World Class 3000 - Emerson Electric...1993/12/14 · World Class 3000 Typical Application with Intelligent Field Transmitters - CENELEC Approved ..... 1-6 Figure 2-1. Probe Figure

Instruction Manual106-300NFX Rev. 4.2January 2002

http://www.processanalytic.com

World Class 3000Oxygen Analyzer (CENELEC)with IFT 3000 Intelligent FieldTransmitter (CENELEC)

Emerson Process ManagementRosemount Analytical Inc.Process Analytic Division1201 N. Main St.Orrville, OH 44667-0901T (330) 682-9010F (330) 684-4434e-mail: [email protected]://www.processanalytic.com

ESSENTIAL INSTRUCTIONSREAD THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national andinternational standards. Because these instruments are sophisticated technical products, youMUST properly install, use, and maintain them to ensure they continue to operate within theirnormal specifications. The following instructions MUST be adhered to and integrated into yoursafety program when installing, using, and maintaining Rosemount Analytical products. Failure tofollow the proper instructions may cause any one of the following situations to occur: Loss of life;personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical repre-sentative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and mainte-nance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate In-struction Manual and per applicable local and national codes. Connect all products to theproper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program,and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement partsspecified 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 are in place, exceptwhen maintenance is being performed by qualified persons, to prevent electrical shockand personal injury.

The information contained in this document is subject to change without notice.

HIGHLIGHTS OF CHANGES

Effective June, 1997 Rev. 4

Page Summary

--- General. Added snubber version of probe to manual. Text and artchanged as necessary to reflect new style of probe.

Effective February, 1998 Rev. 4.1

Page Summary

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

Page 3-10 Add note on test gas flowmeter.

Effective January, 2002 Rev. 4.2

Page Summary

Page 2-13 Updated Figure 2-8.

Page 2-14 Updated analog output current/voltage mode selection procedure.

HIGHLIGHTS OF CHANGESAPPENDIX AX

Effective June, 1997 Rev. 2

Page Summary

-- General. Added snubber version of probe to manual. Text and artchanged as necessary to reflect new style probe.


Page Summary

Page A-12 Changed screw torque in paragraph A-3h.

HIGHLIGHTS OF CHANGESAPPENDIX BX


Page Summary

B-3 Figure B-3. Updated for IB consistency.


Page Summary

Page B-2 Figure B-2. Added fuse locations.

Page B-5 Insert protective cover and ground lead warning.

Page B-8 Insert protective cover and ground lead warning.

Page B-11 Table B-2. Add expanded fuse specifications to replacement parts.

HIGHLIGHTS OF CHANGESAPPENDIX DX

Effective February, 1995 Rev. 2

Page Summary

-- General. Updated appendix with new version of MPS.


Page Summary

Page D-5 Insert protective cover and ground lead warning.

Page D-7 Insert protective cover and ground lead warning. Add fusespecifications and clarify fuse replacement.

Page D-11 Add fuse specifications to replacement parts

HIGHLIGHTS OF CHANGESAPPENDIX EX


Page Summary

Page E-4 Figure E-2. Updated for IB consistency.

Page E-7 Figure E-4. Updated Flowchart.

Effective May, 1995 Rev. 1.2

Page Summary

Page E-4 Figure E-2. Added callout text Heater Power Supply (Optional).


Page Summary

Page E-5 Insert protective cover and ground lead warning.

Page E-9 Insert protective cover and ground lead warning.

Page E-15 Added expanded fuse specifications to replacement parts

HIGHLIGHTS OF CHANGESAPPENDIX JX


Page Summary

Page J-4 Insert warning concerning protective equipment covers and safetyground leads.

Page J-11 Insert warning concerning protective equipment covers and safetyground leads.

Instruction Manual106-300NFX Rev. 4.2

January 2002

Rosemount Analytical Inc. A Division of Emerson Process Management i

World Class 3000

TABLE OF CONTENTS

PREFACE......................................................................................................................... P1Definitions ......................................................................................................................... P1Safety Instructions ........................................................................................................... P2

1-0 DESCRIPTION ................................................................................................................ 1-11-1 Component Checklist Of Typical System (Package Contents) ....................................... 1-11-2 System Overview............................................................................................................. 1-1

2-0 INSTALLATION .............................................................................................................. 2-12-1 Oxygen Analyzer (Probe) Installation.............................................................................. 2-12-2 Intelligent Field Transmitter (IFT) Installation .................................................................. 2-92-3 Heater Power Supply Installation .................................................................................. 2-162-4 Multiprobe Test Gas Sequencer Installation ................................................................. 2-20

3-0 SETUP AND OPERATION ........................................................................................... 3-13-1 Overview.......................................................................................................................... 3-13-2 IFT with GUI and LDP Front Panel Controls and Indicators ........................................... 3-23-3 Help Key .......................................................................................................................... 3-23-4 Status Line....................................................................................................................... 3-33-5 Quick Reference Chart .................................................................................................... 3-33-6 Main Menu ....................................................................................................................... 3-33-7 Probe Data Sub-Menu.................................................................................................... 3-63-8 Calibrate O2 ub-Menu..................................................................................................... 3-63-9 Setup Sub-Menu.............................................................................................................. 3-63-10 System Calibration........................................................................................................... 3-9

4-0 LDP OPERATION .......................................................................................................... 4-14-1 Overview.......................................................................................................................... 4-14-2 IFT with LDP Front Panel Controls and Indicators .......................................................... 4-14-3 LDP Displays ................................................................................................................... 4-14-4 LDP Defaults.................................................................................................................... 4-24-5 Calibration........................................................................................................................ 4-2

5-0 TROUBLESHOOTING.................................................................................................... 5-15-1 Overview.......................................................................................................................... 5-15-2 Special Troubleshooting Notes........................................................................................ 5-15-3 System Troubleshooting.................................................................................................. 5-2

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

7-0 APPENDICES ................................................................................................................. 7-1

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

9-0 DRAWINGS AND SCHEMATICS................................................................................. 9-1


ii Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

LIST OF ILLUSTRATIONS

Figure 1-1. Typical System Package ....................................................................................... 1-1Figure 1-2. Typical System Installation .................................................................................... 1-5Figure 1-3. World Class 3000 Typical Application with Intelligent Field Transmitters -

