to Table 3-4.

Refer to Table 3-5.

3-6. MAIN MENU. When power is first applied to the

IFT, the MAIN menu (Table 3-2) is initially displayed. It is from the MAIN menu that the PROBE DATA (Table 3-3), CALIBRATE O2 (Table 3-4), and SETUP (Table 3-5) menus can be access ed.

IB-106-300N H

3-3

3-7. PROBE DATA SUB-MENU. The PROBE DATA

sub-menu is a list of all the parameters of the system as it is currently configured. To access the PROBE DATA sub-menu, press the DATA key at any time. The increase and decrease keys are used to scroll through the list. The PROBE DATA sub-menu can be

Table 3-3. PROBE DATA Sub-Menu.

SUB-MENU

SELECTION PARAMETER DESCRIPTION

Process Data O2 __% O2

Efficiency __% Stack Temp __DegC

Diagnostic Data

Temperature

Cell __DegC Stack __DegC Cold Junct __DegC

viewed but not changed. The operator must use the SETUP menu to change any of th e parameters.

There are two selections available on the PROBE

DATA sub-menu; Process Data and Diagnostic Data. Refer to Table 3-3 for contents of th e su b-menu.

O2 value for the probe. Efficiency display . Stack temperature.

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

Voltages

Output Values

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

Analog __% FS K1 State OFF/ON K2 State OFF/ON

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

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

IB-106-300N H

3-4

PROCESS DA TA

PROBE DATA DIAGNOSTIC

DATA

O2 Efficiency Stack Temp

TEMPERATURE

VOLTAGES

OUTPUT VALUES

Cell Stack Cold Junct

Cell Cell T/C Stk T/C Cold Jnt

Analog K1 State K2 State

CALIBRATE O2

(CONTINUED ON

SHEET 2)

PERFORM CALIBRATION

VIEW CONSTANTS

CALIBRATION STATUS

LATEST CALIBRATION

PREVIOUS CAL

Next Cal Slope Constant Resist

Figure 3-2. Quick Reference Chart (Sheet 1 of 5)

Slope Constant Resist

686022

IB-106-300N H

3-5

(CONTINUED FROM

SHEET 1)

CALIBRATION

See sheet 4

SLOPE

34.5 mV/D-

57.5 mV/D

SETUP

O2 CALIBRATION

O2 ALARMS

EFFICIENCY CALC

CONSTANT

SET POINT

RESET SLOPE AND CONST

HI ALARM LO ALARM ALARM DB

ENABLE CALC

K1 VALUE K2 VALUE

K3 VALUE

-20.0 mV-

20.0 mV

736 C

843 C

0.1000% O2-

25.00% O2

0.00% O2-

25.00% O2

Yes No

0.0000-

1.000

0.0000-

20.00

(CONTINUED ON

SHEET 3)

RELAY OUTPUT

(CONTINUED ON

SHEET 3)

Figure 3-2. Quick Reference Chart (Sheet 2 of 5)

K1 SETUP

K2 SETUP

IB-106-300N H

3-6

EVENT 1 EVENT 2 EVENT 3

Off In Cal Hi O2 Lo O2 Htr Fail Cal Fail TG Low Cell Res High Range

19860023

(CONTINUED FROM

SHEET 2)

(CONTINUED FROM

SHEET 2)

ANALOG OUTPUTS

SOURCE

AOUT TYPE

Efficiency

Dual Rng O2

HART 4-20 mA

0-20 mA

0-10 V

SETUP

RANGE SETUP

USA

GBR

COUNTRY

FRA

ESP

GER

Figure 3-2. Quick Reference Chart (Sheet 3 of 5)

See sheet 5

27270004

IB-106-300N H

3-7

HIGH GAS

0.1000% O2

25.00% O2

CALIBRATION

(CONTINUED FROM

SHEET 2)

LOW GAS

AUTO CAL

OUTPUT TRACKS

CAL INTRVL

NEXT CAL

0.1000% O2

25.00% O2

Yes No

Off,

1H -

365 D OH

Disabled,

1H -

365 D OH

(1 hour to 365 days and no hours)

GAS TIME

PURGE TIME

RES ALARM

00:30 20:00

50 -

10000

Ω Ω

Figure 3-2. Quick Reference Chart (Sheet 4 of 5)

IB-106-300N H

3-8

16860025

Range Setup

(Source not set to:

Dual Rng O2)

(CONTINUED FROM

SHEET 3)

XFER FNCT

RANGE VALUES

Log LIN

HIGH END

0.000% O2

25.00% O2

RANGE SETUP

Range Setup

(Source not set to:

Dual Rng O2)

XFER FNCT

NORMAL RANGE VALUES

LOW END

Log LIN

HIGH END

LOW END

MODE SETUP

0.000% O2

25.00% O2

0.000% O2

25.00% O2

0.000% O2

25.00% O2

RANGE MODE

Normal Auto High

DUAL RANGE SETUP

Figure 3-2. Quick Reference Chart (Sheet 5 of 5)

HIGH RANGE VALUES

IB-106-300N H

3-9

HIGH IN CAL

SWITCHES AT

LOW END

HIGH END

Yes No

0.000% O2

25.00% O2

0.000% O2

25.00% O2

0.000% O2

25.00% O2

16860026

Table 3-4. CALIBRATE O2 Sub-Menu.

ging

g p

prog

g purg

gh g

prog

SUB-MENU

SELECTION

Perform Calibration

SETUP SETTING (SEE TABLE 3-5) DISPLAY DESCRIPTION

Auto Cal in Probe Setu

is YES

Press ENTER to start Auto Calibration.

Automatic Calibration

Startin

h Gas _____%O

Hi Time Left 0:00

Cell mV ______mV Low Gas _____%O

Time Left 0:00

Cell mV ______mV Resistance Check

MPS will start calibrating probe.

Value for hi

h O2 calibration gas. Amount of time necessar current testin

Cell volta Value for low O

Amount of time necessar current testin

Cell volta

hase in min:sec.

e of the probe.

calibration gas.

hase in min:sec.

e of the probe.

Resistance check in

Time Left 0:00 Cell _____mV _____C

Cell voltage and probe temperature.

Calibration Complete Pur

0:00

Gas lines are bein

as.

Cell _____mV _____C

Cell voltage and probe te mperature.

Calibration Complete

Auto Cal in Probe Setu

is NO.

Press ENTER to start Manual Calibration

Manual calibration se when ENTER is

ressed.

uence will begin

to complete the

ress.

ed of calibration

Switch ON hi

h calibration gas. Press

ENTER when read

as ______%O

Hi Press ENTER when O2 reading is stable. Turn OFF hi

calibration Low

h calibration gas and ON low

as. Press ENTER when ready.

as ______%O Press ENTER when O2 reading is stable. Resistance Check Turn off low ca libration

when read

Press ENTER when process.

View Constants Latest

Calibration

Slo

e _____mV/D Constant _____mV Resist _____ohms

Previous Calibration

Slo

e _____mV/D Constant _____mV Resist _____ohms

Calibration Status N/A Next Cal XD XH

as. Press ENTER

robe has returned to

h O2 calibration gas value.

Low O

calibration gas value.

Resistance check in

Slo

e for probe from latest ca libration. Latest calibration offs et for Latest calibration resistance of

e for probe from previous calibration.

Slo Previous calibration off s et f or

ress.

robe.

Previous calibration res is ta nc e of pr obe . Time until next c alibra tion in number of

s and number of hours .

Slope _____ Constant _____ Resist _____

IB-106-300N H

3-10

Status of the slo Status of the offset. Status of the resistance.

Table 3-5. SETUP Sub-Menu.

SUB-MENU

SELECTION PARAMETERS DESCRIPTION

Calibration High Gas ____%O

Low Gas ____%O

2 2

Auto Cal YES/NO Output Tracks YES/NO Cal Intrvl XD XH

Next Cal XH

Gas Time 0:30 - 20:00

Purge Time 0:30 - 20:00 Res Alarm 50 W - 10 kW

O2 Calculation Slope ____ mV/D

Constant ____ mV Set Point ____°C

Ensure the correct voltage is selected when using HPS 3000 with either World Class 3000 probes or 218 probes. Refer to Figure 2-15, Jumper Selection Label for proper voltage selections. If incorrect SET POINT is selected, damage to the probe may occur.

Value of high O Value of low O

calibration gas (0.1000% - 25.00% O2).

