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Emerson 3000 Oxygen Equipment User Manual

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1. ewe saa wl jue 13 1 1 uum eon von wenn om nm mnn 3 3 1 TL L lem TER ERES bbb mmus oma mm s _ 1 wem Wa BE SE ET me eau 1 16 1 1 1 1 we pubem 1 5I ase x 1 1 1 1 ta m cs NE COE owe fon oon Ie Extended Temperature By Pass Arrangements 2400 F 1300 C GROUP PART NO CODE DESCRIPTION 1U0571 3 By pass Package with ANSI bolt pattern 1U0571 1U0571 6 By pass Package with ANSI bolt pattern 9 By pass Package with ANSI bolt pattern 6 By pass Package with JIS bolt pattern 3 By pass Package with DIN bolt pattern 10057 6 By pass Package with DIN bolt pattern 9 By pass Package with DIN bolt pattern Figure A 13 Bypass Probe Option Sheet 3 of 3 9 By pass Package with JIS bolt pattern 3 By pass Package with JIS bolt pattern G 01 02 03 04 05 06 07 08 09 Rosemount Analytical Inc A Division of Emerson Process Management Appendices 11 Instruction Manual Appendix A Rev 3 6 July 1998 A 7 OVERVIEW World Class 3000 PROBE TROUBLES
2. 19260001 Figure 1 1 Typical System Package Rosemount Analytical Inc Division of Emerson Process Management Description 1 1 Instruction Bulletin 106 300NE Rev 3 4 The equipment measures oxygen percent age 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 log4o P4 P5 C Where 1 the partial pressure of the oxygen in the measured gas on one side of the cell 2 P is the partial pressure of the oxygen in the reference gas on the other side T is the absolute temperature C is the cell constant K is an arithmetic constant Orisa NOTE May 2000 World Class 3000 oxygen The difference will be proportional to the water content of the sampled gas stream System Configuration The equipment discussed in this manual consists of two major components the oxy gen analyzer probe and the heater power supply Probes are available in five length options giving the user the flexibility to use an in situ penetration appropriate to the size of the stack or duct The options on length are 18 inches 457 mm 3 feet 0 91 m 6 feet 1 83 m 9 feet 2 74 m 12 feet 3 66 m The heater power su
3. LZL 62 X OZ IN Z X OL W LL Sc9 O 2 9078 GLY SZL 001 LZL QvauHL c6 v v6 Gly SZ LX ZL N Z X OL W LL Sc9 O 8 cec 622 SOL 161 691 Gc 6 Gc 6 006 069 Gl 00 9 pooesasese 9058sasese ZOOSSESESE 109989197 N d 10 09 0216 N d LObDvEOZLST N d sir ISNV Sir ISNV SNOISN3INIG SNOISN3WIG QI3IHS 3AISVH8v SNOISNAWIG 34vld HOLdVQV 3 avt SNOISNAWIG ALW1d HOLdVOV JNITLOO SALW dOLdVGav A Division of Emerson Process Management Rosemount Analytical Inc Figure 2 1 Probe Installation Sheet 3 of 5 Installation 2 4 World Class 3000 INSTALLATION FOR METAL WALL STACK OR DUCT CONSTRUCTION 8 75 95 MIN DIA HOLE IN WALL STACK OR DUCT METAL WALL MTG HOLES SHOWN ROTATED 22 5 OUT OF TRUE POSITION WELD OR BOLT MOUNTING PLATE TO METAL WALL OF STACK OR DUCT JOINT MUST BE AIRTIGHT Instruction Bulletin 106 300NE Rev 3 4 May 2000 INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION BOLT ADAPTOR PLATE TO OUTSIDE WALL SURFACE FIELD WELD PIPE TO ADAPTOR PLATE MTG HOLES SHOWN ROTATED 22 5 OUT OF TRUE POSITION PIPE 4 00 SCHED 40 PIPE SLEEVE NOT BY ROSEMOUNT LENGTH BY CUSTOMER JOINT MUST BE AIRTIGHT MASONRY STACK WALL OUTSIDE WALL SURFACE NOTE ALL MASONRY STACK WORK AND JOINTS EXCEPT ADAPTOR PLATE NOT FURNISHED BY ROSEM
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5. NOILVHSIIVO 72 NO SI J18vO 19 T NV31O 9ISd HJOS 0SZ0 14 0c ALS O A 9 Appendices Figure A 13 Bypass Probe Option Sheet 1 of 3 A Division of Emerson Process Management Rosemount Analytical Inc Instruction Manual O O c co lt gt 9 Pl lt 81002242 dNMOld Z vZ2 14 6 98972 0 604 lt LODvOOO6EdE dNM ld 1716 14 NO 8 686 07 dNMOld 88281 14 9 NO 981 0 Z 809 HO 4097v0006 G dr13491d lt 987828 14 9 HO 16 14 NO L 29 692 dnMOld 14 6 67861 629 Jdu 1691 099 92201 dO 920 NOILOAYIC SVD OL AYVNOS SI Q T3IHS 33A IVHL OS 39 LSNW ATlaNassv 3HOHd AIGWASSV YOSNssIC OI NVH3O VNOILdO QaddInO3 dl MOVLS OL 5 WO 318VO 19313 dN MOld AGNL svo 2 146 O dfMOld 3g ni svo 88281 14 9 8 dN MOld 3gnL SVO rvie 13 V ALON dfilOu9 5 NI SHSALAWITIIW S3HONI SNOISN3NIG NOILVINSNI
6. aunssaud LON S39NV 3S3H1 QG3OVv4 LV 19 SNH3 LIVd L1O8 Sif NIG SNV OL GSYNLOVANNVW ADNVTA 3712910 H313WVIG HSLSWVIG pog 8 JZIS 3 18VL Figure 2 1 Probe Installation Sheet 2 of 5 r688 681 SEL tact 6192 0862 SLSz L 0L 66 146 041 S902 0091 a 064 1911 989 Ite 22 a Wid Wid SLNAWAYENSVAW IVNIINON NOILVTIVLSNI IWAOWSY 11 519 2 3 Installation A Division of Emerson Process Management Rosemount Analytical Inc World Class 3000 Instruction Bulletin 106 300NE Rev 3 4 May 2000 2009891 I33HS 33S 39Nv13 TS NOLLVTIVISNI 3HOHd GI3IHS 3AISVH8V e 0006 55 19 GTHOM ALS BEES 31V1d HOldVQV ATIVNOA SLNN SH3HSVMMOO1 SGNLS v vid NO d3ovdS S31OH q3qv3tiH1 8 2 144 6 33S SNOLIVTIVISNI T13IHS 3AISVH8V 14 6 9 31V1d HOldVQV 0052 jovduns TIVM 3dls1nO 22 OL 31V 1d ONILIOS S31OH TWNOILIGGY 3GdlAOHd OL 38 AVN SH3NHOO ee NI Q3HO1VHSSOHO lt V JjHvVMQHVH SNIHOVLIV ACGNIONI Saivid dHOLdVOV HO4Jd SH38NNON 1HVd ALON 002 061 161 JjuvMQUVH ONIHOVLIV Pod a J3an17oNI SALV1d HOLdVGV LHVd 31ON QvauHL 081
7. DIFFUSION ELEMENT CEMENT CEMENT PORT FILLET VEE DEFLECTOR 21240026 Figure A 17 Removal of Optional Diffusor and Vee Deflector PROBE TUBE NOT INCLUDED IN KIT CORRUGATED SEAL CELL AND SOCKET HEAD CAP SCREWS CALIBRATION GAS PASSAGE 21240009 Figure A 18 Cell Replacement Kit e If contact assembly is damaged replace contact and thermocouple according to paragraph A 13 Replacement of Contact and Thermocouple Assembly f Remove and discard corrugated seal Clean mating faces of probe tube and retainer Remove burrs and raised surfaces with block of wood and crocus cloth Clean threads on retainer and hub A 18 Appendices A 12 Rosemount Analytical Inc World Class 3000 g Rubasmall amount of anti seize on both sides of new corrugated seal h Assemble cell and flange assembly corru gated seal and probe tube Make sure the calibration tube lines up with the calibration gas passage in each component Apply a small amount of anti seize compound to screw threads and use screws to secure assembly Torque to 55 in lbs 4 N m Apply anti seize compound to threads of cell assembly hub and setscrews Reinstall hub on cell assembly Using pin spanner wrenches torque to 10 ft lbs 14 N m If applicable reinstall vee deflector orienting apex toward gas flow Secure with setscrews and anti seize compound Torque to 25 in lbs 2 8 N m Onsystems equipped with an abrasiv
8. The oxygen analyzer is connected to the HPS and electronics package using seven wires housed within the connecting system cable Features 1 Unique and patented cell protection action that automatically protects sensor cell when analyzer detects reducing atmospheres 2 Output voltage and sensitivity increase as the oxygen concentration decreases 3 In situ non sampling analyzer 4 Field replaceable cell 5 Analyzer constructed of rugged 316 55 for all wetted parts Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 6 Suitable for use in temperatures up to 1300 F 700 C 7 Heater power supply allows World Class 3000 probe to be interfaced with existing analog and 218A digital electronic packages 8 Optional explosion proof HPS enclo sure allows use in hazardous gas areas e Handling the Oxygen Analyzer 1 N Lb C It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to prevent possible equipment damage The oxygen analyzer is designed for industrial application Treat each component of the system with care to avoid physical damage The probe contains components made from ceramics which are susceptible to shock when mishandled NOTE Retain packaging in which the oxygen analyzer arrived from the factory in case any components are to be shipped to another si
9. probe tube Secure with screws Reinstall hoses and probe junction box cover f Power up system Monitor thermocouple output It should stabilize at set point 0 2 mV Recalibrate probe per Instruction Bulle tin applicable to your electronics package A 15 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 in side the probe junction box The kit part number is 4843B93G01 Rosemount Analytical Inc Division of Emerson Process Management a Installation Procedure N C Use heat resistant gloves and clothing when removing probe junc tion box and inner probe assembly Do not attempt to work on these com ponents until they have cooled to room temperature Probe components can be as hot as 800 F 427 C This can cause severe burns Disconnect and lock out power before working on any electrical components There is voltage up to 115 Vac 1 Disconnect and lock out power to digi tal electronics Using heat resistant gloves and clothing remove probe cover Squeezing tabs on hose clamps remove hoses from probe junction box Figure 19 Appendices 23 Instruction Manual Appendix A Rev 3 6 July 1998 World Class 3000 TEFLON SLEEVES Do not use seal
10. 1 Shut off power to electronics Discon nect cable conductors and remove ca ble Figure 16 Shut off and disconnect reference air and calibration gas supplies from probe junction box Wearing heat resistant gloves and clothing carefully remove probe as sembly 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 A 17 using hex wrench from special tools kit and remove vee deflector nspect setscrews If damaged replace with M 6 x 6 stainless setscrews coated with anti seize compound A Division of Emerson Process Management ing wet cement off of ceramic only forces cement into pores 10 Thoroughly mix cement and insert tip of squeeze bottle into cement port Tilt bottle and squeeze while simultane ously turning diffusion element into seat Do not get any cement on upper part of diffusion element Ensure com plete penetration of cement around three grooves in hub Cement should extrude from opposite hole Wipe ex cess 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 Allow filter to dry at room temperature overnight or 1 to 2 hours at 200 F 93 C Appendices A 19 Instruction Manual Appendix A Rev 3 6 July 1998 11 Wipe a heavy layer of anti seize com pound onto the threa
11. 2 74 m or 12 feet 3 66 m depending on duct dimensions 50 to 1300F 10 to 704 C 4 20 mA dc signal factory set 0 196 or 3 of reading whichever is greater using Rosemount calibration gases less than 3 seconds amplifier output 0 01 O transmitted signal NEMA 4X IP56 2 scfh 56 6 L hr clean dry instrument quality air 20 95 regulated to 5 psi 34 kPa Rosemount Hagan Calibration Gas Kit Part No 6296A27G01 contains 0 4 ON Nominal and 8 O N Nominal 5 scfh 141 6 L hr 100 110 220 10 Vac at 50 60 Hz 32 to 120 F 0 to 50 C 300 F 150 C max 55 pounds 24 97 kg 60 pounds 27 24 kg 65 pounds 29 51 kg 72 pounds 78 pounds 35 38 kg All static performance characteristics are with operating variables constant Equipment ordered utilizing this document as reference will be supplied to the USA standard design Custom ers requiring the EEC standard design should request the EEC documentation and utilize its ordering data Temperatures over 1000 F 537 C may affect the ease of field cell replaceability A 2 Appendices Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 A 2 PROBE ASSEMBLY EXTERIOR Primary probe exterior components include a flange mounted zirconium oxide cell mounted on a tube assembly and protected by a snubber diffusion assembly a Cell and Flange Assembly The primary component in the cell and flange assembly