CENELEC Approved ............................................................................................. 1-6Figure 2-1. Probe Installation ................................................................................................... 2-2Figure 2-2. Orienting the Optional Vee Deflector ..................................................................... 2-7Figure 2-3. Air set, Plant Air Connection.................................................................................. 2-8Figure 2-4. Outline of Intelligent Field Transmitter ................................................................... 2-9Figure 2-5. Power Supply Board Jumper Configuration ........................................................ 2-10Figure 2-6. IFT Power Supply Board Jumpers....................................................................... 2-11Figure 2-7. Wiring Layout for IFT 3000 (CENELEC approved) System without HPS............ 2-12Figure 2-8. IFT Microprocessor Board Jumper Configuration................................................ 2-13Figure 2-9. IFT Microprocessor Board Jumpers .................................................................... 2-14Figure 2-10. Interconnect Board Jumper Configuration........................................................... 2-14Figure 2-11. IFT Interconnect Board Output Connections ....................................................... 2-15Figure 2-12. Outline of CENELEC Approved Heater Power Supply........................................ 2-16Figure 2-13. Wiring layout for IFT 3000 (CENELEC approved) with HPS............................... 2-17Figure 2-14. CENELEC Approved Heater Power Supply Wiring Connections........................ 2-19Figure 2-15. Jumper Selection Label. ...................................................................................... 2-19Figure 2-16. Jumpers on HPS Motherboard ............................................................................ 2-20Figure 2-17. MPS Module ........................................................................................................ 2-21Figure 2-18. MPS Gas Connections ........................................................................................ 2-22Figure 2-19. MPS Electrical Connections ................................................................................ 2-23Figure 3-1. IFT with GUI and LDP Front Panel ........................................................................ 3-2Figure 3-2. Typical Calibration Setup..................................................................................... 3-11Figure 3-3. Portable Rosemount Oxygen Test Gas Kit......................................................... 3-12Figure 3-4. Typical Portable Test Calibration Setup .............................................................. 3-13Figure 3-5. Typical Automatic Calibration System ................................................................. 3-15Figure 4-1. IFT with LDP Front Panel ...................................................................................... 4-1

LIST OF TABLES

Table 3-1. Sample HELP Messages....................................................................................... 3-2Table 3-2. Main Menu ............................................................................................................. 3-3Table 3-3. PROBE DATA Sub-Menu. ................................................................................... 3-3Table 3-4. CALIBRATION O2 Sub-Menu ................................................................................ 3-7Table 3-5. SETUP Sub-Menu ................................................................................................. 3-8Table 3-6. Efficiency Constants .............................................................................................. 3-9Table 4-1. LDP Defaults......................................................................................................... 4-3


January 2002

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

World Class 3000

PREFACEThe 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 shouldbecome thoroughly familiar with the operation of this module before operating it. Readthis instruction manual completely.

DEFINITIONSThe following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout thispublication.

Highlights an operation or maintenanceprocedure, practice, condition, state-ment, etc. If not strictly observed, couldresult in injury, death, or long-termhealth hazards of personnel.

Highlights an operation or maintenanceprocedure, practice, condition, state-ment, etc. If not strictly observed, couldresult in damage to or destruction ofequipment, or loss of effectiveness.

NOTEHighlights an essential operating procedure,condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERSThe 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 technicalmanner.


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

World Class 3000

IMPORTANT

SAFETY INSTRUCTIONSFOR THE WIRING AND INSTALLATION

OF THIS APPARATUSThe following safety instructions apply specifically to all EU member states. They shouldbe 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 NationalStandards.

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 cableanchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only bemade through a circuit breaker which will disconnect all circuits carrying conductors during afault 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 providedand clearly marked as such. Circuit breakers or switches must comply with a recognizedstandard 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 beremoved when power is removed from the equipment — and then only bytrained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is adanger from hot surfaces beneath. These covers should only be removed bytrained 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 tothe 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 ISO3864.


January 2002

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

World Class 3000

SECTION 1DESCRIPTION

1-1 COMPONENT CHECKLIST OF TYPICALSYSTEM (PACKAGE CONTENTS)

A typical Rosemount World Class 3000 OxygenAnalyzer (CENELEC approved) with IFT 3000Intelligent Field Transmitter (CENELECapproved) should contain the items shown inFigure 1-1. Record the Part Number, SerialNumber, and Order Number for each compo-nent of your system in the table located on thecover of this manual.

The IFT 3000, Oxygen Analyzer(Probe), and probe abrasive shield areheavy. Lifting and carrying proceduresshould take account of this weight.

1-2 SYSTEM OVERVIEW

a. Scope

This Instruction Bulletin has been designed tosupply details needed to install, start up, oper-ate, and maintain the Rosemount World Class3000 Oxygen Analyzer (CENELEC approved)with IFT 3000 Intelligent FieldTransmitter(CENELEC approved). The Intelligent FieldTransmitter (IFT) can be interfaced with oneWorld Class 3000 probe. The IFT provides allnecessary intelligence for controlling the probeand optional MPS 3000 Multiprobe GasSequencer.

ROSEMOUNT

DONOTOPEN

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8

7

6

5

4

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2

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26030001

Figure 1-1. Typical System Package

1. Intelligent Field Transmitter(CENELEC approved)

2. Instruction Bulletin 3. Multiprobe Test Gas

Sequencer (Optional) 4. Heater Power Supply

(CENELEC approved)(Optional) 5. Oxygen Analyzer (Probe)

(CENELEC approved) 6. System Cable 7. Mounting Plate with Mounting

Hardware and Gasket 8. Reference AIR set (optional)


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

World Class 3000

The Rosemount encode sheets (Prod-uct Ordering Matrix) allow a customerto order either the hazardous area ver-sion of the IFT 3000 or the non-hazardous area version. The hazard-ous area version has the symbol"EExd" on the apparatus nameplate.The non-hazardous area version doesnot. Ensure that if you have receivedthe non-hazardous version that you donot install it in a potentially explosiveatmosphere. This also applies to thehazardous/non-hazardous versions ofthe HPS 3000.

b. System Description

The Rosemount Oxygen Analyzer (Probe) isdesigned to measure the net concentrationof oxygen in an industrial process; i.e., theoxygen remaining after all fuels have beenoxidized. The probe is permanently posi-tioned within an exhaust duct or stack andperforms its task without the use of a sam-pling system.