MPS required for Auto Cal. NO, locks output during calibration. Select time between calibrations in number of days and hours (1 year max). Time until next calibration in number of hours (1 year max). Amount of time calibration gases will be turned on in number of minutes and seconds; allow enough time for signal values to stabilize. Amount of time for gas lines to clear of calibration gas. Resistance alarm s et f rom 50 to 10,000 ohms.

Set value betw een 34.5 an d 57.5. Set value betw een -20.0 and +20.0 mV. Set either 736 for World Cl as s 3000 probes or 843 for 218 probes.

Reset slope and constants Press ENTER to reset slope and constants to values from the

O2 Alarms Hi Alarm ____%O

Lo Alarm ____%O Alarm DB ____%O

Efficiency Calc. Enable Calc. YES/NO

K1 Value _______ K2 Value _______ K3 Value _______

2 2 2

IB-106-300N H

latest successful calibration. Set value for hig h alarm limit (0.1000% - 25.00%).

Set value for low alarm limit (0.1000% - 25.00% ). Set value for alarm dead band (0.0000% - 25.00%).

Select YES to enable, NO to disable. Set between 0.0000 an d 1.000. R efer to Table 3-6. Set between 0.0000 an d 1.000. R efer to Table 3-6. Set between 1.000 an d 20.00. R efer to Table 3-6.

3-11

SUB-MENU

SELECTION

Relay Outputs

Table 3-5. SETUP Sub-Menu (Continued).

PARAMETERS DESCRIPTION

NOTE

K1 and K2 relay outputs can be configured for "OFF" or any one of the eight events listed below. Up to three events can control each relay output. Events are selected in the SETUP sub-menu.

-Off

K1 Setup

Event 1 1. In Cal Event 2 2. Hi O Event 3 3. Lo O Event 1 4. Htr Fail

K2 Setup

Event 2 5. Cal Fail Event 3 6. TG Low

7. Cell Res

8. High Range

Analog Output SOURCE O

AOUT TYPE

RANGE SETUP (Source not set to Dual Rng O2)

Efficiency Dual Rng O

HART 4-20mA 0-20mA 0-10V

No effect. Probe goes into calibration status. Output exceeds high en d alarm limit. Output goes below low alarm limit. Probe heater fault occurs. Probe failed last calibration. Calibration gas pressure gets too low. Probe resistance exceeds high limit. High analog output rang e is s elected.

Select the measuremen t v alu e to be represen ted on th e an alog output.

Select one of the lis t ed opt ion s to define upper and lower limits of probe analog output. Only a selection that matches the position of the analog output selector switch on the microprocessor board (Figure 2-9) will be accepted. The defined limi ts corres pon d t o th e u pper- l ower %O2 values defined in the Range Setup menu.

Xfer Fnct Log

Lin

Range Values

High End

0.000% O

- 25.00% O

Low End

0.000% O

- 25.00% O

IB-106-300N H

Select the transfer function u s ed on th e an alog outpu t . Selecting Log will not effect the output when Efficiency is selected as the Source.

Enter the upper and lower analog output range values. The High End value defines the measured O2 value corresponding to the h i g h an alog output value, i.e, 20mA or 10V, and the Low End v alu e corres pon ds to th e low analog output value, i.e., 0mA, 4mA, or 0V.

3-12

Table 3-5. SETUP Sub-Menu (Continued).

SUB-MENU

SELECTION PARAMETERS DESCRIPTION

Analog Output (continued)

RANGE SETUP (Source set to Dual Rng O2)

Xfer Fnct Log

Lin

Normal Range Values

High End

0.000% O

- 25.00% O

Low End

0.000% O

- 25.00% O

Dual Range Setup

Mode Setup

Range Mode Normal Forces the output to the Normal Range .

High in Cal Yes/No Selecting Yes will cause the High Range to be used whenever

Select the transfer function u s ed on th e an alog outpu t . Selecting Log will not effect the output when Efficiency is selected as the Source.

Enter the upper and lower analog output range values for Normal Operating Range. The High End value defines the measured O2 value correspon din g to th e h i g h an alog ou tpu t

value, i.e, 20mA or 10V, an d t h e L ow End value corresponds to the low analog output value, i.e., 0mA, 4mA, or 0V.

Auto Allows the IFT to select either the High Range or the Normal

Range based on the present O2 valu e an d th e Mode Setu p Values.

High Forces the output to the High Range.

the probe is being calibrated.

Switches at

0.000% O2 - 25.00% O2

Enters the switching point between the High and Normal Ranges. O2 values above this point will use the High Range and values below this point will use the Normal Range. The O2 value mus t be bel ow the switch poin t by 10% (of the "Switches at" value) to cause a switch from High to Normal Range.

High Range Values

High End

0.000% O

- 25.00% O

Low End

0.000% O

- 25.00% O

Enter the upper and lower analog output range values for High Operating Range. The High End value defines the measured O2 value correspon din g to th e h i g h an alog ou tpu t value, i.e, 20mA or 10V, an d t h e L ow End value corresponds to the low analog output value, i.e., 0mA, 4mA, or 0V.

NOTE: Relay output can be initiated upon range change (See Table 3-5, page 3-11).

IB-106-300N H

3-13

CONSTANT

Table 3-6. Efficiency Constants.

UNITED STATES EUROPE

GAS OIL GAS OIL

K1 K2 K3

3-8. CALIBRATE O

SUB-MENU. The CALIBRATE

0.407

0.0

5.12

O2 sub-menu (Table 3-4) is used to enter the calibration mode. To access the CALIBRATE O

sub-menu, press

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

The CALIBRATE O

sub-menu has three selections

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

Perform Calibratio n has two op tions d ep end ing o n how Auto Cal is selected in Probe Setup. Refer to SETUP Setting in Table 3-4.

3-9. SETUP SUB-MENU. The SET UP sub-menu is used

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

0.432

0.0

5.12

0.66

0.0082

12.28

Prior to manual calibration, the IFT should be removed from any automatic control loops. Failure to remove the IFT from control loops prior to calibration may result in faulty equipment performance.

Once initiated from the Setup - Analog Outputs menu, the calibration procedure is self guiding.

3-11. SYSTEM CALIBRATION.

a. Overview. The primary purpose of an oxygen

analyzer is to give an accurate representation of the percentage of O should be calibrated periodically to maintain an accuracy which may otherwise be reduced over time due to cell aging.

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

0.69

0.0051

8.74

in the gas stream. The system

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

Calculation, O2 Alarms,

Efficiency Calc., Relay Outputs, and Analog Outputs. Refer to Table 3-5 for the contents of the SETUP sub-menu , or ESC APE to abort changes.

3-10. ANALOG OUTPUT CALIBRATION. For the

analog output to perform within the published specifications, it must be manually calibrated. The only equipment needed to perform the calibration is a voltage or current meter, d epending on which mode of operation is to be calibrated. Prior to manual calibration, remove the IFT from any control loops it may be in.

IB-106-300N H

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

b. Probe Calibration.

1. Previous Calibration Constants Functionality. There are three sets of registers

used to store calibration constants. These are: Latest Calibration, Previous Calibration, and

3-14

Calculation. Only the values in the Calculation register are used to calculate the oxygen value for display and representation on the analog output signal. These values may be changed in two ways.

manually initiate calibrations between the intervals in the same manner as semiautomatic calibrations.

c. Manual (Semiautomatic) Calibration.

(a) The operator may change the values

through the SETUP menu. The oper ator may adjust the slope and constant individually, or reset both to the values calculated during the last good calibration. To reset the values, move the cursor to RESET SLOPE & CONST and push ENTER.

(b) The IFT will automatically change the

values after each calibration as follows.

The values in the Latest Calibration registers are updated after every complete calibration, even if the calibration is not successful. If the calibration is successful, the values in the Latest Calibration registers are copied into the Previous Calibration registers. This is accomplished prior to the update of the Latest Calibration registers. The new slope and constant are copied into the Calculation register.

If the calibration fails, the Previous Calibration registers retain their existing values, while the Latest Calibration registers record the values of the failed calibration. The Calculation register is not updated when the calibration fails.