12. DIRECTION VEE 1 Power input 100 115 or 220 Vac sin APEX gle phase 50 to 60 Hz 3 amp minimum See label 2 Compressed air 10 psig 68 95 kPag minimum 225 psig 1551 38 kPag DIFFUSION maximum at 2 scfh 56 6 L hr maxi 5 ERE EI mum supplied by one of the following SETSCREW less than 40 parts per million total hy drocarbons Regulator outlet pressure VEE should be set at 5 psi 35 kPa DEFLECTOR a Instrument air clean dry b Bottled standard air with step down regulator P0017 c Bottled compressed gas mixture Figure 2 2 Orienting the Optional Vee Deflector 20 95 oxygen in nitrogen d Other equivalent clean dry oil free air supply 10 39 264 7 00 177 8 325 aba NEMA 4X 9 96 8 50 82 6 92 2 Non hazardous Mm 0 31 0 13 THK U L APPROVED GASKET 7 3 6 00 d 9 17 253 0 56 14 DIA 2 MOUNTING HOLES 100 254 MINIMUM ANC FOR REMOVING COVER 10 52 UNF 2 INSERT THREADED 0 31 x 0 31 FROM CORNER OF PLATE CLASS 1 DIMSION 1 GROUP B ENCLOSURE DESIGN DIMENSIONS ARE IN INCHES DENOTES MILUMETER EQUIVALENTS WHEN USED Figure 2 3 Outline of Heater Power Supply Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 7 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 EXISTING ELECTRONICS RELAY YE PROBE PROBE RD MV TC AD590 MM
13. 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 hazard ous 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 Cer tain 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 follow ing standards EN61010 1 IEC417 and 1503864 P 2 Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 SECTION 1 DESCRIPTION 1 1 COMPONENT CHECKLIST OF TYPICAL SYSTEM PACK
14. in the manual by one or more page numbers Model TC200 VERITRIM Electronics Package 3 3 A Models 218 Electronics Package 3 1 Abrasive Shield 24 Models 225 Electronics Package 3 1 Absolute Temperature 1 2 mother Board 2 10 Adapter Plate 2 1 Mounting Adaptor Plate 1 2 Ambient Temperature 2 9 Arithmetic Constant 1 2 N NEMA 4X Enclosure 2 9 C Nernst Equation 1 2 Cell Constant 1 2 Ceramic Filter 2 1 O Check Valve 1 3 Orsat Apparatus 1 2 Oxygen Analyzer 1 1 D Oxygen lons 1 2 Dust Seal Packings 2 6 P E Probe Heater Set Point 3 1 3 2 3 3 Electrochemical Cell 1 2 Electronic Packages 1 1 R EPROM 3 2 Reference Gas 1 3 Explosion Proof Enclosure 1 2 S F Sampling System 1 1 Fuses 2 10 2 11 sensing Point 2 1 Sensor Cell 1 3 G oolenoid Valve 1 3 Gas Stratification 2 1 T H Transformer 1 2 Heater Power Supply 1 1 Hub Grooves 2 6 V Vee Deflector 2 6 In Situ 1 2 W Instrument Air 1 3 Water Vapor 1 2 M Z Model 132 Digital Electronics Package 3 4 Zirconia Disc 1 2 Model 218A Digital Electronics Package 3 2 Rosemount Analytical Inc Division of Emerson Process Management Index 7 1 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 7 2 Index Rosemount Analytical Inc Division of Emerson Process Management WARRANTY Goods and part s excluding consumables manufactured by Seller are warranted to be free from defects in workmanship and material under normal use an
15. 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 Appendices A 25 Instruction Manual Appendix A Rev 3 6 July 1998 World Class 3000 Table A 3 Replacement Parts for Probe Continued Figure and Index No Part Number Description 4841B03G02 Stainless Steel Diffuser Assembly 3535B63G01 Flame Arrestor Diffuser Dust Seal 3535B62G01 Flame Arrestor Diffuser 3534B48G01 Vee Deflector Assembly For use with standard or dust seal type ceramic diffusers Figure A 17 6292A74G02 Diffusion Element Replacement Kit 1537B70G03 Horizontal and Vertical Brace Clamp Assembly 9 and 12 foot 2 7 and 3 6 m probe Figure A 23 4843B93G01 High Temperature Corrosive Environment Kit Figure 112 4843B37G01 Snubber Diffusion Assembly Figure A 12 4843B38G02 Dust Seal Snubber Diffusion Assembl Heater V strut and backplate assembly includes contact and thermocouple assembly Contact and thermocouple assembly
16. 75 M AND 3 66 M PROBES AS SHOWN ABOVE P0039 Figure 2 1 Probe Installation Sheet 5 of 5 If using the optional ceramic diffusor element the vee deflector must be cor rectly oriented Before inserting the probe check the direction of gas flow in the duct Orient the vee deflector on the probe so that the apex points up stream toward the flow Figure 2 2 This may be done by loosening the setscrews and rotating the vee de flector to the desired position Retighten the setscrews n horizontal installations the probe junction box should be oriented so the system cable drops vertically from the probe junction box In a vertical instal lation the system cable can be ori ented in any direction 6 Rosemount Analytical Inc If the system has an abrasive shield check the diffusion element dust seal packings The joints in the two pack ings must be staggered 1807 Also make sure that the packings are in the hub grooves as the probe slides into the 15 forcing cone in the abrasive shield Insert the probe through the opening in the mounting flange and bolt the unit to the flange When probe lengths se lected are 9 or 12 feet 2 74 or 3 66 m special brackets are supplied to pro vide additional support for the probe inside the flue or stack See Figure 2 1 sheet 5 A Division of Emerson Process Management Instruction Bulletin 106 300NE Rev 3 4 World Class 3000 May 2000 5 FLOW c Service Required
17. Division of Emerson Process Management Hecalibrate recorder or indicator Reference Re corder Instruction Manual Recalibrate system otop air leaks or resite probe Check electronics package Clean port If the flue gas is condensing in the cali bration gas line insulate the back of the probe Make sure that the cali bration gas line is capped between calibrations or a check valve is installed Replace diffusion element Change diffusion element or snubber diffusion element Appendices A 13 Instruction Manual Appendix A Rev 3 6 July 1998 World Class 3000 CHECK CELL MV TERMINALS 1 amp 2 IN PROBE JUNCTION BOX DOES CELL MV CORRESPOND WITH EXPECTED O CONCENTRATION YES NO ZERO OR VERY LOW NO HIGH MEANS LOW O OR COMBUSTIBLES IN GAS STREAM RECONFIRM THE O CONCENTRATION CHECK ELECTRONICS CHECK CELL AND CELL MV RESISTANCE TO ELECTRONICS CHECK CABLE OK TOO HIGH PULL PROBE AND CHECK REPLACE CELL FOR CRACKED DIFFUSION ELEMENT OR CRACKED CELL Figure A 14 Flowchart of Probe Related Problems 1 A 14 Appendices Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual Appendix A Rev 3 6 World Class 3000 July 1998 CHECK THERMOCOUPLE MV AT TERMINALS 3 AND 4 IN PROBE JUNCTION BOX IS IT ABOUT SET POINT MV x0 2 MV THE MV MEASURED 1S NOT YET COLD JUNCTION COMPENSATED SO IT WILL VARY BY 0 022 MV PER DEGREE FAHRENHEIT RISE IN THE TEMPERATUR
18. JM6 and JM7 should be in stalled Additionally make sure that the proper jumper for your line voltage is installed Figure 2 6 Rosemount Analytical Inc Division of Emerson Process Management Instruction Bulletin 106 300NE Rev 3 4 World Class 3000 May 2000 Me 282002 JM1 FUSES JM6 JM7 FUSE NOTE ALL FUSES ARE 5A Q 250 VAC ANTI SURGE CASE SIZE 5 X 20 MM TYPE T TO IEC127 SCHURTER 90806606 22540005 Figure 2 7 Jumpers HPS Mother Board Aven Upon completing installation make sure that the probe is turned on and operating prior to firing up the combustion process Damage can result from having a cold probe exposed to the process gases During outages and if possible leave all probes running to prevent condensation and premature aging from thermal cycling CAUTION If the ducts will be washed down during outage MAKE SURE to power down the probes and remove them from the wash area Rosemount Analytical Inc Division of Emerson Process Management Installation 2 11 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 2 12 Installation Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 Instruction Bulletin 106 300NE Rev 3 4 May 2000 SECTION 3 SETUP OVERVIEW This section covers the setup procedures for the World Class 3000 Oxygen Analyzer with HPS 3000 Heat
19. amp fuses Refer to Table B 1 for replacement fuse specifi cations To check or replace a fuse simply un screw the top of the fuseholder with a flat head screwdriver and remove fuse After checking or replacing a fuse reinstall fuseholder top TRANSFORMER REPLACEMENT N C Install all protective equipment covers and safety ground leads after equip ment repair or service Failure to in stall covers and ground leads could result in serious injury or death a Turn off power to system b Loosen captive screws retaining HPS cover Remove cover c Remove hex nut 25 Figure B 7 from top of transformer assembly Remove retaining plate 24 and gasket 22 d Disconnect transformer harness plug from mother board B 8 Appendices B 8 Rosemount Analytical Inc e Remove old transformer Place new trans former in position and reconnect harness plug as noted in step d f Place gasket and retaining plate on trans former g Tighten hex nut only enough to firmly hold transformer in place h Reinstall HPS cover MOTHER BOARD REPLACEMENT WA N C Install all protective equipment covers and safety ground leads after equip ment repair or service Failure to in stall covers and ground leads could result in serious injury or death a Turn off power to system b Loosen captive screws retaining HPS cover Remove cover c Remove hex nut 25 Figure B 7 from
20. and in ner 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 ther mocouple wire yellow chromel by cutting bomb tail connections from the terminal strip Figure A 16 Hemove two screws Figure A 19 lock washers 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 damaged PROBE JUNCTION BOX TO HEATER STRUT AND BACKPLATE ASSEMBLY SCREW PROBE JUNCTION BOX INNER PROBE ASSEMBLY TO PROBE TUBE SCREWS 21240027 Figure A 19 Probe Junction Box Mechanical Rosemount Analytical Inc Connections A Division of Emerson Process Management World Class 3000 d Use a pencil to mark locations of spring clip on ceramic rod Figure A 20 e Pryor squeeze tabs on spring clips and pull contact and thermocouple assembly out of probe assembly Retain spring clips and spring replace if damaged CAUTION Be very careful when handling contact and thermocouple assembly The ce ramic rod in this assembly is fragile f While very carefully handling new contact and thermocouple assembly lay old as sembly next to new one Transfer pencil marks to new rod CONTACT AND HEATER SCREWS
21. assembly provides a greater filter sur face area for the probe 19280010 Figure A 10 Ceramic Diffusion Assembly C Flame Arrestor Diffusion Assembly Where a high concentration of unburned fuel is present in the exhaust gases a flame arrestor diffusion assembly Figure A 9 anc Figure A 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 tem peratures from igniting unburned fuel in the stack P0011 Figure A 9 Flame Arrestor Diffusion Dust Seal Assembly Rosemount Analytical Inc Division of Emerson Process Management P0012 Figure A 11 Flame Arrestor Diffusion Assembly Appendices 7 Instruction Manual Appendix A Rev 3 6 July 1998 Figure A 12 Snubber Diffusion Dust d Seal Assembly Snubber Diffusion Dust Seal Assembly The snubber diffusion dust seal assembly Figure A 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 pre vent abrasive dust from collecting inside the abrasive shield Bypass Probe Options For processes where the flue gas exceeds the maximum allowable temperature of 1300 704 C bypass sensor package can be employed The bypass system uses A 8 Appendices World Class 3000 an 18 inch 457 mm or 3 foot 0 92 m probe mounted externally on the stack o