The equipment measures oxygen percent-age by reading the voltage developedacross a heated electrochemical cell, whichconsists of a small Yttria-stabilized, Zirconiadisc. Both sides of the disc are coated withporous metal electrodes. When operated atthe proper temperature, the millivolt outputvoltage of the cell is given by the followingNernst equation:

EMF = KT log10(P1/P2) + C

Where:

1. P2 is the partial pressure of the oxygenin the measured gas on one side of thecell,

2. P1 is the partial pressure of the oxygenin the reference gas on the other side,

3. T is the absolute temperature, 4. C is the cell constant, 5. K is an arithmetic constant.

NOTEFor best results, use clean, dry, in-strument air (20.95% oxygen) as a ref-erence gas.

When the cell is at operating temperature,and there are unequal oxygen concentra-tions across the cell, oxygen ions will travelfrom the high partial pressure of oxygenside to the low partial pressure side of thecell. The resulting logarithmic output voltageis approximately 50 mV per decade.Because the magnitude of the output isproportional to the logarithm of the inverseof the sample of the oxygen partial pres-sure, the output signal increases as theoxygen concentration of the sample gasdecreases. This characteristic enables theoxygen analyzer to provide exceptionalsensitivity at low oxygen concentrations.

Oxygen analyzer equipment measures netoxygen concentration in the presence of allthe products of combustion, including watervapor. Therefore, it may be considered ananalysis on a "wet" basis. In comparisonwith older methods, such as the Orsatapparatus, which provides an analysis on a"dry" gas basis, the "wet" analysis will, ingeneral, indicate a lower percentage ofoxygen. The difference will be proportionalto the water content of the sampled gasstream.

c. System Configuration

The equipment discussed in this manualconsists of three major components: theoxygen analyzer (CENELEC approved)(probe), the intelligent field transmitter(CENELEC approved) (IFT), and an op-tional heater power supply (CENELECapproved) (HPS). The HPS is requiredwhen the cable run between the electronicsand the probe exceeds45 m (150 ft). Thereis also an optional multiprobe test gassequencer (MPS), which can be used tofacilitate the automatic calibration of amultiple probe configuration.


January 2002


World Class 3000

CENELEC approved probes are available inthree length options, giving the user theflexibility to use an in situ penetration ap-propriate to the size of the stack or duct.The options on length are 457 mm (18 in.),0.91 m (3 ft), and 1.83 m (6 ft). The probe iscertified EExd IIB T1 [370°C (698°F)] toCENELEC standards EN50014 andEN50018.

The IFT contains electronics that controlprobe temperature (in conjunction with theoptional HPS) and supply power, and pro-vide isolated outputs that are proportional tothe measured oxygen concentration. Theoxygen sensing cell is maintained at a con-stant temperature by modulating the dutycycle of the probe heater. The IFT acceptsmillivolt signals generated by the sensingcell and produces outputs to be used byremotely connected devices. The IFT outputis isolated and selectable to providelinearized voltage or current.

The heater power supply CENELECapproved (HPS) can provide an interfacebetween the IFT and the probe. The HPScontains a transformer for supplying propervoltage to the probe heater. The unit iscertified EExd IIC T6 to CENELEC stan-dards EN50014 and EN50018.

Systems with multiprobe and multiple IFTapplications may employ an optional MPS3000 Multiprobe Test Gas Sequencer. TheMPS 3000 provides automatic test gassequencing for up to four probes and IFTsto accommodate automatic calibration. TheMPS 3000 must be installed in a non-hazardous, explosive-free environment.

d. System Features

1. Unique and patented electronic cellprotection action that automaticallyprotects sensor cell when the analyzerdetects reducing atmospheres.

2. Output voltage and sensitivity increaseas the oxygen concentration de-creases.

3. User friendly, menu driven operatorinterface with context-sensitive on-linehelp.

4. Field replaceable cell.

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

6. The intelligent field transmitter (IFT)can be located up to 45 m (150 ft) fromthe probe when used without optionalheater power supply (HPS). When thesystem includes the optional HPS, theHPS can be located up to 45 m (150 ft)from the probe and the IFT may be lo-cated up to 364 m (1200 ft) from theHPS.

7. All electronic modules are adaptable to120, 220, and 240 line voltages.

8. Five languages may be selected foruse with the IFT. These are:

EnglishFrenchGermanItalianSpanish

9. An operator can set up, calibrate, ortroubleshoot the IFT in one of twoways:

(a) Optional General User Interface(GUI). The GUI is housed withinthe IFT electronics enclosure andmakes use of an LCD display andkeypad.

(b) Optional LED Display Panel (LDP).The LED display and a limitedfunction keypad permit calibrationonly.



World Class 3000

e. Handling the Oxygen Analyzer

It is important that printed circuitboards and integrated circuits arehandled only when adequate antistaticprecautions have been taken to pre-vent possible equipment damage.

The oxygen analyzer is designed forindustrial application. Treat eachcomponent of the system with care toavoid physical damage. The probecontains components made from ce-ramics, which are susceptible toshock when mishandled. See SafetyData Sheets 1M03243, 1M03226, and1M03296 for safety related informa-tion.

NOTERetain packaging in which the oxygenanalyzer arrived from the factory incase any components are to beshipped to another site. This packag-ing has been designed to protect theproduct.

f. System Considerations

Prior to installation of your RosemountCENELEC approved World Class 3000Oxygen Analyzer with Intelligent FieldTransmitter make sure that you have all ofthe components necessary to make thesystem installation. Ensure that all the com-ponents are properly integrated to make thesystem functional.

Once you have verified that you have all thecomponents, select mounting locations anddetermine how each component will beplaced in terms of available power supply,ambient temperatures, environmental con-siderations, convenience, and serviceability.A typical system installation is illustrated inFigure 1-2. Figure 1-3 shows a typicalsystem wiring. For details on installing theindividual components of the system,refer to Section 2, Installation.

After selecting the probe mounting location,provision should be made for a platformwhere the probe can be easily serviced.The intelligent field transmitter (IFT) can belocated up to 45 m (150 ft) cabling distancefrom the probe when used without optionalheater power supply (HPS). When the sys-tem includes the optional HPS, the HPS canbe located up to 45 m (150 ft) cablingdistance from the probe and the IFT may belocated up to 364 m (1200 ft) cablingdistance from the HPS.

A source of instrument air is required at theprobe for reference gas use. Since theprobe is equipped with an in-place calibra-tion feature, provision should be made forconnecting test gas tanks to the oxygenanalyzer when the probe is to be calibrated.

If the test gas bottles will be permanentlyhooked up, a check valve must be con-nected to the calibration gas fitting on theprobe junction box. This is to preventbreathing of calibration gas line and subse-quent gas condensation and corrosion. Thecheck valve is in addition to the stop valvein the test gas kit or the solenoid valve inthe multiprobe test gas sequencer units.