2. Calibration Methods. There are three

calibration methods: manual (semiautomatic), manually initiated automatic, and fully automatic. Manual (semiautomatic) calibration is done without an MPS unit. Calibration gases are switched on and off by the operator and the IFT is sequenced thr ough the calibration procedure by the operator with the front panel keyboard. The IFT prompts the operator for the correct action. Manually initiated automatic calibration is done with an MPS. The operator manually initiates the calibration at the IFT or thro ugh a r emote switch, and the IFT controls the operation of the MPS unit and the calibration sequencing. Fully automatic calibration requires no action from the operator. The setup is the same as semiautomatic except the IFT automatically initiates the calibration at a fixed calibration interval. In this mode the operator can also

1. Calibration Gases For Manual (Semiautomatic) Calibration. There are two

options for supplying calibration gases to the probe during semiautomatic calibration. The first "A" uses refillable bottles and adjustable 2-stage pressure regulators; the second, "B" uses disposable bottles and a fixed single stage regulator to provide a mixed flow. Normally, the first (method "A") will have a higher cost and not be portable. The second ("B") is less costly, portable, and weighs about 10 lbs (4.5 kg).

Test Method "A" Fixed Tanks and Manifolds.

(a) Required Equipment.

Do not use 100% nitrogen as a zero gas. It is suggested that gas for the zero be between

0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

NOTE

Ambient air is not recommended for use as high calibration gas. An 8% O

balance in

nitrogen is recommended for high calibration gas.

1 Two tanks of precision calibration

gas mixtures. Recommended calibration gases are nominally 0.4% and 8.0% oxygen in n i t rog en .

Two sources of calibrated gas mixtures are:

LIQUID CARBONIC GAS CORP. SPECIALTY GAS LABORATORIES

700 South Alam eda S treet Los Angel es , C a li f ornia 90058 213/585-2154

IB-106-300N H

3-15

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

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

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

3 Two, 2-stage pressure regulators

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

4 One instrument air pressure

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

5 Two zero-leakage shutoff valves .

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

255 Brimley R oad Scarborough, Ontario, Canada 416/266-3161

SCOTT ENVIRONMENTAL TECHNOLOGY, INC. SCOTT SPECIALTY GASES

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

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

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

6 Miscellaneous oil-free tubing and

fittings.

(b) Calibration.

1 A typical calibration setup is shown

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

NOTE

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

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

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

2 If 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 the migration of process gases down the calibration gas line.

If an MPS 3000 Multiprobe Gas Sequencer is used, a check valve is required at the probe.

IB-106-300N H

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

When the calibration gas line exceeds 6 ft (1.8 m) in length from the leak tight valves, a check valve, Rosemount P/N 6292A97H02, should be installed next to the calibration gas connection on the probe to prevent breathing of the line with the process gas and subsequent gas condensation and corrosion.

3-16

CALIBRATE

IN-PLACE

FITTING

5 SCFH

CHECK VALV E

PROBE (END VIEW)

REFERENCE AIR

CONNECTION

2 SCFH

FLOW METER

LEAK TIGHT

VALVES

REG

0.4% O

PROBE CALIBRATION GAS FITTING

NOTE:

HAS A SEAL CAP WHICH MUST BE IN PLACE AT ALL TIMES EXCEPT DURING CALIBRATION.

Figure 3-3. Typical Calibration Se tup

NOTE

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

2 Set the calibration gas pressure

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

3 Refer to paragraph d of this section

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

4 Calibration gases will be switched

on and off using the shutoff valves.

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

8.0% O

REFERENCE

AIR

SET

INSTR. AIR IN

Do not use 100% nitrogen as a zero gas. It is suggested that gas for the zero be between

0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

NOTE

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

1 Portable Rosemount Oxygen Cali-

bration Gas Kits (Figure 3-4), Rosemount P/N 6296A27G01, containing 8% and 0.4% gase s in a portable carrying case with regulator, built-in valve, hose and connecting adapter to the calibration gas connection.

balance in

(a) Required Equipment

IB-106-300N H

3-17

CALIBRATION

GAS KIT #1

(P/N 6296A27G01)

Figure 3-4. Portable Rosemou nt Ox ygen Cal ib ration

Gas Kit

2 Extra gas bottles are available at:

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

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

27270007

Rosemount P/N 3530B07G02 for probe 8% oxygen in nitrogen in disposable bottle.

3 A check valve is required at the

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

(b) Calibration with a Portable Rosemount

Oxygen Calibration Gases Kit.

1 A typical portable calibration setup

is shown in Figure 3-5. For manual (semiautomatic) calibration, remove cap plug from the calibrate in place fitting. The cap plug must be retained to seal this fitting after calibration is complete; failure to do so may render the probe useless if the system pressure is slightly negative. The reference air should be flowing as in n ormal operation.

2 Refer to paragraph d of this section

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

3 Screw the push button regulator

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

Rosemount Italy VIA Guido Cavalcanti 8 20127 Milan, Italy

Rosemount Spain Saturnino Calleja 6 28002 Madrid Spain

Rosemount France 165 Boulevard de Vallmy 92706, Colombes, France

Rosemount P/N 3530B07G01 for probe 0.4% oxygen in nitrogen in disposable bottle.

IB-106-300N H

CALIBRATE

CONNECTION

NOTE:

3-18

REFERENCE AIR

IN PLACE

CHECK

VALV E

PUSHBUTTON

REGULATOR

WITH CONTENTS

GAGE - SET 5 SCFH

PROBE CALIBRATION GAS FITTING HAS A SEAL CAP WHICH MUST BE IN PLACE EXCEPT DURING CALIBRATION.

CONNECTION

CALIBRATION GAS HOSE CONNECTS TO CHECK VALV E

0.4 %

8.0 % O

Figure 3-5. Typical Portable Calibrati on S etu p

27270005

d. Manual (Semiautomatic) Calibration Proce-

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

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

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

Sub-menu.

e. Fully Automatic Calibration.

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

Do not use 100% nitrogen as a zero gas. It is suggested that gas for the zero be between

0.4% and 2.0% O2. Do not use gases with hydrocarbon concentrations of more than 40 parts per million. Failure to use proper gases will result in erroneous readings.

NOTE

Ambient air is not recommended for use as high calibration gas. An 8% O

balance in

nitrogen is recommended for high calibration gas.

A typical automatic calibration system is shown in Figure 3-6.

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

Auto Cal YES/NO Output Tracks YES/NO

Cal Intvl XD XH

Next Cal. XD XH

Gas Time 0:00

Purge Time 0:00

Abort Time 0:00

Res Alarm ____

Set to YES Set as desired to configure

analog output tracking . Set the desired time between

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

Displays the time left to the star of the next calibration. Set the desired time until the start of the next calibration (1 year max). I nothing is entered her e, the uni will automatically enter the Cal Intvl and count down from that.

Set the amount of time fo calibration gases to be turned on in minutes and seconds; allo enough time for signal value to stabilize.

Set the amount of time for the gas lines to clear in number o minutes and s econ ds.

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

Set the desired resistance alar between 50 to 10000 ohms.

Two tanks of precision calibration gas mixtures. Recommended calibration gases are nominally 0.4% and 8.0% oxygen in nitrogen set calibration gas pressure at 20 psi (138 kPa).

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

IB-106-300N H

3-19

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

(a) Press SETUP to display the SETUP

sub-menu. Select Calibration Ensure

OPTIONAL

CHECK

VALV E

CALIBRATION GAS

PROBE

(END VIEW)

REFERENCE

HPS

AIR

PROBE SIGNAL CONNECTIONS

that Auto Cal is enabled. Set the cursor on Auto Cal. Press ENTER. Set Auto Cal to YES if not already done.

(b) Press the CAL key. Select Perform

Calibration. "Press ENTER to start Automatic Calibration" will appear on the LCD display. Press ENT ER to start. Refer to Table 3-5, CALIBRATE O Sub-Menu.

IFT

MPS

INSTRUMENT

AIR IN

NOTE: THE MPS CAN BE USED WITH UP

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

NOTE: SHOWN WITH HPS OPTION.

MPS-IFT SIGNAL CONNECTIONS

CALIBRATION

(HIGH )O

GAS 1

CALIBRATION

GAS 2

(LOW O )

27270006

Figure 3-6. Typical Automatic Calibration System.

IB-106-300N H

3-20

SECTION IV. SYSTEM TROUBLESHOOTING

4-1. OVERVIEW.

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

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.