22. be washed down during outage MAKE SURE to power down the probes and remove them from the wash area A 9 OVERVIEW precise surface finishes Do not remove items from packaging until they are ready to be used d Spanner wrenches and hex wrenches needed for yg ae this procedure are part of an available special to are available from Rosemount Probe disas sembly kit 3535B42G01 contains the required tools kit Table A 3 spanner and hex wrenches Refer to the follow ing section of this appendix for part numbers WARNING and ordering information Wear heat resistant gloves and cloth ing to remove probe from stack Nor mal operating temperatures of diffusor and vee deflector are approximately 600 to 800 F 316 to 427 C They could cause severe burns WA N l l N C Install all protective equipment covers and safety ground leads after equip ment repair or service Failure to in stall covers and ground leads could result in serious injury or death Disconnect and lock out power before working on any electrical components There is voltage up to 115 Vac A 10 PROBE RECALIBRATION The oxygen analyzer system should be cali CAUTION brated when commissioned Under normal cir Do not remove cell unless it is certain cumstances the probe will not require frequent that replacement is needed Removal calibration When calibration is required follow may damage cell and plat
23. components neces REF GAS PROBE to make system 222 1 all components are properly integrated to REGULATOR L SUPPLY make the system functional Z e LINE FLOWMETER VOLTAGE Once you have verified you have all the components select mounting locations and determine how each component will be placed in terms of available power supply ambient temperatures environmental con siderations convenience and serviceability ELECTRONICS lt PACKAGE 19260002 Figure 1 2 Typical System Installation Rosemount Analytical Inc A Division of Emerson Process Management Description 1 3 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 EXISTING ELECTRONICS TRIAC RELAY YE RD OR BL BK WH _ GN PROBE PROBE MV TC AD590 M K SHIELD SHIELD e e zl SEE PARAGRAPH 2 2 b STACK PROBE MAINS TC HEATER __ I R H N L SHIELD LINE VOLTAGE BY CUSTOMER HEATER POWER SUPPLY GATE VOLTAGE CONTROLLING TRIAC OUTPUT gt u 24 STANDARD PROBE CABLE dna Dom gt 6 M 20 FT 24 M 80 FT ju 5 ui 12 M 40 FT 30 M 100 FT lt ESO 18 M 60 FT 45 M 150 FT a wa m O gt m GN BK BK PROBE TEST GAS INPUT AT 2 3 L MIN 4 7 SCFH PROBE HEAD CHECK WIRING VALVE REF GAS
24. is because the junction of different metals at the wires and lugs and at the lugs and the terminal strip could act as additional ther mocouple 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 Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 Instruction Manual Appendix A Rev 3 6 July 1998 SZ e BR ara yx Snubber Diffusion Element Socket Hd Cap Screw 0 25 in 28 x 0 063 16 mm Cell and Flange Assembly Corrugated Seal Probe Tube Assembly ua cou 1 1 p i49 9 10 21240012 Gasket 4 0 in 102 mm x 4 0 x 0 12 3 Fillister Hd Screw 8 32 x 0 5 in 12 7 mm Cover Head Assembly Hose Clamp Lockwasher 8 Split Heater Strut Assembly Figure A 22 Oxygen Analyzer Probe Cross Sectional View e Slide assembled probe junction box and in ner probe assembly into probe tube To align calibration gas tube with correspond ing hole in backplate A B Figure A 1 in sert 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
25. m OR BL BK WH PROBE PROBE SHIELD MV T n s SHIELD _ GN T T N LLI LLI I I SEE PARAGRAPH 2 2 b 9 9 STACK PROBE MAINS TC HEATER ar I SHIELD d LINE VOLTAGE BY CUSTOMER HEATER POWER SUPPLY GATE VOLTAGE CONTROLLING TRIAC OUTPUT gt u 4 STANDARD PROBE CABLE eu E 6 M 20 FT 24 M 80 FT dg ui 12 M 40 FT 30 M 100 FT woo lt T 18 M 60 FT 45 M 150 FT gt m GN BK BK PROBE TEST GAS INPUT AT 2 3 L MIN 4 7 SCFH PROBE HEAD CHECK WIRING VALVE REF GAS SUPPLY INPUT AIR AT 1 L MIN 2 SCFH 19260003 Figure 2 4 Electrical Installation of Heater Power Supply 2 8 Installation Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 TERMINAL STRIP FROM ELECTRONICS TRANSFORMER TERMINAL COVERS TERMINAL STRIP FROM PROBE SCREW 2 PER COVER Instruction Bulletin 106 300NE Rev 3 4 May 2000 F TRANSFORMER FRONT Figure 2 5 Heater Power Supply Wiring Connections 2 2 HEATER POWER SUPPLY INSTALLATION i N C Install all protective equipment covers and safety ground leads after installa tion Failure to install covers and ground leads could result in serious injury or death a Mechanical Installation The outline drawing of the heater power suppl
26. mocouple reading for the temperature at the mitter the HPS uses a cold junction tempera junction between the compensated and uncom ture compensation feature This allows for the pensated cables LINE ZERO TO HEATER TRANSFORMER CROSSING DETECTOR RELAY TRIAC d FROM po TO IFT PROBE PROBE TC d m PROBE TC cuw egt N 686015 Figure B 3 Heater Power Supply Block Diagram Rosemount Analytical Inc Division of Emerson Process Management Appendices B 3 Instruction Manual Appendix B Rev 2 2 January 1997 B 3 In operation when connected to the CRE 3000 Control Room Electronics line voltage passes through the relay when on and is converted into 44 volts by the transformer If the probe thermocouple indicates that the probe has dropped below operating temperature a signal from the CRE triggers the triac The triac then supplies voltage to the probe heater warming the cell Conversely if the probe thermocouple indicates that the probe heater has reached the upper limit of operating temperature the CRE deactivates the triac shutting off power to the heater World Class 3000 NOTE When using the HPS 3000 with an ex isting electronics package such as Models 218 218A 225 or TC200 the electronics will not have the in put output capacity to support all of the functions mentioned in this sec tion Refer to Instruction Bulletin IB 106 300NE HPS 3000 TROUBLESHOOTING OVERVIEW The HPS 3000 t
27. stack for holes and air leakage The presence of this con dition will substantially affect the accu racy of the oxygen reading Therefore Rosemount Analytical Inc A Division of Emerson Process Management Instruction Bulletin 106 300NE Rev 3 4 May 2000 either make necessary repairs or install the probe upstream of any leakage 3 Ensure that the area is clear of ob structions internal and external that will interfere with installation Allow ade quate clearance for removal of probe Figure 2 1 CAUTION Do not allow the temperature of the probe junction box to exceed 300 F 149 C or damage to the unit may re sult If the probe junction box tempera ture exceeds 300 F 149 C the user must fabricate a heat shield or provide adequate cooling air to the probe junc tion box b Mechanical Installation 1 Ensure that all components are avail able for installation of the probe Ensure that the system cable is the re quired length If applicable check the ceramic filter to 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 An abrasive shield is recommended for high velocity particulate in the flue stream such as those in pulverized coal kilns and recovery boilers Verti cal and horizontal brace clamps are provided for 9 ft and 12 ft 2 75 m and 3 66 m probes t
28. to work on these components until they have cooled to room tem perature 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 NOTE This replacement may be done without removing the probe from the duct Appendices World Class 3000 Disconnect and lock out power to electron ics Using heat resistant gloves and cloth ing remove probe cover Squeezing tabs on hose clamps and remove hoses from probe junction box Figure 19 Remove four screws and lockwashers 7 10 Figure 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 ther mocouple wire yellow chromel by cutting bomb tail connections from the terminal strip Figure A 16 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 in ner probe assembly Reinstall screws lock washers and flat washers Connect color coded wires to proper termi nals as shown in Figure A 16 Rosemount recommends connecting the thermocouple wires directly to the terminal strip This
29. 03154G02 The adjustment procedure required for the Model TC200 Electronics Package is as a EPROM Replacement follows To replace the EPROM proceed as follows 1 Open keylocked enclosure to access membrane keyboard 1 Shut off and lock out power to the electronics package 2 Put controller in PAR parameter mode by depressing LOCK A 2 Open electronics enclosure 0 INC ACK in sequence oV 3 On the main PCB Figure 3 3 locate and remove old EPROMs U11 and 3 Depress ACK pushbutton to clear U12 display Rosemount Analytical Inc Division of Emerson Process Management Setup 3 3 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 4 Press NUM pushbutton EPROM needed is as identified below 5 Using INC DEC buttons display United States IM03222G01 parameter 125 United Kingdom Germany 6 Press VAL button France Italy 7 Using INC DEC buttons change parameter 125 value to 15 4 To replace the EPROM proceed as follows 8 Press ENT to save new value a Shut off and lock out power to the electronics package 3 5 MODEL 132 DIGITAL ELECTRONICS SETUP b Open electronics enclosure Before beginning operation it is important that c Onthe Main PCB Figure 3 4 locate and the probe heater set point of the existing elec remove old EPROM tronics be changed to support the World Class 3000 Probe To convert the Model 132 Digital d Replace with new EPROM Electronics P
30. 2 3534856605 3534856606 3534856007 3534856608 302390036012 302390036027 302390036077 30239003608 4847B61G01 4847B61G02 4847B61G03 4847B61G04 4847B61G05 4847B61G06 4847B61G07 4847B61G08 4847B61G09 4847B61G10 4847B61G11 4847B61G12 4847B61G13 4847B61G14 4847B61G15 4847B61G16 4847B61G17 4847B61G18 3535B42G01 3534B18G01 3535B60G01 REPLACEMENT PARTS A Division of Emerson Process Management Instruction Manual Appendix A Rev 3 6 July 1998 Table A 3 Replacement Parts for Probe Part Number Description Heater V Strut and Backplate Assembly 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 cm Contact and Thermocouple Assembly 3 ft 0 9 m Contact and Thermocouple Assembly 6 ft 1 8 m Contact and Thermocouple Assembly 9 ft 2 7 m Contact and Thermocouple Assembly 12 ft 3 6 m 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
31. 322 3 millivolts nominal TP1 PIN 2 PIN 7 PSC Figure 3 1 Temperature Controller Card Calibration Points Setup 3 1 Instruction Bulletin 106 300NE Rev 3 4 May 2000 3 3 MAIN PCB O 5 3 2 NOTE The voltage given above is for an am bient machinery space temperature of 77 F 25 C For each degree of am bient temperature above or below 77 F 25 C add or subtract 0 242 mV from the nominal Example at 87 F 31 C the nominal voltage of 322 3 should be increased made less negative by 10 x 0 242 or 2 42 mV making the ad justed nominal 319 9 f Remove voltmeter leads g Remove jumper wire MODEL 218A ELECTRONICS SETUP Before beginning operation it is important that the probe heater set point of the existing elec tronics be changed to support the World Class 3000 probe To convert the Model 218A Digital Electronics Package for use with the World Class 3000 Probe and Heater Power Supply an EPROM change is necessary Remove Main PCB and check back of board to identify unit as 502 or 604 The replacement EPROM needed is as identified below BIO 00 C 0 gt 501 Co C I World Class 3000 United States 1M03192G01 1M02982G01 United Kingdom 1M03192G02 1M02982G02 Germany 1M03192G03 1M02982G03 France 1M03192G04 1M02982G04 Italy 1M03192G05 1M02982G05 NOTE The replacemen
32. 40 1vnO3 M ALIALLONGNOOD VINH3HIL NOILVINSNI MHL 8 09 HONI 02 QG3aN3WINOO3U 0 086 OL 2059 4 008L OL 002L 39NvH 3univHadWal 9NIIVH3dO SVD JNT AINO NOILOSYIC SQHVMNMOGQ ATIVOLLH3A V H3ZATIVNV HLIM TIVLSNI 02 009 4 2 6 Q332X3 HO LNIOd MO 138 OD LON 5400 aunivaadal SVD adnsNa OL 9VI GAYINDAY Sv9 NOIlIVHSITVO XVIN 39nv9 79020 9ISd 1 HJOS 01 IdO H3MHVd ONILLId ALIA NOLLO3NNOO SVD ADYNd NOIIVHSITVO ACIS NO 31 9071 SI 9NILLIH GSYINOAY NV31O 39nv9 6902 9ISd LV HJOS ONIdQ L 0620 HOS IdO H3MHvd 9NILLIH 3148 NOLLO3NNOO AlddNS HIV 3ON3H3H3UH H Y3W0LSN9 aaa SAYVMCYVH l33 V9 6002090 J9NV SALON LOODZv6edE HOS 09 08 61 pe y L TWAOWSY ANY NOLLH3SNI 3ONVHV312 9 69 16772 TR T V4 M j18vO 15 IN 9 14 OC Figure A 13 Bypass Probe Option Sheet 2 of 3 A Division of Emerson Process Management Rosemount Analytical Inc A 10 Appendices Instruction Manual Appendix A Rev 3 6 World Class 3000 July 1998 FLANGE STYLE AT Te 4T lo MAIL CODE SIZE PART NUMBER PART NAME REFERENCE INFORMATION OR REF DWG G07 Le vous so ons rese