January 2002


World Class 3000

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OXYGENANALYZEREExd IIB T1(370°C) (PROBE)

OXYGEN ANALYZEREExd IIB T1 (370°C)(PROBE)

INTELLIGENTFIELD TRANSMITTER

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INTELLIGENTFIELD TRANSMITTER

EExd IIB T6

*NOTE: THE MPS 3000 MUST BEINSTALLED IN A NON-HAZARDOUSEXPLOSIVE FREE ENVIRONMENT.

Figure 1-2. Typical System Installation



World Class 3000

*MPS 3000

TEST GASSEQUENCER

HPS 3000

HPS 3000

(OPTIONAL)

(OPTIONAL)

Explosion ProofRequired only forHazardous AreaApplications, otherwiseuse NEMA 4X.Lengths Exceeding150 feet.

2-Conductor T/CWire [46 (150) max]

(optional)Line Voltage

Line Voltage

Line Voltage

Line Voltage

2-Conductor T/CWire [46 (150) max]

(optional)

4 Twisted Pair Plus 2 Twisted Pairfor Options [366 (1200) max]

5 Conductor[305 (1000) max]

Modular DesignUp to 4 Probes

IFT 3000

IFT 3000

Intelligent Field Transmitter

Line Voltage100 to 120 Volt220 to 240 Volt

Intelligent Field Transmitter

Line Voltage100 to 120 Volt220 to 240 Volt

Stack Thermocouple(optional)

Stack Thermocouple(optional)

World Class 3000Probe

World Class 3000Probe

7-Conductor Cable[46 (150) max]

7-Conductor Cable[46 (150) max]

2-Pneumatic Linesby Customer

[91 (300) max]

Test Gasby

Customer

[HPS not required for lengths of less than 46 (150) max]

P00003

*NOTE 1:

NOTE 2:

THE MPS 3000 MUST BE INSTALLEDIN A NON-HAZARDOUS EXPLOSIVE FREEENVIRONMENT.

ALL DIMENSIONS APPEAR IN METERSWITH FEET IN PARENTHESES.

Figure 1-3. World Class 3000 Typical Applicationwith Intelligent Field Transmitters - CENELEC Approved


January 2002

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

World Class 3000

SECTION 2INSTALLATION

2-1 OXYGEN ANALYZER (PROBE)INSTALLATION

Before probe installations, consultprobe Safety Data Sheet 1M03226.

The probe and probe abrasive shieldare heavy. Use proper lifting andcarrying procedures to avoidpersonnel injury.

Install all protective equipment coversand safety ground leads after installa-tion. Failure to install covers andground leads could result in seriousinjury or death.

a. Selecting Location

1. The location of the probe in the stackor flue is most important for maximumaccuracy in the oxygen analyzing pro-cess. The probe must be positioned sothat the gas it measures is representa-tive of the process. Best results arenormally obtained if the probe is posi-tioned near the center of the duct (40to 60% insertion). A point too near theedge or wall of the duct may not pro-vide a representative sample becauseof the possibility of gas stratification. Inaddition, the sensing point should beselected so that the process gas tem-perature falls within a range of 10° to704°C (50° to 1300°F). Figure 2-1

provides you with mechanical installa-tion references.

2. Check the flue or stack for holes andair leakage. The presence of thiscondition will substantially affect theaccuracy of the oxygen reading.Therefore, either make necessaryrepairs or install the probe upstreamof any leakage.

3. Ensure that the area is clear ofobstructions internal and external thatwill interfere with installation. Allowadequate clearance for removal ofprobe (Figure 2-1).

Do not allow the temperature of theprobe junction box to exceed 150°C(302°F) or damage to the unit mayresult. If the probe junction box tem-perature exceeds 150°C (302°F), theuser must fabricate a heat shield orprovide adequate cooling air to theprobe junction box.

b. Mechanical Installation

1. Ensure that all components are avail-able for installation of the probe. Checkthe ceramic filter to ensure that it is notdamaged and that the system cable isthe required length.

2. The probe may be installed intact as itis received. It is recommended that youdisassemble the adapter plate for eachinstallation.

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


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

World Class 3000

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BE

S

21

0(8

.25

)

18

(0.7

08

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17

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3)

45

9(1

8.0

7)

91

3(3

5.9

5)

18

31

(72

.09

)

75

5(2

9.7

)

12

09

(47

.6)

21

26

(83

.7)

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


January 2002


World Class 3000

1.5

2(0

.06

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23800007




World Class 3000

BO

TT

TO

MV

IEW

OP

TIO

NA

LC

ER

AM

ICD

IFF

US

OR

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HV

EE

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IEW

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75

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9.7

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09

(47

.6)

21

26

(83

.7)



January 2002


World Class 3000

NO

TE

:D

IME

NS

ION

SA

RE

INM

ILL

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TE

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WIT

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.




World Class 3000

PROBE MOUNTING

ABRASIVE SHIELD MOUNTING

INSTALLATION FOR MASONRYWALL STACK CONSTRUCTION

INSTALLATION FOR METALWALL STACK OR DUCT

CONSTRUCTION

13 (0.50)

95 (3.75)

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

MTG HOLESSHOWN ROTATED

22.5 OUT OFTRUE POSITION

o

WELD OR BOLTMOUNTING PLATE TO

METAL WALL OF STACKOR DUCT. JOINT MUST

BE AIR TIGHT.

13 (0.50)

114 (4.50)O.D. REF

PIPE 4.00 SCHED 40PIPE SLEEVE (NOTBY ROSEMOUNT)LENGTH BY CUSTOMER

MASONRYSTACK WALL

OUTSIDE WALLSURFACE

JOINT MUSTBE AIRTIGHT

MTG HOLESSHOWN ROTATED

22.5 OUT OFTRUE POSITION

o

FIELD WELDPIPE TO

ADAPTOR PLATE

BOLT ADAPTORPLATE TO OUTSIDE

WALL SURFACE

NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPTMOUNTING PLATE NOT FURNISHED BY ROSEMOUNT.

82.5 (3.25)

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

WELD OR BOLT MOUNTINGPLATE TO METAL WALL

OF STACK OR DUCT.JOINT MUST BE AIR TIGHT.