4-2. SPECIAL TROUBLESHOOTING NOTES.

a. Grounding. It is essential that adequate

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

b. Electrical Noise. The IFT has been designed to

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

4-3. SYSTEM TROUBLESHOOTING. The IFT

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

a. GUI Equipped IFT. The status line of the GUI

equipped IFT will display one of ten conditions. The system status displays will be displayed one at a time in priority sequence, as indicated in the following list. Refer to Table 2-1, Appendix E for additional troubleshooting information on the GUI equipped IFT.

1. Off - The probe has been turned off because

the IFT cannot control the heater temperature.

2. Param - IFT has been unlocked using the

user’s password.

3. Serv - IFT has been unlocked using the

service passw ord.

4. PrbE r - The probe is disconnected, cold, or

leads are reversed.

5. HtrE r - If HtrEr is displayed, there is a fault

within the heater sy s tem.

6. InCal - If InCal is displayed, the system is

currently undergoing calibration.

c. Loose Integrated Circuits. The IFT uses a

microprocessor and supporting integrated circuits. Should the electronics unit receive rough handling during installation in a location where it is subjected to severe vibration, an Integrated Circuit (IC) could work loo se. The fault finding guides in paragraph 5-3.a. and Table 2-1 Appendix E, show the resulting variety of failure modes. It is recommended that all IC's be confirmed to be fully seated before troubleshooting on the system begins.

d. Electrostatic Discharge. Electrostatic discharge

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

IB-106-300N H

4-1/4-2

7. LowO2 - If LowO2 is displayed, the O

value

is below the low alarm limit.

8. Hi O2 - If HiO2 is displayed, the O

value is

above the high alarm limit.

9. NoG as - If NoGas is displayed, there is no

calibration gas pressure.

10. CalEr - If CalEr is displayed, an error was

detected during the calibration process.

11. ResHi - If ResHi is displayed, the cell

resistance is above the high limit.

12. OK - If OK is displayed, the system is

operating normally.

SECTION V. RETURNING EQUIPMENT TO THE FACTORY

If factory repair of defective equipment is required,

5-1.

proceed as follows:

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.

Carefully pack defective unit in a sturdy box with

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

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. S it e f rom which equipment was remov ed.

4. Whether warranty or nonwarranty service is requested.

5. Complete shipping instructions for return of equipment.

Enclose a cover letter and purchase order and ship

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

American

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

European

Rosemount Ireland Equipment Return Repair Dept. Site 7 Shannon Industrial Estate Co. Clare Ireland

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.

6. Reference the return authorization number.

IB-106-300N H

5-1/5-2

INDEX

This index is an alphabetized listing of parts, terms, and procedures related to the World Class 3000 Oxygen Analyzer with IFT 3000 Intelligent Field Transmitter. Every item listed in the index refers to a location in the manual by page number or numbers.

Abrasive Shield, 2-6 Absolute Temperature, 1-2 Adapter Plate, 1-1, 2-1 Air Pressure Regulator Valve, 2-20 Analog Outpu t , 2- 12, 3-12, 3-13 Annunciator, 2-12 Arithmetic Constant, 1-2 Automati c C a li brat ion , 1- 2, 2- 21, 3-10, 3-19 Auto Cal, 3-10

Blind Version, 3-1

Cable Shields, 5-1 CAL, 3-2 Calibrate O

Sub-men u , 3-9, 3-14

Calibration, 3-14, 3- 15 Calibration Constants, 3-14 Calibration Fitting, 1-4 Calibration Gas, 3-16 Calibration Gas Out, 2-21 Cell Constant, 1-2 Ceramic Filter, 2-1 Chart Recorder, 2-12 Check Valve, 1-4, 3- 16

Gas Kits, 3-17 Gas Mixture, 2-8, 3-15, 3- 19 Gas Stratification, 2-1 General User Interface, 1-3 Grounding, 5-1 GUI, 3-1, 5-1

HART HART

Commun i cati on s , 1- 2, 3- 1

Commun i cator, 1-1 HART Interface, 1-3 Heater Power Supply, 1-1, 1-2, 2-18, 2-19 HELP Key, 3-2 High Gas, 2-20

Interconnect Board, 2-14 Instrumen t Air, 1-4 Instrumen t Air In, 2-20 Intelligent Field Transmitter, 1-1, 1-2, 3-1

Languages, 1-3, 3-1 Low Gas, 2-21

MAIN Menu, 3-3 Manual Calibration, 3-10 Manual (Semiautomatic) Calibration, 3-15, 3-19 Microprocessor Board, 2-13 Mother Board, 2-19 MPS Probe Wiring, 2-22 Multiprobe Test Gas Sequencer, 1-1, 1-2

DATA, 3-2 Diagnostic Data, 3-4 Dust seal packings, 2-6

Electrical Noise, 5-1 Electrostatic Discharge, 5-1

Field Replaceable Cell, 1-3 Forcing Cone, 2-6 Fully Automatic Calibration, 3-19 Fuses

IFT Unit, 2-8, 2-10 HPS Unit, 2-15, 2-19 MPS Unit, 2-21, 2-22

NEMA 4X Enclosure, 2-8, 2- 12

Orsat Apparatus, 1-2 Oxygen An alyzer, 1-1, 1-2

Power Cable, 2-9 Power Supply Board, 2-10 Pressure Regul ators , 3- 16, 3-17 PROBE DATA Sub-menu , 3- 4 Push Button R e g u l at or, 3- 18

IB-106-300N H

I-1

Quick Reference Chart, 3-3

Vee Deflector, 2-6

Reference Air, 1-1, 2-7 Ref Air Out, 2- 21

Semiautomatic Calibration, 2-21, 3-15 Setup Sub-menu, 3-14 Status Line, 3-3 Stop Valve, 1-4

TGH, 3-2 TGL, 3-2 Troubleshooting, 5-1

Wiring Lay ou t , 2-11, 2-16, 2-17

Z-purge, 1-4 Zirconia Disc, 1-2

IB-106-300N H

I-2

APPENDIX A, REV. 3.6 WORLD CLASS 3000 OXYGEN ANALYZER (PROBE)

Instruction Bulletin IB-106-300N SERIES

HIGHLIGHTS OF CHANGES

Effective May, 1996 Rev. 3

PAGE SUMMARY

-- General. Updated appendix to reflect probe desi g n ch an g es . 1-10 Added “Extended temperature by-pass arrang ements” to Figure 1-13, Sh eet 3 of 3.

Effective June, 1996 Rev. 3.1

PAGE SUMMARY

1-10 Updated part ordering information.

Effective August, 1996 Rev. 3.2

PAGE SUMMARY

4-1 Updated cell replacement kit part numbers f or the probe.

Effective October, 1996 Rev. 3.3

PAGE SUMMARY

1-5 Added NOTE to Figure 1-7.

Effective January, 1997 Rev. 3.4

PAGE SUMMARY

1-1 2-1 3-1

PAGE SUMMARY

3-3 Changed screw torque in paragraph 3-3 h.

PAGE SUMMARY

Added warning to read new safety instructions. Added protective covers an d g rou n ds warning. Added protective covers an d g rou n ds warning.

Effective February, 1998 Rev. 3.5

Effective July, 1998 Rev. 3.6

-- Changed test gas to calibration gas and reference gas to reference air throughout the appendix.

APPENDIX A

Section Page

I. DESCRIPTION

1-1. Oxygen An alyzer (Probe) - General ........................................................................................ 1-1

1-2. Probe Assembly Ex terior......................................................................................................... 1-1

1-3. Inner Probe Assembly.............................................................................................................. 1-3

1-4. Probe Junction Box.................................................................................................................. 1-4

1-5. Cable Assembly........................................................................................................................ 1-4

1-6. Probe Options........................................................................................................................... 1-4

II. PROBE TROUBLESHOOTING

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

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

III. SERVICE AND NORMAL MAINTENANCE

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

3-2. Probe Recalibration.................................................................................................................. 3-1

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

3-4. Optional Ceramic Diffu s ion Element Replacement................................................................. 3-3

3-5. Replacement of Contact an d Thermocouple Assembly........................................................... 3-5

3-6. Replacement of Heater, V-Stru t an d Back plate A s s embly...................................................... 3-6

3-7. Calibration Gas and Reference Air Lines

For High Temperature - Corrosiv e En v iron ment Operation ................................................ 3-8

IV. REPLACEMENT PARTS

.................................................................................................................................. 1-1

.................................................................................................... 2-1

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

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

LIST OF ILLUSTRATIONS

Figure Page

1-1. Oxygen Analyzer (Probe) Exploded View.......................................................................................... 1-0