33. AGE CONTENTS A typical Rosemount World Class 3000 Oxygen Analyzer with HPS 3000 Heater Power Supply package should contain the items shown in Figure 1 1 Record the Part Number Serial Number and Order Number for each component of your system in the table located on the first page of this manual 1 2 OVERVIEW a Scope This Instruction Bulletin has been designed to supply details needed to install start up and troubleshoot the Rosemount World Class 3000 Oxygen Analyzer with HPS 3000 Heater Power Supply Field Module Oxygen Analyzer Probe Heater Power Supply Instruction Bulletin Mounting Adaptor Plate with Mounting Hardware and Gasket 1 opo s Instruction Bulletin 106 300NE Rev 3 4 May 2000 The Heater Power Supply allows the World Class 3000 Oxygen Analyzer Probe to be interfaced to a number of different and earlier model electronic packages These electronic packages are not covered in this manual For specific information concerning calibration and operation of the system refer to the Instruction Bulletin applicable to your electronics package 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 posi tioned within an exhaust duct or stack and performs its task without the use of a sam pling system
34. E OF THE ELECTRONICS BOX LOCATION NORMAL IS SET POINT MV AT 77 F 25 C HEATER THERMOCOUPLE AND CONTROL 15 SATISFACTORY REFER TO HEATER POWER SUPPLY TROUBLESHOOTING YES IS IT HIGHER LOWER OR ZERO HIGHER LOWER THERMOCOUPLE 1 ALLOW ADDITIONAL TIME FOR TEMP CONTROL TO SETTLE 2 COLD JUNCTION TEMP HEATER MAY BE DEAD AT ELECTRONICS BOX THERMOCOUPLE MAY MAY BE MUCH LOWER YES BE READING STACK THAN 77 F 25 C TEMPERATURE REPLACE 3 CONFIRM MV VALUE ON THERMOCOUPLE 1 CHECK HEATER FUSE ELECTRONICS UNIT IF OK AND TRIAC OUTPUT RESOLVE DIFFERENCE TO HEATER BETWEEN VOLTMETER AND ELECTRONICS 2 CHECK HEATER CONDITION TURN OFF POWER RESISTANCE BETWEEN TERMINALS 7 AND 8 SHOULD BE 11 14 OHMS RESISTANCE BETWEEN TERMINALS 6 AND 7 AND 6 AND 8 SHOULD BE OPEN CIRCUIT IF FAILED REPLACE HEATER Figure A 15 Flowchart of Probe Related Problems 2 Rosemount Analytical Inc A Division of Emerson Process Management Appendices A 15 Instruction Manual Appendix A Rev 3 6 July 1998 World Class 3000 SERVICE AND NORMAL MAINTENANCE A wor UPON COMPLETING INSTALLATION MAKE SURE THAT THE PROBE IS TURNED ON AND OPERATING PRIOR TO FIRING UP THE COMBUSTION PROCESS DAMAGE CAN RESULT FROM HAVING A COLD PROBE EXPOSED TO THE PROCESS GASES During outages and if possible leave all probes running to prevent condensation and prema ture aging from thermal cycling CAUTION If the ducts will
35. FITTING REFERENCE AIR FITTING 27270016 Figure A 6 Probe Junction Box A 4 PROBE JUNCTION BOX The probe junction box Figure A 6 5 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 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 can be used for this purpose accuracy can only be assured if a reference air set is used Rosemount Analytical Inc Division of Emerson Process Management A 5 Instruction Manual Appendix A Rev 3 6 July 1998 During calibration two gases of different known oxygen concentrations are injected one at a time through the calibration gas fitting Stainless steel tubing
36. HASE PRICE OF THE GOODS SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY NO OTHER WAR RANTIES ARE GRANTED INCLUDING BUT NOT LIMITED TO EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Limitations of Remedy SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DE LAY IN PERFORMANCE THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WAR RANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE IN NO CASE REGARDLESS OF THE FORM OF THE CAUSE OF AC TION SHALL SELLER S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION BUYER AGREES THAT IN NO EVENT SHALL SELLER S LIABILITY EXTEND TO INCLUDE INCIDEN TAL OR CONSEQUENTIAL DAMAGES CONSEQUENTIAL DAMAGES SHALL INCLUDE BUT ARE NOT LIMITED TO LOSS OF ANTICIPATED PROFITS LOSS OF USE LOSS OF REVE NUE COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND OR INDEMNITY COVERAGE PROVIDED TO BUYER ITS ASSIGNS AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER Force Majeure Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller s direct control 2461 3333 5 00 Instruction Manual 106 300NE Rev 3 4 May 2000 World Class 3000 Probe Pa
37. HOOTING The probe troubleshooting section describes how to identify and isolate faults which may de velop in the probe assembly N C Install all protective equipment and safety ground leads after trouble shooting Failure to replace covers and ground leads could result in seri ous injury or death a Probe Faults PROBE TROUBLESHOOTING Listed below are the four symptoms of probe failure Symptom 1 Noresponse to oxy gen concentration change when 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 Table A 2 check Thermocouple continuity Heater cold resistance to be 11 ohm to 14 ohm Triac O P to heater Hecorder chart Cell mV input to electron ics and cell mV at probe junction box 1 The system does not respond to changes in the oxygen concentration 2 The system responds to oxygen changes but does not give the correct indication 3 The system does not give an accept able indication of the value of the oxy gen calibration gas being applied during calibration 4 The system takes a long time to return to the flue gas value after the calibra tion gas is turned off b Table A 2 provides a guide to fault finding for the above symptoms c and provide an al ternate approach to finding probe related problems Fault Finding Thermocouple failure Heater failure Failure of e
38. Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 Oxygen Analyzer with HPS Heater Power Supply Field Module for use with Existing Signal Conditioning Electronics ROSEMOUNT Analytical 250202200200 EMERSON http www processanalytic com ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING Rosemount Analytical designs manufactures and tests its products to meet many national and international standards Because these instruments are sophisticated technical products you MUST properly install use and maintain them to ensure they continue to operate within their normal specifications The following instructions MUST be adhered to and integrated into your safety program when installing using and maintaining Rosemount Analytical products Failure to follow the proper instructions may cause any one of the following situations to occur Loss of life personal injury property damage damage to this instrument and warranty invalidation Read all instructions prior to installing operating and servicing the product e f you do not understand any of the instructions contact your Rosemount Analytical repre sentative for clarification Follow all warnings cautions and instructions marked on and supplied with the product e Inform and educate your personnel in the proper installation operation and mainte nance of the product e Install your equipment as specified in the Installation Instruct
39. K THAT LINE VOLTAGE HEATER BY PLACING IS CORRECT BY SELECTING POSSIBLE TRIAC FAILURE PROBES ON TERMINAL CORRECT JUMPERS REPLACE HPS BLOCK J2 FROM PROBE ACCORDING TO CHART ON MOTHERBOARD PROBE HEATER INSIDE OF HPS COVER SIMPSON MODEL 260 OR EQUIVALENT MULTIMETER RESISTANCE MEASURED SHOULD BE NOMINALLY REPLACE BLOWN FUSES 12 OHMS HEATER IS OPEN REPLACE HEATER 35730004 Figure B 4 HPS Troubleshooting Flowchart 1 Rosemount Analytical Inc Division of Emerson Process Management Appendices 5 Instruction Manual Appendix B Rev 2 2 January 1997 SYMPTOM HEATER OVERHEATS NOTE ON INITIAL STARTUP THE TEMPERATURE OF THE PROBE MAY OVERHEAT TO A NOMINAL TEMP OF 800 C CHECK IF THE YELLOW WIRE IS CONNECTED TO POSITIVE AND THE RED TO NEGATIVE ON BOTH FROM ELECTRONICS AND FROM PROBE TERMINAL BLOCKS MODELS 218 AND 225 ONLY SET METER ON 250 VAC SCALE CHECK FROM ELECTRONIC ANALOG HEATER TERMINALS IF THERE IS A PULSATING NOMINAL 115 VAC YES SET METER ON 50 VAC SCALE CHECK FROM PROBE TERMINALS AT PROBE HEATER IF THERE IS A PULSATING NOMINAL 44 VOLTS YES CHECK PROBE ELECTRONICS SETPOINT HAS BEEN CHANGED ACCORDING TO APPLICABLE ELECTRONICS PACKAGE IB YES CHECK IF PROBE HEATER VOLTAGE SELECTION JUMPER JM7 INSTALLED REMOVE 8 World Class 3000 CONNECT THE WIRING ACCORDING TO THE DECALS ON THE TERMINAL COVERS IF
40. M2 ELECTRONICS SELECTION JUMPER ANALOG EXISTING INSTALL JM3 JM6 DIGITAL REMOVE JM3 JM6 NEXT GENERATION DENOTES JUMPERS THAT MUST BE INSTALLED WHEN USING THE WORLD CLASS 3000 OXYGEN ANALYZER PROBE AND THE HPS 3000 HEATER POWER SUPPLY WITH EXISTING ANALOG MODEL 218A AND TC 2000 ELECTRONICS NOTES 100 V A C OPERATION REQUIRES TRANSFORMER PART NUMBER 1 02961002 HEATER POWER IS ALSO REFERRED TO AS LINE VOLTAGE RELAY Figure 2 6 Jumper Selection Label NOTE Refer to Figure 2 7 for HPS unit fuse locations and specifications NOTE Before supplying power to the heater power supply verify that jumpers JM2 JM3 JM6 and JM7 are installed 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 2 6 For 100 Vac usage the heater power supply is factory supplied with a differ ent transformer When using the HPS with 100 Vac transformer install jumpers JM1 and JMA 2 10 Installation 3 The power cable should comply with all applicable codes and safety regula tions in the user s country and should not be smaller than 16 gauge 3 amp NOTE ANALOG under ELECTRONICS SE LECTION on the label refers to Models 218 225 TC200 and Model 218A elec tronics 4 Before supplying power to the heater power supply verify that the jumpers on the mother board are properly configured Jumpers JM2 JM3
41. OUNT ABRASIVE SHIELD MOUNTING 3 25 82 5 MIN DIA HOLE N WALL STACK OR DUCT BOLT MOUNTING PLATE TO OUTSIDE WALL SURFACE FIELD WELD PIPE TO ADAPTOR PLATE 4 0 102 O D REF D 3 5 SCHED 40 PIPE SLEEVE METAL WALL BY ROSEMOUNT JOINT MUST LENGTH BY CUSTOMER BE AIRTIGHT WALL WELD OR BOLT MOUNTING STAC PLATE TO METAL WALL OF STACK OR DUCT INT MUST BE AIRTIGHT in d NOTE DIMENSIONS IN INCHES WITH MILLIMETERS IN PARENTHESES PROBE MOUNTING P0038 Figure 2 1 Probe Installation Sheet 4 of 5 Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 5 Instruction Bulletin 106 300NE Rev 3 4 May 2000 BRACE BARS NOT BY ROSEMOUNT 200 51 World Class 3000 NOTE DIMENSIONS IN INCHES WITH MILLIMETERS IN PARETHESES 2 HOLES 0 625 16 DIA FOR 0 50 12 DIA BOLT 5 62 143 VERTICAL BRACE CLAMP ASSY HORIZONTAL BRACE CLAMP ASSY BY ROSEMOUNT BOTH BRACE CLAMP ASSEMBLIES ARE THE SAME INSTALLATION AND LOCATION OF CLAMP ASSEMBLIES AND BRACE BARS TO BE DONE IN FIELD ABRASIVE SHIELD 4 2 6 Installation 36 00 914 NOTE BRACING IS FOR VERTICAL AND HORIZONTAL PROBE INSTALLATION EXTERNAL BRACING REQUIRED FOR 9 FT AND 12 FT 2
42. Q9 8v 585 an AIG edd Hasnddala OIINVH3O F1 HOS FI iW WIG OL aav s 96 08 Hi XYN VIG 89 222 SNOILIGNOO YSHLVAM OL QSSOdxXd dl SALVINSNI 9626187 862615 15074 8217 AYOSSAOOV 9 ddldvav LIX NI Q3HSINH J LOHSTvHSESt NIA LOH8vdse9e SIF c0H8LIg8SESE ISNV 133SV9 MHL 6900 Figure 2 1 Probe Installation Sheet 1 of 5 A Division of Emerson Process Management Rosemount Analytical Inc Installation 2 2 Instruction Bulletin May 2000 106 300NE Rev 3 4 World Class 3000 80006112 SNOILIGNOO GAHLVAM 1 OL Q3SO0dX43 Jl 31V INSNI HOLO3NNOO 5 NI 5 1 HLIM S3HONI SNOISN3NIG 3 LON SVO WO HOLO3NNOO Iv9IH193 13 SANIT SVO WO JAVA MOAHO I N d AlaW3assv Was LSNA NOISN4SIG HSEENNS 9 P ALLE GI AL DDD LIL lt lt NIG 9OD8SESESE SI PODSSESESE ADVMOVd dHvVMQHVvH NI GAHSINYNA 194579 MHL 900 53215 3S9NV14 Al gavl 335 N 841 LS 007 69 Srl 3dOT3AN3 WIG F I ISNV ZOD8SESESE m iJ gt YOLSSYYHV HLIM 3 gt