FIELD WELDPIPE TOADAPTOR PLATE

102 (4.0)O.D. REF

PIPE 3.5 SCHED 40PIPE SLEEVE (NOTBY ROSEMOUNT)LENGTH BY CUSTOMER

MASONRYSTACK WALLOUTSIDE WALL

SURFACE

JOINT MUSTBE AIRTIGHT

BOLT MOUNTINGPLATE TO OUTSIDE

WALL SURFACE

P00007



January 2002


World Class 3000

4. If using the optional ceramic diffuserelement, the vee deflector must be cor-rectly oriented. Before inserting theprobe, check the direction of flow of thegas in the duct. Orient the vee deflectoron the probe so that the apex pointsupstream toward the flow (Figure 2-2).This may be done by loosening thesetscrews, and rotating the vee de-flector to the desired position.Retighten the setscrews.

5. In horizontal installations, the probecover should be oriented so that thesystem cable drops vertically from theprobe cover. In a vertical installation,the system cable can be oriented inany direction.

6. If the system has an abrasive shield,check the diffusion element dust sealpackings. The joints in the two pack-ings must be staggered 180°. Also,make sure that the packings are in thehub grooves as the probe slides intothe 15° forcing cone in the abrasiveshield.

NOTEIf process temperatures will exceed1000°F (538°C), use anti-seize com-pound on stud threads to ease futureremoval of probe.

APEX

FILTER

GAS FLOWDIRECTION

VEEDEFLECTOR

CERAMICDIFFUSIONELEMENT

VEEDEFLECTOR

SETSCREW

23800008

Figure 2-2. Orienting the Optional Vee Deflector

7. Insert the probe through the opening inthe mounting flange and bolt the unit tothe flange.

8. Ensure that probe is properly earthedby way of both the internal and externalpoints.

9. Ensure that the installation does notobscure the messages on either theprobe nameplate or the junction boxlid.



World Class 3000

c. Reference Air Package

After the oxygen analyzing (probe) unit isinstalled, connect the reference gas air setto the probe cover. The reference gas airset should be installed in accordance withFigure 2-3.

d. Service Required.

1. Power input: 44 VAC from HPS 3000or IFT 3000.

2. Compressed air: 68.95 kPa (10 psig)minimum, 1551.38 kPa (225 psig)

maximum at 56.6 L/hr (2 scfh) maxi-mum; supplied by one of the following(less than 40 parts-per-million total hy-drocarbons).

(a) Instrument air - clean, dry.

(b) Bottled standard air with step-downregulator.

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

(d) Other equivalent clean, dry, oil-freeair supply.

17300016

TO PROBEJUNCTION BOX

REF GAS SET263C152G01

1 FLOWMETER 0.2-2.0 SCFH 771B635H02

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

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

NOTE: DIMENSIONS ARE IN MILLIMETERSWITH INCHES IN PARENTHESES.

12

3

122.17 (4.81)

FLOW SETPOINT KNOB

0.125-27 NPT FEMALEOUTLET CONNECTION

30.22(1.19)

254 REF(10.0)

DRAIN VALVE

79.25 (3.12) MAX

215.90 MAX(8.50)

50.80(2.0) 2 MOUNTING HOLES

81.03 (3.19) LGTHROUGH BODY FOR7.92 (0.312) DIA BOLTS

38.10(1.50)

57.15 (2.250)

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

OUTLET

0.25-18 NPT FEMALEINLET CONNECTION

COMPRESSED AIR SUPPLY10-225 PSIG MAX PRESSURE

6 (0.250) OD TUBING(SUPPLIED BY CUSTOMER)

6 (0.250) ODTUBE COMPRESSION

FITTING (SUPPLIED BY WECO)

NOTE: DIMENSIONS ARE IN MILLIMETERSWITH INCHES IN PARENTHESES.

Figure 2-3. Air set, Plant Air Connection


January 2002


World Class 3000

2-2 INTELLIGENT FIELD TRANSMITTER (IFT)INSTALLATION

The Rosemount Encode Sheet (Prod-uct Ordering Matrix) allows a customerto order either the hazardous area ver-sion of the IFT 3000 or the non-hazardous area version. The hazard-ous area version has the symbol"EExd" on the apparatus nameplate.The non-hazardous area version doesnot. Ensure that if you have the non-hazardous area version that you donot install it in a potentially explosiveenvironment. This warning appliesequally to the hazardous area andnon-hazardous area versions of theHPS 3000.

Before IFT 3000 Installation, consultSafety Data Sheet 1M03296.

The IFT 3000 is heavy. Lifting and car-rying procedures should take accountof this weight.

a. Mechanical Installation

The outline drawing of the IFT module(CENELEC approved) in Figure 2-4 showsmounting centers and clearances. The en-closure is designed to be mounted on awall. The IFT should be installed no morethan 364 m (1200 ft) from the optional HPSor 45 m (150 ft) from the probe if HPS is notinstalled in the system. Ambient tempera-ture must be between 0°C and 50°C (32°Fand 122°F).

NOTEFuse specifications are included inFigure 2-4.

310 (12.2)

EXTERNALEARTH

INTERNALEARTH

FUSES

NOTES: ALL DIMENSIONS ARE IN MILLIMETERS WITH INCHES IN PARENTHESES UNLESSOTHERWISE INDICATED.

FUSES SHOWN (F3 THROUGH F6) ARE 5 AMP, ANTI-SURGE, TYPE T TO IEC127(ROSEMOUNT PART NUMBER 1L01293H02). IF INTERNAL HEATER IS INSTALLED,TWO ADDITIONAL 5 AMP FUSES (F1 AND F2) ARE USED.

18 (0.7) 300(11.8)

350 (13.8)

270 (10.6)

350(13.8)

225(8.9)

320(12.6)

35870001

Figure 2-4. Outline of Intelligent Field Transmitter



World Class 3000

ALWAYS DISCONNECT LINE VOLTAGEFROM INTELLIGENT FIELD TRANSMITTERBEFORE CHANGING JUMPERS.

JUMPERCONFIGURATION

LINE VOLTAGESELECTION

JUMPER(INSTALL)

PROBE HEATERVOLTAGE SELECTION

JUMPER(INSTALL)

120 V.A.C.

220 V.A.C.

240 V.A.C.

JM8, JM7, JM1

JM6, JM5, JM2

JM6, JM5, JM1

WORLD CLASS PROBE (44V) JM10

P00010

If you reconfigure the equipment for a line voltage other than the one marked on the seriallabel and the mains filter of the power supply then you should change the marking on theserial label and the mains filter to state the new line voltage.

If incorrect heater voltage is selected, damage to the probe may occur. For HPS voltageselection jumper, refer to Figure 2-15.