1-2. Main Probe Componen ts...................................................................................................................... 1-1

1-3. Cell and Tube Ass emblies.................................................................................................................... 1-2

1-4. Optional Cerami c Dif f u s or an d Vee Def lector Assembly................................................................... 1-2

1-5. Inner Probe Assembly.......................................................................................................................... 1-3

1-6. Probe Junction Box.............................................................................................................................. 1-4

1-7. Abrasive Shield Assembly................................................................................................................... 1-5

1-8. Ceramic Dif f u s ion /Du s t Seal Assembly............................................................................................... 1-6

1-9. Flame Arres tor Dif fusion/Dust Seal Assem bly.................................................................................... 1-6

1-10. Ceramic Diffusion A s s embly............................................................................................................... 1-6

1-11. Flame Arrestor Diffusion Assembly.................................................................................................... 1-6

1-12. Snubber Diffusion/Dust Seal A s s embly............................................................................................... 1-7

1-13. Bypass Probe Option............................................................................................................................ 1-8

2-1. Flowchart of Probe Related Problems, #1 ........................................................................................... 2-3

2-2. Flowchart of Probe Related Problems, #2 ........................................................................................... 2-4

3-1. Cell Wiring Conn ection....................................................................................................................... 3-2

3-2. Removal of Option al Diffusor and Vee Deflector .............................................................................. 3-3

3-3. Cell Replacemen t Kit .......................................................................................................................... 3-3

3-4. Probe Junction Box Mechanical C on n ection s..................................................................................... 3-5

3-5. Inner Probe Replacemen t (Heater, V-Strut, and Backplate Assembly) ............................................. 3-5

3-6. Heater, Strut, and Backplate As s embly (Inner Probe Assem bly) ....................................................... 3-6

3-7. Oxygen Analyzer (Probe), Cross-Sectional View ..............................................................................3-7

3-8. High Temperature - C orrosi v e En v iron ment Kit................................................................................. 3-8

APPENDIX A

IB-106-300N S E RIES

NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FOR

PURCHASE SEPARATELY. FOR LIST OF AVAILABLE PARTS, SEE TABLE 4-1.

1. Heater, Strut, and Backplate Assembly

2. Diffusion Assembly

3. Retainer Screw

4. Cell and Flange Assembly

5. Corrugated Seal

6. Probe Tube Assembly

7. Screw

8. Washer

9. Cover Chain Screw

10. Cover Chain

11. Probe Junction Box Cover

12. Cover Gasket

13. Wiring Diagram

14. O-Ring

15. Terminal Block S crews

16. Terminal Block

17. Terminal Block Marker

18. Terminal Block Mounting Plate

19. Probe Junction Box Screws

20. Hose Clamp

21. Hose

22. Gas Connection

23. Seal Cap

24. Label

25. Probe Junction Box

26. Ground Wires

27. Insulating Gasket

28. Washer

29. Screw

21240005

NOTE: ITEM , CALIBRATION GAS TUBE,

FITS INTO HOLES WHEN PROBE IS ASSEMBLED.

Figure 1-1. Oxygen Analyzer (Probe) Exploded View

APPENDIX A

IB-106-300N S E RIES

1-0

SECTION I. DESCRIPTION

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.

1-1. OXYGEN ANALYZER (PROBE) - GENERAL.

The Oxygen Analyzer (Probe), Figure 1-1, consists of three component groups: probe exterior, inner probe, and probe junction box , F ig ure 1-2.

PROBE EXTERIOR (SENSING CELL INSTALLED)

1-2. PROBE ASSEMBLY EXTERIOR. Primary probe

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

a. Cell and Flange Assembly. The primary

component in the cell and flange assembly, Figure 1-3, is a yttria-stabilized zirconium oxide cell. It 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. Four screws secure the

cell and flange assembly, Figure 1-3, to the probe tube assembly. When in place, the cell is inside the tube.

PROBE

JUNCTION

BOX

Figure 1-2. Main Probe Components

APPENDIX A

IB-106-300N S E RIES

1-1

PROBE INTERIOR

21240006

Table 1-1. Specifications for Ox ygen An al yzin g E qu i pment.

1, 2

Probe lengths, nomin al ................................................................................................ 18 inches (457 m m), 3 feet (0.91 m), 6 feet

(1.83 m), 9 feet (2.74 m), or 12 f eet (3.66 m), depending on duct dimensions

Temperature limits in process

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

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

indication (Digital display

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

or ±3% of reading, whichever is

greater using Rosemount calibration gases

System speed of res pon se............................................................................................. less than 3 seconds (amplifier output)

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

transmitted signal

HPS 3000 housing........................................................................................................ NEMA 4X (IP56)

Probe reference air flow............................................................................................... 2 s cf h (56.6 L / h r) clean, dry, instrumen t

quality air (20.95% O

), regulated to

5 psi (34 kPa)

Calibration gas mix tu res............................................................................................... Rosemoun t Hagan Calibration Gas Kit Part

No. 6296A27G01 contains 0.4% O

2N2

Nominal and 8% O2N2 Nominal

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

HPS 3000 Power supply............................................................................................. 100/110/220 ±10% Vac at 50/60 Hz

HPS 3000 Power requiremen t.................................................................................... 200 VA

HPS 3000 Ambient Operat in g Temperature.............................................................. 32° to 120°F (0° t o 50°C )

Ambient operati n g te mperature (Probe Junction Box)................................................ 300°F (150°C) max

Approximate shipping weight s:

18 inch (457 mm) pack ag e................................................................................ 55 poun ds (24.97 k g )

3 foot (0.91 m) package.................................................................................... 60 pounds (27.24 kg)

6 foot (1.83 m) package.................................................................................... 65 pounds (29.51 kg)

9 foot (2.74 m) package.................................................................................... 72 pounds (32.66 kg)

12 foot (3.66 m) package.................................................................................. 78 pounds (35.38 kg)

All static performance ch aracteristics 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 af f ect th e eas e of f ield cell replaceability.

PROBE TUBE

CORRUGATED

SEAL

CELL AND

FLANGE

ASSEMBLY

Figure 1-3. Cell and Tube Assemblies

21240007

APPENDIX A

IB-106-300N S E RIES

1-2

HUB

WRENCH

Figure 1-4. Optional Ceramic Diffusor and

Vee Deflector Assembly

DIFFUSION

ELEMENT

VEE

DEFLECTOR

21240024

The tube assembly includes a flange which mates with a stack-mounted flange (shown attached to the probe flange in Figure 1-2). Studs on the stack flange make installation easy. There is also a tube to carry calibration gas from the probe junction box to the process side of the cell during calibration.

c. Snubber Diffusion Assembly. The snubber

diffusion assembly protects the cell from heavy particles and isolates the cell from changes in temperature. The snubber diffusion assembly threads onto the cell and flange assembly. Pin spanner wrenches (probe disassembly kit 3535B42G01) are applied to holes in the snubber diffusion element hub to remove or install the snubber diffu s i on as s e mbly.

An optional ceramic diffusor element and vee deflector, shown in Figure 1-4, is available. The ceramic diffusor assembly is also available in a flame arresting version to keep heat from the cell from igniting flue gases.

Systems that use an abrasive shield require a special snubber diffusion 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, s ection 1- 6.

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 ch eck ed after repair or replacement of cell, pad and wire, heater, and thermocouple, or after disassembly of the probe.

1-3. INNER PROBE ASSEMBLY. The inner probe

assembly, Figure 1-5, consists of six main parts:

a. Ceramic support rod with four holes running

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

b. A heater that is helically wrapped on a quartz

support cylinder an d i n s u l ate d.

c. A chromel-alumel thermocouple which acts as the

sensing element for the temperature controller. (Not visible in Figure 1-5; located within ceramic support rod.)

d. A platinum screen pad which forms electrical

contact with the inner electrode of the electrochemical cell. (Not visible in Figure 1-5; located at end of ceramic support rod.) The pad is attached to an inconel wire which carries the signal to the terminal strip.

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

probe assembly.

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

Turn to Section III, Service and Normal Maintenance, for repair procedures for probe components.