43. SUPPLY INPUT AIR AT 1 L MIN 2 SCFH 19260003 Figure 1 3 Typical System Wiring 1 4 Description Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 SECTION 2 INSTALLATION 2 1 OXYGEN ANALYZER PROBE INSTALLATION WARNING Before starting to install this equip ment read the Safety instructions for the wiring and installation of this ap paratus at the front of this Instruction Bulletin Failure to follow the safety instructions could result in serious injury or death i N C Install all protective equipment covers and safety ground leads after installa tion Failure to install covers and ground leads 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 pro cess he probe must be positioned so that the gas it measures is representa tive of the process Best results are normally obtained if the probe is posi tioned near the center of the duct 40 to 60 insertion A point too near the edge or wall of the duct may not pro vide a representative sample because of the possibility of gas stratification In addition the sensing point should be selected so that the process gas tem perature falls within a range of 50 to 1300 F 10 to 704 C Figure 2 1 vides mechanical installation references 2 Check the flue or
44. THE VOLTAGE IS CONSTANTLY ON THEN THE TRIAC IN THE PROBE ELECTRONICS IS SHORTED IF THE VOLTAGE IS CONSTANTLY ON THEN THE TRIAC MODULE IN THE HPS IS SHORTED SIMPSON MODEL 260 OR EQUIVALENT MULTIMETER 35730003 Figure B 5 HPS Troubleshooting Flowchart 2 B 6 Appendices Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Appendix B Rev 2 2 World Class 3000 January 1997 SYMPTOM PROBE HEATER START TO HEAT UP AND THEN LOOSES TEMPERATURE MODEL TC200 ONLY CHECK PARAMETER 35 ON TC200 IF THE NUMBER IS NEGATIVE THEN SOMEWHERE THE THERMOCOUPLE WIRES ARE REVERSED 35730005 Figure B 6 HPS Troubleshooting Flowchart 3 Rosemount Analytical Inc A Division of Emerson Process Management Appendices B 7 Instruction Manual Appendix B Rev 2 2 January 1997 B 5 B 7 World Class 3000 SERVICE AND NORMAL MAINTENANCE OVERVIEW This section describes service and routine maintenance of the HPS 3000 Heater Power Supply Field Module Replacement parts re ferred to are available from Rosemount Refer to Table B 2Jof this manual for part numbers and ordering information WA N C Install all protective equipment covers and safety ground leads after equip ment repair or service Failure to in stall covers and ground leads could result in serious injury or death FUSE REPLACEMENT The heater power supply mother board 12 contains four identical 5
45. THERMOCOUPLER NOT SHOWN ASSEMBLY MOUNTING SCREW REAR VIEW i N 5 9 m a HEATER CERAMIC ROD INSULATING SPRING GASKET CLIP 21240010 Figure A 20 Inner Probe Replacement Heater V Strut and Backplate Assembly Instruction Manual Appendix A Rev 3 6 July 1998 g Note wire lengths of old assembly as an aid for trimming new lengths in step J Trim ming of wires will not always be necessary Throw away old contact and thermocouple assembly h Carefully guide new contact and thermo couple assembly through V strut assembly leaf spring 4 Figure A 21 spring 9 spring clip 10 held open by squeezing tabs and tube supports 11 13 until spring clip reaches pencil mark I Reinstall insulating gasket on backplate re place two screws O rings lockwashers and flat washers connecting probe junction box to inner probe assembly CAUTION 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 0 k Connect color coded wires to proper termi nals as shown in Figure A 16 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 Heater Ceramic Rod Contact and Thermocouple Assemb
46. TION Q REFERENCE GAS FITTING AIR FITTING CABLE PROBE JUNCTION BOX COVER 27270019 Figure A 16 Cell Wiring Connection b Ifthe probe uses the standard diffusion to gently pry the flange away from the element use a spanner wrench to remove probe Note that the contact pad inside the the diffusion element probe will sometimes fuse to the oxygen sensing cell If the cell is fused to the con assembly remove and discard setscrews D Figure A 17 the probe against spring pressure and Figure 17 and remove vee deflector Use AT from probe disassembly quickly twist the cell assembly The cell and kit Table A 3j to turn hub free from retainer Hi Oi Inspect diffusion element If damaged re pad stays fused to the cell a new con 999 tact thermocouple assembly must be in place element stalled Disconnect the cell and the c lfequipped with the optional ceramic diffusor d Loosen four socket head cap screws from thermocouple wires at the probe junction the cell and flange assembly and remove box and withdraw the cell with the wires still the assembly and the corrugated seal The attached see paragraph cell flange has a notch which may be used Rosemount Analytical Inc Division of Emerson Process Management Appendices 17 Instruction Manual Appendix A Rev 3 6 July 1998 PIN WRENCH RETAINER OPTIONAL CERAMIC
47. XYGEN ANALYZER PROBE GENERAL Read the Safety instructions for the The Oxygen Analyzer Probe Figure 1 con wiring and installation of this appara sists of three component groups probe exterior tus at the front of this Instruction inner probe and probe junction box Figure A 2 Bulletin Failure to follow the safety instructions could result in serious injury or death PROBE EXTERIOR SENSING CELL INSTALLED A gt P 22 INTERIOR PROBE JUNCTION BOX 21240006 Figure A 2 Main Probe Components Rosemount Analytical Inc Division of Emerson Process Management Appendices 1 Instruction Manual Appendix A Rev 3 6 July 1998 World Class 3000 Table 1 Specifications for Oxygen Analyzing Equipment Probe lengths nominal Temperature limits in process measurement area Standard current output indication Digital display and analog OUtplil ceci pci dessen oystem speed of response Resolution sens tivi ynein a a HPS 3000 housing Probe reference air flow Calibration gas mixtures Calibration gas flow HPS 3000 Power supply HPS 3000 Power requirement HPS 3000 Ambient Operating Temperature Ambient operating temperature Probe Junction Box Approximate shipping weights 18 inch 457 mm package 3 foot 0 91 m package 6 foot 1 83 m package 9 foot 2 74 m package 12 foot 3 66 m package 18 inches 457 mm 3 feet 0 91 m 6 feet 1 83 m 9 feet
48. ackage for use with the World Class 3000 Probe and Heater Power Supply an e Close electronics enclosure and power up EPROM change is necessary The replacement system dL og ot i a L E D Figure 3 4 Main PCB Model 132 EPROM Replacement 3 4 Setup Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 SECTION 4 Instruction Bulletin 106 300NE Rev 3 4 May 2000 TROUBLESHOOTING 4 1 OVERVIEW Troubleshooting for the oxygen analyzer system is broken down to the main component level Faults within the probe or heater power supply may cause symptoms which overlap WA N C Install all protective equipment covers and safety ground leads after trouble shooting Failure to replace covers and ground leads could result in seri ous injury or death 4 2 SYSTEM TROUBLESHOOTING Troubleshooting of individual components within the oxygen analyzer system are contained in the following a World Class 3000 Probe Troubleshooting information for the World Class 3000 Probe is contained in Appendix A Probe Troubleshooting Rosemount Analytical Inc Division of Emerson Process Management b HPS 3000 Heater Power Supply Troubleshooting information for the HPS 3000 Heater Power Supply is contained in Appendix B HPS 3000 Troubleshooting Model 218 and 225 Analog Electronics Package Tr
49. ant when installing the stainless steel tubes Gas samples may become contaminated 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 A 23 STAINLESS STEEL NOTE TUBING If abrasive conditions of high ash con tent and high velocity exist an abra sive shield is recommended To balance out the wear on the shield ro tate the shield 90 every time the probe is powered down for service 21240028 Figure A 23 High Temperature Corrosive Environment Kit A 24 Appendices Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 Figure and Index No igure A 2 Figure 2 igure A 2 Figure A 2 igure A 2 igure A 2 Figure A 2 Igure 2 igure A 2 igure A Figure A 7 igure A igure A igure A Figure A 1 igure A 1 Figure 1 igure A 1 Figure A 1 igure A 1 igure A 1 igure A 1 Figure A 1 igure A 1 igure A 1 igure A 1 Figure A 1 Figure A 1 iqure A 1 igure 1 Figure A 1 igure A 1 Figure A 8 x cO U OO TI TI O TI TI N f h CO U Co CO 09 00 CO 09 CO I CO coco Rosemount Analytical Inc ho 3D39441G06 3D39441G07 3D39441G08 3D39441G09 3D39441G10 3534856004
50. configuration Updated art to reflect new probe configuration Updated art to reflect new probe configuration Update installation procedure to include optional ceramic diffusor and vee deflector Updated art and dimensions to reflect new probe configurations Updated art and dimensions to reflect new probe configurations Updated art and dimensions to reflect new probe configurations Effective June 1996 Rev 3 1 Summary Added ambient air note Updated Probe Installation Figure 2 1 sheets 1 and 2 of 5 Effective January 1997 Rev 3 2 Summary Added Safety instructions for the wiring and installation of this apparatus Added one WARNING to read new safety instructions and another WARNING regarding protective covers and grounds Added WARNING regarding protective covers and grounds and added NOTE regarding HPS fuse locations and specifications Added NOTE regarding HPS fuse specifications to Figure 2 7 Added WARNING regarding protective covers and grounds Added WARNING regarding protective covers and grounds Added fuses to index listing Page Page P 2 Page Page 2 2 Effective May 1997 Rev 3 3 Summary Added safety sheets Effective February 1998 Rev 3 4 Summary Figure 2 1 Changed calibration gas tube dimensions Instruction Bulletin 106 300NE Rev 3 4 World Class 3000 May 2000 TABLE OF CONTENTS Rosemount Analytical Inc Division of Emerson Process Management Instruction Bullet
51. d service for a period of twelve 12 months from the date of shipment by Seller Consumables glass electrodes membranes liquid junctions electrolyte o rings etc are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety 90 days from date of shipment by Seller Goods part s and consumables proven by Seller to be defective in workmanship and or material shall be replaced or repaired free of charge F O B Seller s factory provided that the goods part s or consumables are returned to Seller s designated factory transportation charges prepaid within the twelve 12 month period of warranty in the case of goods and part s and in the case of consumables within the ninety 90 day period of warranty This warranty shall be in effect for replacement or repaired goods part s and the remaining portion of the ninety 90 day warranty in the case of consumables A defect in goods part s and consumables of the com mercial unit shall not operate to condemn such commercial unit when such goods part s and consumables are capable of being renewed repaired or replaced The Seller shall not be liable to the Buyer or to any other person for the loss or damage directly or indirectly arising from the use of the equipment or goods from breach of any warranty or from any other cause All other warranties expressed or implied are hereby excluded IN CONSIDERATION OF THE HEREIN STATED PURC
52. 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 CAUTION 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 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 jacket and braided stainless steel shield The Teflon 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 PROBE OPTIONS a Abrasive Shield Assembly The abrasive shield assembly Figure 7 is a stainless steel tube that surrounds the probe assembly The shield protects the probe against particle abrasion and c