Figure 2-5. Power Supply Board Jumper Configuration

b. Electrical Connections

1. The IFT can be configured for 100,120, 220, or 240 line voltages. For 120Vac usage, install JM8, JM7, and JM1.For 220 Vac usage, install jumpersJM6, JM5, JM2 (refer to Figure 2-5 andFigure 2-6).

If you reconfigure the equipment for aline voltage other than the one markedon the serial label and the mains filterof the power supply you shouldchange the marking on the serial labeland the mains filter to state the newline voltage.

2. The IFT can be configured to connectdirectly to a probe or to an optionalHPS. The electrical connections for anon-HPS equipped system should bemade as described in the electrical in-stallation diagram, Figure 2-7.

Do not install jumper JM6 on the mi-croprocessor board, or JM1 on the in-terconnect board, if an HPS isinstalled in the system. This will resultin system failure.

3. The IFT must have JM6 on the micro-processor board (Figure 2-8 and Figure2-9) and JM1 on the interconnectboard (Figure 2-10 and Figure 2-11)installed if an HPS is not installed inthe system.

4. If an MPS is not used in the system,wire jumper between CAL RET and NOGAS must be installed on the intercon-nect board. Remove wire jumper ifMPS is installed in the system. Refer toFigure 2-7, note 6.

5. The power cable should comply withthe safety regulations in the user'scountry and should not be smaller than16 gauge, 3 amp.


January 2002


World Class 3000

P00011

THIS TERMINAL BLOCKIS A 44VAC OUTPUTSPECIFICALLY FORPOWERING THEWC 3000 PROBE.!

Figure 2-6. IFT Power Supply Board Jumpers



World Class 3000

LG. BR

GN/YE

BL

SHIELD

SHIELD

SHIELD

CAL RET

NO GAS

LO GAS

HI GAS

IN GAS

SHIELD

SHIELD

STACK TC -

STACK TC +

PROBEMV+

PROBE MV -

PROBE TC +

PROBE TC -GN

RD

WH

SM.BR

WH

SM. BR

GN

RD

INTELLIGENT FIELDTRANSMITTER IFT3000

WC 3000 PROBE(CENELEC APPROVED)

1 2 3 4 5 6 7 8

WH

SM

.B

R

RD

GN

PROBE INTERIOR

GN

/YE

BL

LG

.B

R

GN

CE

LL

-VE

OR

CE

LL

+V

E

YE

CH

RO

ME

L

RD

AL

UM

EL

GN

BK

BK}HEA

TE

R

PROBE JUNCTIONBOX WIRING

STACK TC WIRING AS REQUIRED

SPECIAL PROBE CABLE BETWEEN PROBE ANDIFT BY ROSEMOUNT (FITTED WITH EExdGLANDS)

INSTALL JM1 ON INTERCONNECT BOARD

INSTALL JM6 ON MICROPROCESSOR BOARD

IF STACK TEMPERATURE NOT USED

IF MPS 3000 NOT USED

1 RELAY PER PROBE AVAILABLE FORCALIBRATION STATUS INDICATION(48 V max, 100 mA max)

CABLE COLORS SHOWN HERE APPLY TOROSEMOUNT SUPPLIED SPECIAL CABLE FITTEDWITH EExd GLANDS(P/N 1U03066)

NOTES


LINEVOLTAGESECTION

JUMPER(INSTALL)

PROBE HEATERVOLTAGE SECTION

JUMPER(INSTALL)

120 V.A.C.

220 V.A.C.

240 V.A.C.

J1

J5 J6

J1

JM1

JM5JM6

J2J3

J4J5

J6J7

J8J9

3D39122G REV

POWER SUPPLY BOARD

3D3911BG REV

MICROPROCESSOR BOARD

3D39120G REV

INTERCONNECT BOARD

JM8, JM7, JM1

JM6, JM5, JM2

JM6, JM5, JM1

WORLD CLASS PROBE

218 PROBE

JM10

JM9

JUMPER CONFIGURATION

CA

LR

ET

CA

LR

ET

CA

LR

ET

CA

LR

ET

HI

GA

S

HI

GA

S

HI

GA

S

HI

GA

S

INC

AL

INC

AL

INC

AL

INC

AL

NO

GA

S

NO

GA

S

NO

GA

S

NO

GA

S

LO

GA

S

LO

GA

S

LO

GA

S

LO

GA

S

NC NC NCNC C C CC NO NO NONO

J13 J14 J15 J16 J17 J18 J12

J9LINE INLL

NN

J8J7J6J5J4J3J2J1LINE OUT

J10

J11

PROBE 1

PROBE 1

PROBE 2

PROBE 2

PROBE 3

PROBE 3

PROBE 4

PROBE 4

J19 J20 J21 J22

3D39064G REV

5 CONDUCTOR SHIELDED CABLEPER PROBE #16 AWG BY CUSTOMER

L

E

E

N

N

L

LINEVOLTAGE

LINEVOLTAGE

MPS TERMINATION BOARDMPS3000 MULTI GAS SEQUENCER (OPTIONAL)

ERH

35870007

Figure 2-7. Wiring Layout for IFT 3000 (CENELEC approved) System without HPS


January 2002


World Class 3000

JM7

JM6

J4

SW

1

TOI/

OB

OA

RD

3D39513GREV TO LDP CARD

TOP

OW

ERS

UP

PLY

CA

RD

TP4

+30V

ISO

-CG

ND

C+5

VIS

O-C

TP5

TP6

TO GUI CARD

J3

J2J1

TP1

-5V

TP2

+15V

TP8

+5V

TP3

-15V

TP7

JM7CURRENT/VOLTAGESELECTOR SWITCH

JM6

29850004

Figure 2-8. IFT Microprocessor Board Jumper Configuration



World Class 3000

OUTPUT JUMPER

HPSProbe (No HPS)

Remove JM6Install JM6

(See Figure 2-8 for jumper locations.)

Figure 2-9. IFT Microprocessor Board Jumpers

OUTPUT JUMPER

HPSProbe (No HPS)

Remove JM1Install JM1

Figure 2-10. Interconnect Board JumperConfiguration

6. Before supplying power to the IFT, ver-ify that the jumpers have been properlyset in the IFT, Figure 2-5, Figure 2-8,and Figure 2-10.

7. Terminal strip J5 on the power supplyboard is used for supplying the IFT withpower. Terminal strip J6 on the powersupply board is used to supply theprobe heater with power if an HPS isnot used (Figure 2-6).