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

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

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

V-STRUT

APPENDIX A

IB-106-300N S E RIES

1-3

HEATER

INSULATING

GASKET

CERAMIC

SUPPORT

ROD

REFERENCE

Figure 1-5. Inner Probe Assem b ly

AIR TUBE

27270015

PROBE

JUNCTION BOX

TERMINAL

STRIP

CALIBRATION

GAS FITTING

REFERENCE

AIR FITTING

COVER

27270016

Figure 1-6. Probe Junction Box

1-4. PROBE JUNCTION BOX. The probe junction box,

Figure 1-6, is positioned at the external end of the probe and contains a terminal strip for electrical connections and fittings for reference air and calibration gases. Fittings are for 0.250 inch stainless steel tubing on American units and 6 mm 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.

can be used for this purpose, accuracy can only be assured if a reference air set is u sed.

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

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

1-5. CABLE ASSEMBLY. The system uses a

7-conductor cable to connect the probe to the electronics package. Standard length for this cable is 20 feet (6 m), but lengths up to 150 feet (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 type K Teflon shield. The Teflon

jacket and braided stainless steel

and stainless steel jacketing 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.

1-6. PROBE OPTIONS.

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 air is supplied through the reference air fitting to the reference side of the cell. This gives the system a known quantity of oxygen with which to compare the oxygen level in the process gas. Though ambient air

APPENDIX A

IB-106-300N S E RIES

a. Abrasive Shield Assembly. The abrasive shield

assembly, Figure 1-7, is a stainless-steel tube that surrounds the pro be 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 diffusor and vee deflector assembly, fitted with dual dust seal packing.

1-4

.187 .187

3.584

3.554

ON INSIDE BREAK FOR SMOOTH ROUNDED EDGE ON BOTH ENDS OF CHAMFER

NOTES:

.45 MIN

125

SKIN CUT FACE FOR 90

.187

6.00

VIEW A

0.75 THRU 4 PLS,

EQ SP ON 4.75 B.C.

1 WELD ON BOTH SIDES WITH EXPANDING

CHILL BLOCK.

2 BEFORE WELDING, BUTT ITEM 2 OR 4 WITH

ITEM 1 AS SHOWN.

VIEW B

22.5

.745

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

.755

Figure 1-7. Abrasive Shield Assembly

NOTE

In highly abrasive applications, rotate the shield 90 degrees at norm al

service intervals to present a new wear surface to the abrasive flow stream.

APPENDIX A

IB-106-300N S E RIES

1-5

16860033

P0010

19280010

Figure 1-8. Ceramic Diffusi on /Du s t S eal As s embly

These modified diffusion and vee deflector assemblies are available in standard, Figure 1-8, and flame arrestor ve rsion , Fig u re 1- 9.

b. Ceramic Diffusion Assembly. The ceramic

diffusion assembly, Figure 1-10, 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.

Figure 1-10. Ceramic Diffusion Ass embly

c. Flame Arrestor Diffusion Assembly. Where a

high concentration of unburned fuel is present in the exhaust gases, a flame arrestor diffusion assembly, Figu res 1- 9 an d 1- 11 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.

Figure 1-9. Flame Arrestor Diffusion/Dust

Seal Assembly

P0012

P0011

Figure 1-11. Flame Arrestor Diffusion Assembly

APPENDIX A

IB-106-300N S E RIES

1-6

Figure 1-12. Snubber Diffusion/Dust Seal Assembly

d. Snubber Diffusion/Dust Seal Assembly. The

snubber diffusion/dust seal assembly, Figure 1-12, 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.

e. Bypass Probe Options. For processes where the

flue gas exceeds the maximum allowable temperature of 1300°F (704°C) a bypass sensor package 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 st ack or du ct .

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 1-13.

f. Probe Mounting Jacket Options. 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.

APPENDIX A

IB-106-300N S E RIES

1-7

A-A

OF FLOW

DIRECTION

27270017

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

0.250 O.D. TUBING. 2 SCFH AT 3 PSIG MAX. CLEAN DRY AIR REQUIRED. FITTING

IS LOCATED ON FAR SIDE.

NOTES:

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

10 SCFH AT 32 PSIG MAX. CALIBRATION GAS REQUIRED.

LAG TO ENSURE GAS TEMPERATURE DOES NOT GO BELOW DEW POINT OR

EXCEED 500 C.

oooo

RECOMMENDED TWO INCH THK INSULATION. THERMAL CONDUCTIVITY K

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

INSTALL WITH ANALYZER IN A VERTICALLY DOWNWARDS DIRECTION ONLY.

EQUALS 0.5 FOR INSULATION.

DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.

GROUP NOTE

A 3 FT (914.4) GAS TUBE PICK-UP

FLANGE

B 6 FT (1828.8) GAS TUBE PICK-UP

C 9 FT (2743.2) GAS TUBE PICK-UP

GASKET AND HARDWARE

CAL

GAS

ELECT CABLE

BY CUSTOMER

OPTIONAL MOUNTING

ARRANGEMENT, 4 IN.

150# FLANGE SUPPLIED

HARDWARE

GASKET AND

REF

AIR

4.026

VIEW

02 03

I.D.

(102.26)

30.62 (777.75) REF (4507C26G01)

62.50 (1587.5) REF (4507C26G03)

26.50 (673.1) REF (4507C26G01 AND G02)

6.0

(152.4) REF

6.50

(165.1) REF

37.00 (939.8) REF (4507C26G01)

73.00 (1854.2) REF (4507C26G02)

109.00 (2768.6) REF (4507C26G03)

STD 20 FT

(6.1 M) CABLE

DRAIN

FOR

FOR PROBE

27.31 (693.67) CLEARANCE REQ

INSERTION

AND REMOVAL

3D3947G01

19.80 (502.92)

IF EQUIPPED WITH THE OPTIONAL

CERAMIC DIFFUSOR ASSEMBLY, PROBE

VEE SHIELD IS SQUARE TO GAS FLOW.

ASSEMBLY MUST BE ORIENTED SO THAT

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

APPENDIX A

IB-106-300N S E RIES

1-8

A-A

27270018

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

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

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

REQUIRED. FITTING IS LOCATED ON FAR SIDE.

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

LAG TO ENSURE GAS TEMPERATURE DOES NOT GO BELOW DEW POINT OR

EXCEED 932 F (500 C).

INSTALL WITH ANALYZER IN A VERTICALLY DOWNWARDS DIRECTION ONLY.

4.5.6.

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

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

0.5 FOR INSULATION.

DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.

FLANGE

GROUP NOTE

A 3 FT (914.4) GAS TUBE PICK-UP

06 07

B 6 FT (1828.8) GAS TUBE PICK-UP

C 9 FT (2743.2) GAS TUBE PICK-UP

AND

GASKET

HARDWARE

CAL

GAS

ELECT

CABLE

WELD BY CUSTOMER

REF

AIR

VIEW

OF FLOW

DIRECTION

I.D.

4.026 (102.26)

PLATE

WELDED

TO STACK

PICKUP (3D390004G07 OR G08)

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

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

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

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

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

STD CABLE

20 FT (6.1 M)

FOR PROBE

27.31 (693.67) CLEARANCE REQ

INSERTION

AND REMOVAL

FOR

19.80 (502.92)

3D3947G01

Figure 1-13. Bypass Probe Option (Sheet 2 of 3)

APPENDIX A

IB-106-300N S E RIES

1-9

DRAIN

6.50 (165.1) REF

IF EQUIPPED WITH THE OPTIONAL

CERAMIC DIFFUSOR ASSEMBLY, PROBE

VEE SHIELD IS SQUARE TO GAS FLOW.

ASSEMBLY MUST BE ORIENTED SO THAT

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

PART NO. GROUP

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

APPENDIX A

IB-106-300N S E RIES

1-10

SECTION II. PROBE TROUBLESHOOTING

2-1. OVERVIEW.

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

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.

2-2. PROBE TROUBLESHOOTING.

a. Probe Faults. Listed below are the four symptoms

of probe failure.

1. The s ystem does not respond to ch an g e s i n the oxygen concen tration .

SYMPTOM CHECK FAULT REMEDY

1. No response to oxygen concentration change when:

2. The s ystem 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 calibration gas being applied during calibration.

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

b. Table 2-1 provides a guide to fault finding for the

above symptoms.

c. Figures 2-1 and 2-2 provide an alternate approach

to finding probe relate d problems.

Table 2-1. Fault Finding.