53. ds and mating surfaces of the diffusion hub and retainer 12 Assemble retainer and diffusion hub with two pin spanner wrenches Torque to 10 ft lbs 14 N m 13 On systems equipped with abrasive shield install dust seal gaskets with joints 180 apart 14 Reinstall vee deflector orienting apex toward gas flow Apply anti seize com pound to setscrews and tighten with hex wrench 15 Reinstall probe on stack flange 16 Turn power on to electronics and monitor thermocouple output It should stabilize at 29 3 0 2 mV Calibrate probe per Instruction Bulletin applica ble to your electronics package A 13 REPLACEMENT OF CONTACT AND THERMOCOUPLE ASSEMBLY N l C Use heat resistant gloves and cloth ing when removing probe junction box and inner probe assembly Do not at tempt to work on these components until they have cooled to room tem perature 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 a Disconnect and lock out power to electron ics Using heat resistant gloves and cloth ing remove probe junction box cover A 20 Appendices PROBE JUNCTION BOX HOSE CLAMP HOSE World Class 3000 Squeezing tabs on hose clamps hoses from probe junction box Figure A 19 Remove four screws in corners of probe junction box Pull probe junction box
54. e shield install dust seal gaskets with joints 180 apart k Reinstall probe and gasket on stack flange If there is an abrasive shield in the stack make sure dust seal gaskets are in place as they enter 15 reducing cone l Turn power on to electronics and monitor thermocouple output It should stabilize at 29 3 0 2 mV Set reference air flow at 2 scfh 56 6 L hr After probe stabilizes calibrate probe per Instruction Bulletin applicable to your electronics package If new components have been installed repeat calibration after 24 hours of operation OPTIONAL CERAMIC DIFFUSION ELEMENT REPLACEMENT a General The diffusion element protects the cell from particles in process gases It does not nor mally 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 Ex amine the diffusion element whenever re moving the probe for any purpose Replace if damaged A Division of Emerson Process Management World Class 3000 Damage to the diffusion element may be come 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 pro cedure are available as part of a special tool kit Table N C Wear heat resistant g
55. een HPS 3000 and Probe Maximum 150 feet 45 m Cabling Distance Between HPS 3000 and CRE 3000 Maximum 1200 feet 364 m Cabling Distance Between HPS 3000 and IFT 3000 Maximum 1200 feet 364 m Approximate Shipping 12 pounds 5 4 kg B 2 THEORY OF OPERATION use of a less expensive cable between the HPS and CRE or HPS and IFT The HPS and elec The HPS 3000 Heater Power Supply may per tronics package can be located up to 1200 feet form slightly different functions depending upon 364 m apart which electronics package it is used with Figure shows a functional block diagram of the The standard cable between probe and HPS is unit The HPS contains a transformer for con thermocouple compensated This prevents the verting line voltage to 44 volts needed to power additional junctions between thermocouple and the probe heater The relay Figure B 3 can be cable from producing a voltage which would af used to remotely turn the probe on or off manu fect the thermocouple output signal A tem ally A triac module is used to turn the heater on perature sensor in the HPS monitors the or off depending on probe temperature temperature at the junction and sends a voltage signal to the CRE and IFT The CRE and IFT When used with the CRE 3000 Control Room uses this signal to compensate the probe ther Electronics or IFT 3000 Intelligent Field Trans
56. er Power Supply Field Module Since this equipment may be used with a number of different electronics packages this section has been divided into three parts Models 218 225 and 132 Analog Electronics Model 218A Electronics and Model TC200 Electronics Each of the three parts contain setup information ap plicable to that electronics package N C Install all protective equipment covers and safety ground leads after setup Failure to replace covers and ground leads could result in serious injury or death Models 218 225 and 132 Analog Electronics refer to paragraph 3 2 Model 218A Electronics refer to paragraph MODEL TC200 Electronics refer to paragraph Model 132 Digital Electronics refer to paragraph 3 2 MODELS 218 225 AND 132 ANALOG ELECTRONICS SETUP Before beginning operation it is important that the probe heater set point of the existing elec tronics be changed to support the World Class 3000 probe The set point adjustment procedure required for Models 218 225 and 132 analog electronics is as follows Rosemount Analytical Inc Division of Emerson Process Management a Open electronics enclosure b temperature controller card Figure 3 1 connect jumper wire from TP3 to either Pin 2 or Pin 7 c Set voltmeter to read DC millivolts MV d Attach voltmeter with positive lead on TP1 and negative on either Pin 2 or 7 e Adgjust potentiometer M110 1 to read
57. erminal Cover Screw 10 Stand Off 11 HexNut 12 Mother Board 13 Fuse Se er Instruction Manual Appendix B Rev 2 2 January 1997 Subplate Enclosure Box Lockwasher Stand Off Screw Lockwasher Mounting Plate Screw Gasket Transformer Retaining Plate Hex Nut REPLACEMENT PARTS Table B 2 Replacement Parts for Heater Power Supply FIGURE and INDEX NO 3D39129G01 3D39129G02 3D39129G03 1U05667G01 1U05667G02 1U05667G03 1L01293H02 3D39080G02 3D39078G01 1M02961G01 1M02961G02 Rosemount Analytical Inc A Division of Emerson Process Management PART NUMBER DESCRIPTION Non Hazardous HPS 120 Vac Non Hazardous HPS 100 Vac Non Hazardous HPS 220 240 Vac Explosion Proof HPS 120 Vac Explosion Proof HPS 100 Vac Explosion Proof HPS 220 240 Vac Fuse 5A 250 Vac anti surge case size 5 x 20 mm type T to IEC127 ochurter Mother Board Daughter Board Transformer 120 220 240 Vac Transformer 100 Vac Appendices 11 Instruction Manual Appendix B Rev 2 2 January 1997 World Class 3000 B 12 Appendices Rosemount Analytical Inc Division of Emerson Process Management Instruction Bulletin 106 300NE Rev 3 4 World Class 3000 May 2000 SECTION 7 INDEX This index is an alphabetized listing of parts terms and procedures having to do with the Haz ardous Area Oxygen Combustibles Transmitter Every item listed in this index refers to a location
58. ics When service on the HPS is completed restore power at the HPS and the associated electronics Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Appendix B Rev 2 2 January 1997 Turn off power to system Loosen captive screws retaining HPS cover Remove cover Remove screws on either side of terminal strip covers 2 Figure B 7 Remove termi nal strip covers 4 and 8 Making a note of the location and color of each wire disconnect wires from the termi nal strip on the daughter board 7 Unplug ribbon cable from receptacle on daughter board Unscrew two stand offs from daughter board Remove daughter board 7 Position new daughter board on four stand offs on mother board Reinstall the stand offs removed in step f Plug ribbon cable into receptacle on daughter board Reconnect wires to terminal strip in posi tions noted in step d Reinstall terminal covers Reinstall HPS cover Appendices 9 Instruction Manual Appendix B Rev 2 2 January 1997 World Class 3000 NOTE NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASE SEPARATELY FOR LIST OF AVAILABLE PARTS SEE TABLE B 2 35730006 Figure B 7 Heater Power Supply Exploded View B 10 Appendices Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 LEGEND FOR FIGURE B 7 Enclosure Cover Screw Lockwasher Terminal Cover Stand Off Lockwasher Daughter Board T
59. ield in stalled Refer to paragraph B 7 Transformer Replacement for installation procedure refer to Table B 2 for transformer part numbers OPTIONAL CLASS 1 DIVISION 1 GROUP 56 EXPLOSION PROOF ENCLOSURE Rosemount Analytical Inc Division of Emerson Process Management NEMA 4X 56 NON HAZARDOUS ENCLOSURE 35730001 Figure B 1 HPS 3000 Heater Power Supply Field Module Appendices B 1 Instruction Manual Appendix B Rev 2 2 January 1997 World Class 3000 TRANSFORMER TERMINAL COVERS FRONT TERMINAL STRIP FROM ELECTRONICS TERMINAL STRIP NA FROM PROBE TRANSFORMER SIDE 35730002 Figure B 2 Heater Power Supply Interior B 2 Appendices Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual Appendix B Rev 2 2 World Class 3000 January 1997 Table B 1 Specifications for Heater Power Supply Environmental Classification NEMA 4X IP56 Optional Class 1 Division 1 Group B IP56 Electrical Classification Category Humidity Range 95 Relative Humidity Ambient Temperature Range 20 to 140 30 to 60 C VIDrallofi PERMET 5 m sec2 10 to 500 xyz plane Cabling Distance Betw
60. in 106 300NE Rev 3 4 May 2000 Figure 1 1 Figure 1 2 World Class 3000 LIST OF ILLUSTRATIONS Rosemount Analytical Inc Division of Emerson Process Management Instruction Bulletin 106 300NE Rev 3 4 World Class 3000 May 2000 N CAUTION If the HPS 3000 and World Class 3000 probe are used with any of the following model electronics 218 225 218A and TC200 read appropriate set point adjustment in Instruction Bulletin IB 106 300NE to prevent damage to the World Class 3000 probe PREFACE The purpose of this manual is to provide information concerning the components func tions installation and maintenance of this particular oxygen analyzer Some sections may describe equipment not used in your configuration The user should become thoroughly familiar with the operation of this module before operating it Read this instruction manual completely DEFINITIONS The following definitions apply to WARNINGS CAUTIONS and NOTES found throughout this publication WARNING CAUTION Highlights an operation or maintenance Highlights an operation or maintenance procedure practice condition state procedure practice condition state ment etc If not strictly observed could ment etc If not strictly observed could result in injury death or long term result in damage to or destruction of health hazards of personnel equipment or loss of effectiveness NOTE Highlights an essential operati
61. includes platinum pad and inconel wire Abrasive shield assembly includes accessories necessary for its use and a mounting plate and gasket A 26 Appendices Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 APPENDIX B REV 2 2 HPS 3000 HEATER POWER SUPPLY Instruction Manual Appendix B Rev 2 2 January 1997 DESCRIPTION N C Read the Safety instructions for the wiring and installation of this appara tus at the front of this Instruction Bulletin Failure to follow the safety instructions could result in serious injury or death B 1 DESCRIPTION The Rosemount HPS 3000 Heater Power Sup ply Field Module acts as an interface between probe and electronics and supplies power to the probe heater The unit allows the use of probes with a number of different electronics packages The HPS is available in a NEMA 4X IP56 non hazardous enclosure or an optional Class 1 Division 1 Group B IP56 explo sion proof enclosure igre Bil The heater power supply Figure 2 consists of a mother board daughter board and a transformer for supplying correct voltage to the probe heater The mother and daughter boards contain terminal strips for connecting probe electronics and power supply The HPS is jumper configurable for 120 220 or 240 Vac For 100 Vac usage the HPS is fac tory supplied with a special transformer The 100 Vac transformer can also be easily f