8. Ensure that the IFT 3000 is properlyearthed by way of both the internal andexternal earthing hardware.

9. Ensure that the installation does notobscure the message on either the IFTnameplate or the IFT lid.

c. Analog Output and Relay OutputConnections

1. The microprocessor board has aswitch to select voltage or current op-erations. Figure 2-8 shows the switchlocation. In voltage mode, output is 0-10 V. In the current mode, the outputcan be configured from the setup menuto be 0-20 mA or 4-20 mA.

2. The analog output and relay outputsare programmed by the user asneeded. The analog output is typicallysent to recording equipment such aschart recorders. Relay outputs are typi-cally sent to annunciators.

3. Relays K1 and K2 are user configur-able from the PROBE SETUP sub-menu (Table 3-5). Typically these areused to indicate O2 values above orbelow specified tolerances. OK relay isenergized when unit is functioningproperly.

4. All wiring must conform to local andnational codes.

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


January 2002


World Class 3000

22

11

33

44

55

66

77

88

99

1010

1111

1212

1313

1414

1515

1616

1717

1818

1919

2020

2121

2222

2323

2424 OK-COM

OK-NO

K1-COM

K1-NO

K2-COM

K2-NO

ANOUT-ANOUT+

STACK T/C

STACK T/C

PROBE T/C

PROBE T/C

PROBE MV-

PROBE MV+

OK-NC

K1-NC

K2-NC

CAL INIT-2

CAL INIT-1

CALRET

NOGAS

LOGAS

HIGAS

INCAL

RELAY-RELAY+

AD590-AD590+

TRIAC-

TRIAC+ JM1(UNDERSHIELD)

NOTES:

DENOTES SHIELD CONNECTION.

OK RELAY IS ENERGIZED WHENUNIT IS FUNCTIONING PROPERLY.

730002

Figure 2-11. IFT Interconnect Board Output Connections



World Class 3000

2-3 HEATER POWER SUPPLY INSTALLATION

The Rosemount encode sheets (Prod-uct Ordering Matrix) allow a customerto order either the hazardous area ver-sion of the HPS 3000 or the non-hazardous area version. The hazard-ous area version has the symbol"EExd" on the apparatus nameplate.The non-hazardous area version doesnot. Ensure that if you have receivedthe non-hazardous version that you donot install it in a potentially explosiveatmosphere. This also applies to thehazardous/non-hazardous version ofthe IFT 3000.

Before HPS installation, consult SafetyData Sheet 1M03243.


The outline drawing of the CENELEC ap-proved heater power supply enclosure inFigure 2-12, shows mounting centers andclearances. The CENELEC approved en-closure is designed to be mounted on a wallor bulkhead. The heater power supplyshould be installed no further than 45 m(150 ft) from the probe. The heater powersupply must be located in a location freefrom significant ambient temperaturechanges and electrical noise. Ambient tem-perature must be between 0° to 60°C (32°to 140°F).

b. Electrical Connections

1. Electrical connections should be madeas described in the electrical installa-tion diagram, Figure 2-13. The wiringterminals are divided into two layers:the bottom (FROM PROBE) terminalsshould be connected first, the top(FROM ELECTRONICS) terminalsshould be connected last (Figure 2-14).Each terminal strip has a protectivecover which must be removed whenmaking connections. To remove the

253(9.96)

233(9.17)

120(4.72)

157(6.18)

216.0(8.50)

264.0(10.39)

EExd IIC T6ENCLOSURE

14.22 (0.56) DIAMTG HOLE (2 PLS)

NOTE: DIMENSIONS ARE IN MILLIMETERSWITH INCHES IN PARENTHESESUNLESS OTHERWISE INDICATED. 219005

Figure 2-12. Outline of CENELEC Approved HeaterPower Supply

terminal covers, remove two slottedscrews holding cover in place. Alwaysreinstall terminal covers after makingconnections.

2. Power Input: 120, 220 or 240 Vac. For120 Vac usage, install jumpers JM4and JM1 and remove JM5 if installed.For 220 or 240 Vac usage, installjumper JM5 and remove JM1 and JM4if installed (see label, Figure 2-15).

If you reconfigure the equipment for aline voltage other than the one markedon the serial label and the mains filterof the power supply then you shouldchange the marking on the serial labeland the mains filter to state the newline voltage.

NOTEFuse specifications are shown inFigure 2-14.


January 2002


World Class 3000

+

+

+

+

+

+

+

+

+

-

-

-

-

-

-

-

-

-

BK WHJ9

J8

J3

J2 J1

TRIAC RELAYSTACK

TCANALOGHEATER

PROBEMV

PROBEMV

PROBETC

PROBETC

AD590

SM. BR CELL+

RD HTR TC +

WH CELL -

GN HTR TC -

LG. BR

BL

GN/YE

STACKTC

PROBEHEATER

R H N L

LINEVOLTAGESHIELD

TOP

BOTTOM

4 TWISTED PAIR SHIELDED#22 AWG BY CUSTOMER

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

HPS 3000 INTERFACE MODULE

LINE

WC PROBE 3000 CENELEC APPROVED

1 2 3 4 5 6 7 8

WH

SM

.B

R

RD

GN

PROBE INTERIOR

GN

/YE

BL

LG

.B

R

GN

CE

LL

-VE

OR

CE

LL

+V

E

YE

CH

RO

ME

L

RD

AL

UM

EL

GN

BK

BK}HEA

TE

R

PROBE JUNCTIONBOX WIRING

ALWAYS DISCONNECT LINE VOLTAGEFROM HEATER POWER SUPPLY ANDANALOG ELECTRONICS (IF USED)BEFORE CHANGING JUMPERS.

JUMPERCONFIGURATIONS


JUMPER(INSTALL)

JUMPER(INSTALL)

HEATERPOWER JUMPER

120 V.A.C.

220/240 V.A.C.