Heater is cold and TC mV output is less than set point

Heater is hot and T/C mV output is at set point ±0.2 mV

Thermocouple continuity

Heater cold resistance to be 11 ohm to 14 ohm

Triac O/P to heater

Recorder chart

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

Thermocouple failure

Heater failure

Failure of electronics

Recorder failure

No cell mV at probe when calibration gas applied

Probe cell mV OK but no input to electronics

Cell mV satisfactory both at probe junction box an d input to electronics - failure of electronics

Replace thermocouple or return probe to Rosem ount.

Replace heater or return probe to Rosemount.

Check HPS and electronics package.

See Recorder Instruction Manual.

Replace cell or return probe to Rosemount.

Check out cable connection.

Check electronics package.

APPENDIX A

IB-106-300N S E RIES

2-1

Table 2-1. Fault Finding (Continued).

SYMPTOM CHECK FAULT REMEDY

2. System responds t o oxygen concentration changes but does n ot give correct indication

Good response, wit h incorrect indication

3. System does not give accurate indication of applied calibration gas

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

Recorder or remote indicator

Calibration error

Recalibrate recorder or indicator. Reference Recorder Instruction Manual.

System calibration

Probe mounting and

Calibration error

Air ingress into duct

Recalibrate system.

Stop air leaks or resite probe.

condition of duct

Cell mV input to electronics Calibration gas input port

Failure of electronics Blocked port

Check electronics package. Clean port. If the flue gas is

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

Ceramic diffus i on element

Diffusion elemen t crack ed,

Replace diffusion elem en t.

broken, or missi n g

Diffusion element Plugged diffusion element Change diffusion element or

snubber diffu si on el ement.

APPENDIX A

IB-106-300N S E RIES

2-2

Figure 2-1. Flowchart of Probe Related Problem s , #1

APPENDIX A

IB-106-300N S E RIES

2-3

Figure 2-2. Flowchart of Probe Related Problem s , #2

APPENDIX A

IB-106-300N S E RIES

2-4

SECTION III. SERVICE AND NORMAL MAINTENANCE

NOTE

Upon completing installation, make sure that the probe is turned on and operating prior to firing u p 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.

3-1. OVERVIEW.

maintenance of the oxygen analyzer probe. Spare parts referred to are available from Rosemount. Probe disassembly kit 3535B42G01 contains the required spanner and hex wrenches. Refer to Section IV of this appendix for part numbers and ordering inform at ion .

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.

3-2. PROBE RECALIBRATION.

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.

This section describes routine

The oxygen analyzer

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 4-1.

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 b urn s .

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

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.

3-3. CELL REPLACEMENT.

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 4-1.

The cell replacement kit contains a cell and flange assembly, corrugated seal, setscrews, socket head cap screws, and anti-seize compound. Items are carefully

This paragraph covers

APPENDIX A

IB-106-300N SERIES

3-1

Disconnect and lock out power to electronics. Shut

off and disconnect reference air and calibration gas supplies from probe junction box, Figure 3-1. 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.

BOMB TAIL

CONNECTOR

CELL EXTENSION

WIRE (ORANGE)

INCONEL

CELL WIRE

(CLEAR

SLEEVING)

HEATER

WIRES

(BLACK

SLEEVING)

THERMOCOUPLE -

(RED ALUMEL)

THERMOCOUPLE +

(YELLOW CHROMEL)

CALIBRATION

GAS FITTING

CABLE

Figure 3-1. Cell Wiring Connection

If the probe uses the standard diffusion element,

use a spanner wrench to remove the diffusion element.

If equipped with the optional ceramic diffusor

assembly, remove and discard setscrews, Figure 3-2, and remove vee deflector. Use spanner wrenches f rom probe disassembly k i t, Table 4-1, to turn hub free from retainer. Inspect diffusion element. If damag ed, replace element.

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

REFERENCE

AIR FITTING

PROBE JUNCTION

BOX COVER

27270019

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 3-5).

APPENDIX A

IB-106-300N S E RIES

3-2

WRENCH

RETAINER

OPTIONAL CERAMIC

DIFFUSION ELEMENT

HUB

CEMENT

PORT

CEMENT

FILLET

Figure 3-2. Removal of Optional Diffu s or

and Vee Deflector

PROBE TUBE

(NOT INCLUDED

IN KIT)

CORRUGATED

SEAL

CALIBRATION GAS

PASSAGE

SETSCREW

VEE

DEFLECTOR

21240026

CELL AND

FLANGE

ASSEMBLY

SOCKET HEAD

CAP SCREWS

Assemble cell and flange assembly, corrugated

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 55 in-lbs

•

(4 N

m).

Apply anti-seize compound to threads of cell

assembly, hub, and setscrews. Reinstall hub on c ell 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

On systems equipped with an abrasive shield,

install dust seal gaskets, with joints 180

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

•

m).

apart.

reducing

cone.

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.

3-4. OPTIONAL CERAMIC DIFFUSION ELEMENT

REPLACEMENT.

Figure 3-3. Cell Replacement Kit

If contact assembly is damaged, replace contact

and thermocouple according to paragraph 3-5, Replacement of Contact and Thermocouple Assembly.

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 h u b.

Rub a small amount of anti-seize on both sides of

new corrugated seal.

21240009

APPENDIX A

IB-106-300N S E RIES

3-3

a. General.

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

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 4-1.

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). They can cause severe burn s .

6. Break out remaining diffusion element by tapping lightly around hub with hammer. Clean grooves w ith poin ted tool if necessary.

7. Replace diffusion element, using replacement kit listed in Table 4-1. This consists of a diffusion element, cement, setscrews, anti-seize compound and in s tru ction s .

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

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

b. Replacement Procedure.

1. Shut off power to electronics. Disconnect cable conductors and remove cable, Figure 3-1. Shut off and disconnect reference air and calibration gas supplies from probe junction box. 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 3-2, using hex wrench from special tools kit, Table 4-1, and remove vee deflector. Inspect setscrews. If damaged, replace with M-6 x 6 stainless setscrews coated w ith anti-seize compound.

3. On systems equipped with abrasive shield, remove dual dust seal g as k ets .

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 gro oves 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.

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

11. Wipe a heavy layer of anti-seize compound onto the threads and mating surfaces of the diffusion h u b an d ret ainer.

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

4. Use spanner wrenches from special tools kit, Table 4-1, 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 thr ough cement port.

APPENDIX A

IB-106-300N S E RIES

13. On systems equipped with abrasive shield, install dust s eal g a s k ets with joints 180° apart.

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

3-4

15. R ei n s tal l probe on s t ack f l an g e.

21240010

MOUNTING SCREW

(REAR VIEW)

CONTACTAND

THERMOCOUPLER

ASSEMBLY

V-STRUT

HEATER SCREWS

(NOT SHOWN)

HEATER

CERAMIC ROD

SPRING

CLIP

INSULATING

GASKET

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.

3-5. REPLACEMENT OF CONTACT AND

THERMOCOUPLE ASSEMBLY.

Use heat resistant gloves and clo thing when removing probe junction box and inner probe assembly. Do not attempt to work on these components until they have cooled to room temperature. Probe components can be as hot as 800°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.

PROBE JUNCTION BOX TO HEATER,

STRUT, AND BACKPLATE

ASSEMBLYSCREW

PROBE JUNCTION BOX

INNER PROBE ASSEMBLY

TO PROBE TUBE SCREWS

PROBE

JUNCTION

BOX

HOSE

CLAMP

HOSE

21240027

Figure 3-4. Probe Junction Box Mechanical Conn ecti ons

Disconnect and lock out power to electronics.

Using heat resistant gloves and clothing, remove probe junction box cover. Squeezing tabs on hose clamps, remove hoses from probe junction box, Figure 3-4. Remove four screws in corners of probe junction box. Pull probe junction box and inner probe assembly free from probe tube. Set on bench and allow to cool t o room temperature.

Disconnect cell extension wire (orange),

thermocouple wire (red alumel), and thermocouple wire (yellow chromel) by cutting bomb tail connections from th e terminal strip, Figure 3-1.

Remove two screws, Figure 3-4, lockwashers, and

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

Use a pencil to mark locations of spring clip on

ceramic rod, Figure 3-5.

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.

While very carefully handling new contact and

thermocouple assembly, lay old assembly next to new one. Transf er pen ci l marks to new rod.

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.

Figure 3-5. Inner Probe Replacement

(Heater, V-Strut, and Backplate Assembly)

APPENDIX A

IB-106-300N S E RIES

3-5

Carefully guide new contact and thermocouple

assembly through V-strut assembly leaf spring (4, Figure 3-6), spring (9), spring clip (10) (held open by squeezing tabs), and tube supports (11, 13) until spring clip reaches pencil mark.