62. inum pad Go the procedure described in the Instruction Bulle through complete troubleshooting tin applicable to your electronics package procedure to make sure cell needs re placement before removing it A 11 CELL REPLACEMENT This paragraph covers oxygen sensing cell re a Disconnect and lock out power to electron placement Do not attempt to replace the cell ics Shut off and disconnect reference air until all other possibilities for poor performance and calibration gas supplies from probe have been considered If cell replacement is junction box Wearing heat re needed order cell replacement kit Table 3 sistant 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 comfort able working temperature The cell replacement kit contains a cell and flange assembly corrugated seal setscrews socket head cap screws and anti seize com pound Items are carefully packaged to preserve A 16 Appendices Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual Appendix A Rev 3 6 World Class 3000 July 1998 INCONEL HEATER CELL WIRE WIRES CLEAR BLACK THERMOCOUPLE SLEEVING SLEEVING ALUMEL 77 SN BOMB TAIL I CONNECTOR CELL EXTENSION WIRE ORANGE THERMOCOUPLE YELLOW CHROMEL FED le mmm _ T XE mor LL Y nere CALIBRA
63. ion Bulletin 106 300NE Rev 3 4 World Class 3000 May 2000 SECTION 6 APPENDICES APPENDIX A WORLD CLASS 3000 OXYGEN ANALYZER PROBE APPENDIX B HPS HEATER POWER SUPPLY FIELD MODULE Rosemount Analytical Inc Division of Emerson Process Management Appendices 6 1 Instruction Manual Appendix A Rev 3 6 July 1998 World Class 3000 jm 2 3 4 5 6 T 8 J Heater Strut and Backplate Assembly Diffusion Assembly Retainer Screw Cell and Flange Corrugated Seal Probe Tube Assembly Screw Washer Cover Chain Screw Cover Chain Probe Junction Box Cover Cover Gasket Wiring Diagram O Ring Terminal Block Screws Terminal Block Terminal Block Marker Terminal Block Mounting Plate NOTE NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASE SEPARATELY FOR LIST OF AVAILABLE PARTS SEE TABLE A 3 19 Probe Junction Box Screws 20 Hose Clamp 21 Hose 22 Gas Connection 23 Seal 24 Label 25 Probe Junction Box 26 Ground Wires 27 Insulating Gasket NOTE ITEM CALIBRATION GAS TUBE a Hid FITS INTO HOLES A gt WHEN PROBE IS ASSEMBLED 21240005 Figure A 1 Oxygen Analyzer Probe Exploded View A 0 Appendices Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual Appendix A Rev 3 6 World Class 3000 July 1998 APPENDIX A REV 3 6 WORLD CLASS 3000 OXYGEN ANALYZER PROBE DESCRIPTION WARNING A 1 O
64. ions of the appropriate In struction Manual and per applicable local and national codes Connect all products to the proper electrical and pressure sources proper performance use qualified personnel to install operate update program and maintain the product e When replacement parts are required ensure that qualified people use replacement parts specified by Rosemount Unauthorized parts and procedures can affect the product s per formance place the safe operation of your process at risk and VOID YOUR WARRANTY Look alike substitutions may result in fire electrical hazards or improper operation Ensure that all equipment doors are closed and protective covers in place except when maintenance is being performed by qualified persons to prevent electrical shock and personal injury The information contained in this document is subject to change without notice Emerson Process Management Rosemount Analytical Inc Process Analytic Division 1201 N Main St Orrville OH 44667 0901 T 330 682 9010 F 330 684 4434 e mail gas csc EmersonProcess com http www processanalytic com E M E RSO N Page Page 1 1 Page 1 3 Page 1 4 Page 2 1 Page 2 2 Page 2 3 Page 2 8 Page Page 1 3 Page 2 3 Page Page Page 2 1 Page 2 9 Page 2 11 Page 3 1 Page 4 1 Page 7 1 HIGHLIGHTS OF CHANGES Effective October 1995 Rev 3 Summary Updated art to reflect new probe
65. isa yttria stabilized zirconium oxide cell It cre ates 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 as sembly Figure A 3 to the probe tube as sembly When in place the cell is inside the tube The tube assembly includes a flange which mates with a stack mounted flange shown attached to the probe flange in Faure A2 otuds 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 PROBE TUBE CORRUGATED SEAL CELL AND FLANGE ASSEMBLY 21240007 Figure A 3 Cell and Tube Assemblies Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual Appendix A Rev 3 6 July 1998 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 diffusion assembly An optional ceramic diffusor element and vee deflector shown in Figure A 4 is available The ceramic diffusor assemb
66. lectronics Hecorder 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 and input to electronics fail ure of electronics Remedy Replace thermocouple or return probe to Rosemount Replace heater or return probe to Rosemount Check HPS and electron ics package See Recorder Instruction Manual Replace cell or return probe to Rosemount Check out cable connection Check electronics package A 12 Appendices Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Appendix A Rev 3 6 World Class 3000 July 1998 Table A 2 Fault Finding Continued 2 System responds to oxygen concentration changes but does not give correct indication Good response with 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 calibra tion gas is turned off Rosemount Analytical Inc Hecorder or remote indicator oystem calibration Probe mounting and con dition of duct Cell mV input to electronics Calibration gas input port Ceramic diffusion element Diffusion element Calibration error Calibration error Air ingress into duct Failure of electronics Blocked port Diffusion element cracked broken or missing Plugged diffusion element A
67. loves and cloth ing to remove probe from stack Nor mal operating temperatures of diffusor and vee deflector are approximately 600 to 800 F 300 to 425 C They can cause severe burns Disconnect and lock out power before working on any electrical component There is voltage up to 115 Vac CAUTION It is not necessary to remove the cell Instruction Manual Appendix A Rev 3 6 July 1998 On systems equipped with abrasive shield remove dual dust seal gaskets Use spanner wrenches from special tools kit Table A 3 to turn hub free from retainer Put hub in vise Break out old diffusion element with chisel along cement line 3 8 inch 9 5 mm pin punch through cement port Break out remaining diffusion element by tapping lightly around hub with hammer Clean grooves with pointed tool if necessary Replace diffusion elemen ing re placement kit listed in Fabio A 3 This consists of a diffusion element ce ment setscrews anti seize compound and instructions Test fit replacement element to be sure seat is clean CAUTION Do not get cement on diffusion ele ment except where it touches the hub unless it is certain that replacement is necessary Cell cannot be removed for inspection without damaging it Refer Any cement on ceramic element to paragraph A 11 Cell Replacement blocks airflow through element Wip Rosemount Analytical Inc b Replacement Procedure
68. ly Strut Leaf Spring o aaa po Ring Lug Butt Connector Extension Backplate 9 Spring 10 Spring Clip Assembly 11 Common Tube Support 12 Heater 13 Short Tube Support Figure A 21 Heater Strut and Backplate Assembly Inner Probe Assembly Rosemount Analytical Inc A Division of Emerson Process Management Appendices A 21 Instruction Manual Appendix A Rev 3 6 July 1998 terminal strip could act as additional ther mocouple 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 l Slide assembled probe junction box and in ner probe assembly into probe tube To align calibration gas tube with correspond ing hole in backplate A B Figure 1 in sert scriber through hole in backplate and into calibration gas tube Secure with screws Reinstall hoses and probe junction box cover m 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 A 14 REPLACEMENT OF HEATER V STRUT AND BACKPLATE ASSEMBLY INNER PROBE ASSEMBLY INCLUDES CONTACT AND THERMOCOUPLE ASSEMBLY N C Use heat resistant gloves and clothing when removing probe junction box and inner probe assembly Do not at tempt
69. ly is also available in a flame arresting version to keep heat from the cell from igniting flue gases oystems 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 6 DIFFUSION ELEMENT PIN WRENCH VEE DEFLECTOR 21240024 Figure A 4 Optional Ceramic Diffusor and Vee Deflector Assembly Appendices A 3 Instruction Manual Appendix A Rev 3 6 July 1998 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 N C 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 Every probe should be calibrated and checked after repair or replacement of cell pad and
70. ng procedure condition or statement EARTH GROUND TERMINAL PROTECTIVE CONDUCTOR TERMINAL N RISK OF ELECTRICAL SHOCK Z WARNING REFER TO INSTRUCTION BULLETIN NOTE TO USERS The number in the lower right corner of each illustration in this publication is a manual illus tration number It is not a part number and is not related to the illustration in any technical manner Rosemount Analytical Inc Division of Emerson Process Management P 1 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 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
71. o provide mechanical support of the probe Refer Figure 2 1 Sheet 5 3 Weld or bolt adapter plate Figure 2 1 onto the duct Installation 2 1 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 LOOOLOVE 1 aunssuagd LON SNH3 LIVd 1109 SIF NIG ISNV OL qaancovadnNvIiW S39NV 14 Q39V4 1V 14 3S3Hl NI SaHa lalWI TIN HLIM SAHONI NI 3HV SNOISNAWIG L SSLON SASAHLNAYVd WOLLOd AHL LV SNOILOANNOO HLIM TIVLSNI MAIA WOLLOd vesc c est 2096 zv L 0862 692 901 sgoz e18 8221 0 si esp 98 ve ld 6 WAOWSY NOILVTIVLSNI d 18avL NO dS 141 S31OH v SZ Y Sr 1 76 081 SSL 0 9 640 81 20 981 824 02 70 ESL 00 9 ASNV 1A WIN 9 2 go LOH8LOZISP LOH6LOZLSY 10 10212 WIN 9 NINGO O P 5 ISNV NI v L 9313 ONILNNOW I13 1avL 3dO 13AN3 T1VAOWZH NIG SVO Ju SVO IVO 261 894 LODer8rese HOlOd 143 uasnaalia OIINVH3O 38OHd OL LOAdSSY HLIM Y3ggNNS Va WId OL dav NOILO3HIG SIHL NI 38 QuvaNvis HLIM s vci 06 7 ge
72. orrosive 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 Appendices 5 Instruction Manual Appendix A Rev 3 6 July 1998 World Class 3000 187 A 187 B ON INSIDE 0 BREAK FOR SMOOTH ROUNDED EDGE ON BOTH ENDS OF CHAMFER 45 MIN 4 SKIN CUT FACE FOR 90 6 0 75 THRU 4 PLS EQ SP 4 75 B C NOTES JN WELD ON BOTH SIDES WITH EXPANDING CHILL BLOCK 2 BEFORE WELDING BUTT ITEM 2 OR 4 WITH ITEM 1 AS SHOWN 745 DIA ON A 7 50 DIA B C REF Figure A 7 Abrasive Shield Assembly NOTE In highly abrasive applications rotate the shield 90 degrees at normal service intervals to present a new wear surface to the abrasive flow stream A 6 Appendices Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 Instruction Manual Appendix A Rev 3 6 July 1998 P0010 Figure A 8 Ceramic Diffusion Dust Seal Assembly These modified diffusion and vee deflector assemblies are available in standard Figure and flame arrestor version Figure A 9 b Ceramic Diffusion Assembly The ceramic diffusion assembly Figure is the traditional design for the probe Used for over 25 years the ceramic diffu sion
73. oubleshooting information for the Model 218 and 225 Electronics Package is con tained in IB 106 101 Model 218A Electronics Package Troubleshooting information for the Model 218 Electronics Package is contained in IB 106 10 TC200 Veritrim Electronics Package Troubleshooting information for the TC200 VeriTrim Electronics Package is contained in IB 107 020 Model 132 Digital Electronics Package Troubleshooting information for the Model 132 Electronics Package is contained in IB 106 106 Troubleshooting 4 1 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 4 2 Troubleshooting Rosemount Analytical Inc Division of Emerson Process Management World Class 3000 SECTION 5 Instruction Bulletin 106 300NE Rev 3 4 May 2000 RETURN OF MATERIAL If factory repair of defective equipment is required proceed as follows a Secure a return authorization number from a Rosemount Analytical Sales Office or Representative before returning the equip ment Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted In no event will Rosemount be responsible for equipment returned without proper authorization and identification b Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to insure that no additional damage will occur during shipping c In a cover letter describe completely 1 The s