Reinstall insulating gasket on backplate, replace

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

Slide assembled probe junction box and inner

probe assembly into probe tube. To align calibration gas tube with corresponding hole in backplate (A, B, Figure 1-1), insert scriber through hole in backpl ate and into c alib ra tion gas tube. Secure with screws. Reinstall hoses and probe junction box cover.

Power up system. Monitor thermocouple output.

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

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

Trim wires, if necessary, as noted in step (g).

Connect color coded wires to proper terminals as

shown in Figure 3-1. 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 add itional thermocouple junctions. This could produce a voltage that would affect the thermocouple output signal.

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

3-6. REPLACEMENT OF HEATER, V-STRUT

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

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

1011

1. Heater Ceramic Rod 5. Ring Lug 19. Spring

2. Contact and Thermocouple Assembly 6. Butt Connector 10. Spring Clip Assembly

3. Strut 7. Extension Wire 11. Comm on Tube S u pport

4. Leaf Spring 8. Backplate 12. Heater

13. Short Tube Support

Figure 3-6. Heater, Strut, and Backplate Assembly

(Inner Probe Assembly)

APPENDIX A

IB-106-300N S E RIES

3-6

NOTE

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

Disconnect and lock out power to electronics.

Using heat resistant gloves and clothing, remove probe cover. Squeezing tabs on hose clamps and remove hoses from probe j unctio n b ox, Figure 3 -4. Remove four screws and lockwashers (7, 10, Figure 3-7) that hold probe junction box and inner probe assembly to probe tube. Pull probe junction box and inner probe assembly free from probe tube. Set on bench and allow to cool to room temperature.

Disconnect cell extension wire (orange),

thermocouple wire (red alumel), and thermocouple wire (yellow chromel) by cutting bomb tail connections from th e terminal strip, Figure 3-1.

Remove two screws, lockwashers, and flat washers

that connect probe 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.

Connect color coded wires to proper terminals as

shown in Figure 3-1. 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 inch (6.4 mm) from end of ceramic rod. Dress wires so they do not touch sides of probe junction box.

Slide assembled probe junction box and inner

probe assembly into probe tube. To align calibration gas tube with corresponding hole in backplate (A, B, Figure 1-1), 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 junc ti on box cov e r.

ITEM

4 5

124

DESCRIPTION

Snubber Diffus i on Element Socket Hd Cap Screw Cell and Flange Assembly Corrugated Seal Probe Tube Assembly

SIZE-REFERENCE INFORMATION ITEM

0.25 in.-28

x 0.63 (16 mm)

9 10 11

DESCRIPTION

Gasket

Fillister Hd Screw Cover Head Assembly Hose Clamp Lockwasher Heater Strut Assembly

678 9

21240012

SIZE-REFERENCE INFORMATION

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

0.12 in. (3 mm) 8-32 x 0.5 in. (12.7 mm)

#8 Split

Figure 3-7. Oxygen Analyzer (Probe), Cross-Sectional View

APPENDIX A

IB-106-300N S E RIES

3-7

Power up system. Monitor thermocouple output. It

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

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

3-7. CALIBRATION GAS AND REFERENCE AIR

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 probe junction box. The kit part number is 4843B93G01.

a. Installation Procedure.

Use heat resistant gloves and clothing when removing probe junction box and inner probe assembly. Do not attempt to work on these components until they have cooled to room temperature. Probe components can be as hot as 800°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.

2. First install the stainless steel tubing on the fitting at the bottom of the probe junction box. Install the other end of the stainless steel tube onto the tube going to the probe (Figure 3-8).

NOTE

If abrasive conditions of h i gh 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

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 probe junction box (Figure 3-4).

APPENDIX A

IB-106-300N S E RIES

21240028

Figure 3-8. High Temperature - Corrosive

Environment Kit

3-8

SECTION IV. REPLACEMENT PARTS

Table 4-1. Replacement Parts for Probe.

FIGURE and INDEX No. PART NUMBER DESCRIPTION

3-5 3-5 3-5 3-5 3-5 3-6, 2 3-6, 2 3-6, 2 3-6, 2 3-6, 2 1-7 1-7 1-7 1-7 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-3 1-10 1-8

1-10 1-9 1-11 1-4

3-2

3D39441G06 3D39441G07 3D39441G08 3D39441G09 3D39441G10 3534B56G04 3534B56G05 3534B56G06 3534B56G07 3534B56G08 3D39003G01 3D39003G02 3D39003G07 3D39003G08 4847B61G01 4847B61G02 4847B61G03 4847B61G04 4847B61G05 4847B61G06 4847B61G07 4847B61G08 4847B61G09 4847B61G10 4847B61G11 4847B61G12 4847B61G13 4847B61G14 4847B61G15 4847B61G16 4847B61G17 4847B61G18 3535B42G01 3534B18G01 3535B60G01

4841B03G02 3535B63G01 3535B62G01 3534B48G01

6292A74G02 1537B70G03

3-8 1-1,2 1-12

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

Contact and thermocouple assembly includes platinum pad and in con el wire.

Abrasive shield assem bly includes accessories necessary for its u s e an d a mounting plate and gasket.

4843B93G01 4843B37G01 4843B38G02

1 1 1 1 1 2 2 2 2 2 3 3 3 3

Heater, V-Strut , and Ba ck pl at e A sse m bly, 18 in. (45.6 cm) Heater, V-Strut, and Backplate Assembly, 3 ft (0.9 m) Heater, V-Strut, and Backplate Assembly, 6 ft (1.8 m) Heater, V-Strut, and Backplate Assembly, 9 ft (2.7 m) Heater, V-Strut, and Backplate Assembly, 12 ft (3.6 m) Contact and Thermocouple Assembly, 18 in. ( 45.6 c m ) 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 ) 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) Cell Replacement Kit, ANSI, No Lead Wire Cell Replacement Kit, ANSI 18 in. (45.6 cm) Cell Replacement Kit, ANSI 3 ft (0.9 m) Cell Replacement Kit, ANSI 6 ft (1.8 m) Cell Replacement Kit, ANSI 9 ft (2.7 m) Cell Replacement Kit, ANSI 12 ft (3.6 m) Cell Replacement Kit, JIS, No Lead Wire Cell Replacement Kit, JIS 18 in. (45.6 cm) Cell Replacement Kit, JIS 3 ft (0.9 m) Cell Replacement Kit, JIS 6 ft (1.8 m) Cell Replacement Kit, JIS 9 ft (2.7 m) Cell Replacement Kit, JIS 12 ft (3.6 m) Cell Replacement Kit, DIN, No Lead Wire Cell Replacement Kit, DIN 18 in. (45.6 cm) Cell Replacement Kit, DIN 3 ft (0.9 m) Cell Replacement Kit, DIN 6 ft (1.8 m) Cell Replacement Kit, DIN 9 ft (2.7 m) Cell Replacement Kit, DIN 12 ft (3.6 m) Probe Disassembly Kit Diffuser Assembly Diffuser Dust Seal Hub Assembly (For use with Abrasive Shield) Stainless Steel Diffuser Assembly Flame Arrestor Diffuser Dust Seal Flame Arrestor Diffuser Vee Deflector Assembly (For use with sta ndar d or dust se a l type ceramic diffuser s) Diffusion Element Replacement Kit Horizontal and Vertical Brace Clamp Assembly, 9 and 12 foot (2.7 and 3.6 m) probe High Temperature - Corrosive Environment Kit Snubber Diffusion Assembly Dust Seal/Snubber Di ffusion A ssembly

APPENDIX A

IB-106-300N S E RIES

4-1/4-2

Rosemount World Class 3000 O2 Analyzer with IFT 3000 Intelligent Field Transmitter-Rev 3.6 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

ROSEMOUNT WARRANTY

PURPOSE

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

SECTION I. DESCRIPTION

SECTION II. INSTALLATION

SECTION III. GENERAL USER INTERFACE (GUI) OPERATION

3-3. HELP KEY. The HELP key will display explanatory

3-7. PROBE DATA SUB-MENU. The PROBE DATA

SECTION IV. SYSTEM TROUBLESHOOTING

INDEX

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

SECTION I. DESCRIPTION

SECTION II. PROBE TROUBLESHOOTING

SECTION III. SERVICE AND NORMAL MAINTENANCE