74. pply HPS provides an interface to the electronics package and contains a transformer for supplying proper voltage to the 44 Vac and 115 Vac probe heaters The enclosure has been designed For best results use clean dry instrument air 20 95 oxygen as a reference gas to meet NEMA 4X IP56 specifications for water tightness an optional enclosure to meet Class 1 Division 1 Group B IP56 When the cell is at operating temperature and there are unequal oxygen concentra tions 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 Be cause the magnitude of the output is pro portional 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 ap paratus which provides an analysis on a dry gas basis the wet analysis will in general indicate a lower percentage of Description explosion proof is also available
75. r duct The process or exhaust gases are di rected out to the probe through a passive sampling system using inconel tubes Flue gas flow induces the movement of gases into through and out of the bypass unit The bypass arrangement does not require the use of aspiration air and the gas which flows past the probe is returned to the stack or duct The bypass probe package is normally used for process temperatures of 1300F 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 sys tems are shown in Figure A 13 Probe Mounting Jacket Options A probe mounting jacket option is available to allow the probe to operate at tempera tures of up to 2000 F 1095 A separate instruction bulletin is available for this option Rosemount Analytical Inc Division of Emerson Process Management 21004220 SVD OL AYVNOS SI Q T3IHS ASA July 1998 IWHL OS GSLNFIHO 38 LSNW A18IW3SSV 109929409 8 626 ee AIGWSASSV 44 JINYHO E0592020Sv 434 98972 00601 TVNOLLdO di lt 200922709 438 077581 00 Z 1090922 09 SZ ZZZ 2906 lt 434 01 t994 0 9 9 9 oO S S gt
76. roubleshooting section de scribes how to identify and isolate faults which may develop in the HPS 3000 assembly WA N C Install all protective equipment covers and safety ground leads after trouble shooting Failure to replace covers and ground leads could result in seri ous injury or death B 4 Appendices HPS 3000 TROUBLESHOOTING The HPS 3000 troubleshooting may overlap with the probe in use in the system Faults in either system may cause an error to be dis olayed in the electronics package Figure B 4 Figure B 5 and Figure B 6 provide trouble shooting information Rosemount Analytical Inc Division of Emerson Process Management Instruction Manual Appendix B Rev 2 2 World Class 3000 January 1997 SYMPTOM SET METER TO 250 VAC HEATER DOES NOT HEAT UP DOES NOT INCREASE PLACE METER PROBES ON IN OUTPUT J2 FROM ELECTRONICS ANALOG HEATER SET METER FOR 50 VAC PLACE PROBES ON METER SHOULD REGISTER TERMINAL BLOCK J2 A PULSATING NOMINAL FROM PROBE PROBE 115 VAC HEATER CHECK FUSES IN PROBE ELECTRONICS YES DISCONNECT POWER TO HPS AND PROBE ELECTRONICS CHECK ALL FOUR FUSES IN HPS METER INDICATES PULSATING NOMINAL 44 VAC IF FUSES OK POSSIBLE PROBE ELECTRONICS TRIAC FAILURE YES DISCONNECT POWER FROM HPS amp PROBE ELECT SET FUSES BLOWN IN 5 METER ON RX1 CHECK JUMPER JM2 IS INSTALLED YES YES MEASURE RESISTANCE OF CHEC
77. rt No Serial No Order No Emerson Process Management Rosemount Analytical Inc Process Analytic Division 1201 N Main St Orrville 44667 0901 T 330 682 9010 F 330 684 4434 E gas csc emersonprocess com ASIA PACIFIC Fisher Rosemount Singapore Private Ltd 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65 777 8211 F 65 777 0947 http www processanalytic com Rosemount Analytical Inc 2001 Fisher Rosemount GmbH amp Co Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884209 EUROPE MIDDLE EAST AFRICA Fisher Rosemount Ltd Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 World Class 3000 HPS 3000 Part No Serial No Order No LATIN AMERICA Fisher Rosemount Av das Americas 3333 sala 1004 Rio de Janeiro RJ Brazil 22631 003 T 55 21 2431 1882 EMERSON
78. t EPROM when using a multiprobe averager unit is 1M02982G10 To replace the EPROM proceed as follows a Shut off and lock out power to the electron ics package b Open electronics enclosure c the Main Figure 3 2 locate and remove old EPROM d Replace with new EPROM e Close electronics enclosure and power up system des S oO AN E Figure 3 2 Main PCB Model 218A EPROM Replacement Setup Rosemount Analytical Inc A Division of Emerson Process Management Instruction Bulletin 106 300NE Rev 3 4 World Class 3000 May 2000 EPROMS 011 AND U12 Ur pn al of oand 000 2059 OD n0 EX nooo 3 D 200 Doa 7 Figure 3 3 Main Model TC200 EPROM Replacement 3 4 MODEL TC200 VERITRIM ELECTRONICS 4 Replace with new EPROMSs part num SETUP ber 1M03154G02 being careful to in stall U11 and U12 in their proper Before beginning operation it is important that locations the probe heater set point of the existing elec tronics be changed to support the World Class 5 Close electronics enclosure and power 3000 Probe To convert the Model TC200 Elec up system tronics Package for use with the World Class 3000 Probe and Heater Power Supply an b Heater Set Point Adjustment EPROM change is necessary The replacement EPROM needed is part number 1M
79. te This packag ing has been designed to protect the product f System Considerations Prior to installation of your Rosemount CALIBRATION GAS Instruction Bulletin 106 300NE Rev 3 4 May 2000 A typical installation is illustrated in Figure 1 2 and Figure 1 3 After selecting the probe mounting location provision should be made for a platform where the probe can be easily serviced The heater power supply can be located up to 150 feet 45 m cable distance from the probe A source of instrument air is required at the probe for reference gas use Since the probe is equipped with an in place calibra tion feature provision should be made for connecting test gas tanks to the oxygen analyzer when the probe is to be calibrated NOTE Ambient air is not recommended for use as high test gas An 8 bal ance in nitrogen is recommended for high test gas If test gas bottles will be hooked up perma nently a check valve is required next to the calibration fittings on the probe junction box This is to prevent breathing of calibration gas line and subsequent flue gas conden sation and corrosion The check valve is in addition to the stop valve in the test gas kit or the solenoid valve in the multiprobe test gas sequencer units ADAPTER PLATE World Class 3000 Oxygen Analyzer with SES gt N OXYGEN Heater Power Supply Field Module make AIR SUPPLY QD ee sure you have all of the
80. top of transformer assembly Remove retaining plate 24 and gasket 22 d Disconnect transformer harness plug from mother board e Remove screws on either side of terminal strip covers 2 Remove terminal strip cov ers 4 and 8 f Unplug ribbon cable from the receptacle on the daughter board 7 g Unscrew stand offs on either side of the daughter board Remove daughter board 7 h Unscrew four stand offs that supported the daughter board A Division of Emerson Process Management World Class 3000 I Making a note of the location and color of each wire disconnect wires from terminal strip on mother board Remove four screws 9 holding mother board to stand offs 10 on subplate 14 k Remove mother board 12 l Position new mother board on stand offs and reinstall screws removed in step j m Reconnect wires to terminal strip in posi tions noted in step i n Reinstall four stand offs removed in step h Position daughter board on stand offs and reinstall stand offs removed in step g o Plug ribbon cable back into receptacle on daughter board Reinstall terminal covers p Reinstall transformer tightening hex nut only enough to hold transformer firmly in position Reconnect transformer harness plug to mother board q Reinstall HPS cover B 9 DAUGHTER BOARD REPLACEMENT CAUTION When turning power off at the HPS also turn off the respective probe at associated electron
81. wire heater and thermocouple or after disassembly of the probe INNER PROBE ASSEMBLY The inner probe assembly Figure A 5 consists of six main parts a Ceramic support rod with four holes running through the length The holes serve as insulated paths for the cell signal wire and thermocouple wires 4 Appendices f World Class 3000 A heater that is helically wrapped on a quartz support cylinder and insulated A chromel alumel thermocouple which acts as the sensing element for the temperature controller Not visible in Figure A 5 located within ceramic support rod A platinum screen pad which forms electrical contact with the inner electrode of the electrochemical cell Not visible in Figure A 5 located at end of ceramic support rod The pad is attached to an inconel wire which carries the signal to the terminal strip A V strut assembly to give support to the inner probe assembly A tube to carry reference air to the cell Turn to Service and Normal Maintenance for repair procedures for probe components IX V STRUT Rosemount Analytical Inc HEATER INSULATING GASKET REFERENCE AIR TUBE CERAMIC _ _ SUPPORT f as ROD A 27270015 Figure 5 Inner Probe Assembly A Division of Emerson Process Management World Class 3000 PROBE JUNCTION BOX COVER TERMINAL STRIP Q CALIBRATION GAS
82. y enclosure 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 tem Rosemount Analytical Inc A Division of Emerson Process Management perature changes and electrical noise Ambient temperature must be between 20 to 140 F 30 to 60 C b Electrical Connections 1 Electrical connections should be made as described in the electrical installa tion diagram Figure 2 4 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 Figure 2 5 Each terminal strip has a protective cover which must be removed when making connections To remove the terminal covers remove two slotted screws holding the cover in place Al ways reinstall terminal covers after making connections Installation 2 9 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 ALWAYS DISCONNECT LINE VOLTAGE FROM HEATER POWER SUPPLY AND ANALOG ELECTRONICS USED JUMPER CONFIGURATIONS BEFORE CHANGING JUMPERS LINE VOLTAGE JUMPER SELECTION INSTALL 100 120 V A C JM4 JM1 PROBE HEATER JUMPER VOLTAGE SELECTION INSTALL WORLD S PROBE ELE 218 aS 115V A REMOTE REMOVE J
83. ymptoms from which it was de termined that the equipment is faulty 2 The environment in which the equip ment has been operating housing weather vibration dust etc 3 Site from which equipment was removed 4 Whether warranty or nonwarranty service is requested Rosemount Analytical Inc Division of Emerson Process Management 5 Complete shipping instructions for return of equipment 6 Reference the return authorization number d Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in Rosemount Return Authorization prepaid to Rosemount Analytical Inc RMR Department 1201 N Main Street Orrville Ohio 44667 If warranty service is requested the defec tive 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 cus tomer 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 Return of Material 5 1 Instruction Bulletin 106 300NE Rev 3 4 May 2000 World Class 3000 5 2 Return of Material Rosemount Analytical Inc Division of Emerson Process Management Instruct

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