JM4, JM1

JM5

REMOTE

ON

REMOVE JM2

INSTALL JM2

ELECTRONICSSELECTION

JUMPERPROBE HEATER

VOLTAGE SECTION

REMOVE JM3, JM6NEW GENERATIONELECTRONICS

WORLD CLASS PROBE JM7

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

STACK TC WIRING AS REQUIRED

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

SPECIAL PROBE CABLE BETWEEN PROBE AND HPSBY ROSEMOUNT

REMOVE JM1 ON INTERCONNECT BOARD (IFT 3000)

REMOVE JM6 ON MICROPROCESSOR BOARD

IF RELAY WIRE OF NOTE 1 INSTALLED THEN REMOVEJM2 ON HPS 3000

IF STACK TEMPERATURE NOT USED

IF MPS 3000 NOT USED

1 RELAY PER PROBE AVAILABLE FOR CALIBRATIONSTATUS INDICATION (48 V max, 100 mA max)

CABLE COLORS SHOWN HERE APPLY TO ROSEMOUNTSUPPLIED SPECIAL CABLE FITTED WITH EExd GLANDS(P/N 1U03066)

NOTES

35870008

B

A

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



World Class 3000

MPS TERMINATION BOARDMPS3000 MULTIPROBE CALIBRATION GAS SEQUENCER (OPTIONAL)

L

E

N

LINEVOLTAGE

J13 J14 J15 J16 J17 J18

J9

J8J7J6J5J4J3J2J1

J19 J20 J21 J22

J12

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

LO

GA

S

LO

GA

S

LO

GA

S

LO

GA

S

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

L

N

L

N

LINE OUT LINE IN

J10

J11

PROBE 1 PROBE 2 PROBE 3 PROBE 4

PROBE 1 PROBE 2 PROBE 3 PROBE 4

PR

OB

E1

SO

LEN

OID

PR

OB

E2

SO

LEN

OID

PR

OB

E3

SO

LEN

OID

PR

OB

E4

SO

LEN

OID

HIG

HG

AS

SO

LEN

OID

LO

WG

AS

SO

LEN

OID

PR

ES

SU

RE

SW

ITC

H

SHIELD

SHIELD

RELAY –

RELAY +

TRIAC +

CAL RET

SHIELD

NO GAS

AD590 –

LO GAS

AD590 +

HI GAS

SHIELD

IN CAL

TRIAC –

SHIELD

SHIELD

STACK TC –

STACK TC +

PROBE MV –

PROBE MV +

PROBE TC +

PROBE TC –

INTELLIGENT FIELDTRANSMITTER IFT 3000


LINEVOLTAGESECTION

JUMPER(INSTALL)

PROBE HEATERVOLTAGE SECTION

JUMPER(INSTALL)

100 V.A.C.

120 V.A.C.

220 V.A.C.

200 V.A.C.

240 V.A.C.

J1

J5 J6

J1

JM1

JM6 JM5

J2J3

J4J5

J6J7

J8J9

3D39122G REV

POWER SUPPLY BOARD

3D39118G

MICROPROCESSOR

BOARD

3D39120G REV

INTERCONNECT BOARD

JM3, JM7, JM2

JM8, JM7, JM1

JM6, JM5, JM2

JM4, JM5, JM2

JM6, JM5, JM1

NOT USED REMOVEJM9, JM10

JUMPER CONFIGURATION

ENL

LINEVOLTAGE

NOT USED

5 CONDUCTOR SHIELDED CABLEPER PROBE #16 AWG BY CUSTOMER

A

B

5

34990011

3D390646 REV

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


January 2002


World Class 3000

JM8

JM5JM4

JM2

JM

1

JM7

J7

J2

SCREW(2 PER COVER)

TERMINALCOVERS

(PROVIDED)

EXTERNALEARTHING

HARDWARE

INTERNALEARTHING

HARDWARE

TERMINALSTRIP(FROM PROBE)

219006-1

TERMINALSTRIP (FROMELECTRONICS)

TRANSFORMER

FRONT VIEW SIDE VIEW

FUSES

FUSE

NOTE: FUSES SHOWN (F1 THROUGH F4) ARE 5 AMP, ANTI-SURGE,TYPE T TO IEC127 (ROSEMOUNT PART NUMBER 1L01293H02).

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

ALWAYS DISCONNECT LINE VOLTAGEFROM HEATER POWER SUPPLY ANDANALOG ELECTRONICS (IF USED)BEFORE CHANGING JUMPERS.

JUMPERCONFIGURATIONS


JUMPER(INSTALL)

JUMPER(INSTALL)

HEATERPOWER JUMPER

120 V.A.C.

220/240 V.A.C.

JM4, JM1

JM5

*ON

REMOTE

INSTALL JM2

REMOVE JM2

ELECTRONICSSELECTION

JUMPERPROBE HEATER

VOLTAGE SELECTION

REMOVE JM3, JM6NEW GENERATION

ELECTRONICS*WORLD CLASS PROBE

(44V)JM7

219007

Figure 2-15. Jumper Selection Label.

If you reconfigure the equipment for a line voltage other than the one marked on the serial la-bel and the mains filter of the power supply then you should change the marking on the seriallabel and the mains filter to state the new line voltage.



World Class 3000

3. The power cable should comply withsafety regulations in the user's countryand should not be smaller than 16gauge, 3 amp.

Before supplying power to the heaterpower supply, verify that jumpers JM3and JM6 are removed, and JM7 is in-stalled. If relay wire (Figure 2-13, Note1) is installed, JM2 must be removedfrom HPS Motherboard (Figure 2-16).

4. Before supplying power to the heaterpower supply, verify that the jumperson the motherboard, Figure 2-16, areproperly configured. Jumpers JM3,JM6, should be removed and JM7should be installed. Additionally, makesure that the proper jumper for yourline voltage is installed, Figure 2-15. Ifrelay wire (Figure 2-13, note 1) is notinstalled, JM2 should be installed onthe HPS Motherboard (Figure 2-16).

5. Ensure that the HPS 3000 is properlyearthed by way of both the internal andexternal earthing points.

6. Ensure the installation does not ob-scure the messages on either the HPSnameplate or HPS lid.

NOTERefer to Figure 2-8 and Figure 2-10 forproper IFT jumper configuration. IFTmicroprocessor and interconnectboard jumper configurations must beset correctly in order for HPS to workproperly.

Figure 2-16. Jumpers on HPS Motherboard

2-4 MULTIPROBE TEST GAS SEQUENCERINSTALLATION

The MPS 3000 Multiprobe Test GasSequencer must be installed in a non-hazardous, explosive-free environ-ment.

NOTEA Z-Purge option is available for theMPS 3000. Appendix DX contains in-formation concerning the Z-Purge.


The outline drawing of the MPS module inFigure 2-17 shows mounting centers andclearances. The box is designed to bemounted on a wall or bulkhead. The MPSmodule should be installed no further than91 m (300 ft) piping distance from theprobe, and no more than 303 m (1000 ft)cabling distance from the IFT. Install theMPS module in a location where the ambi-ent temperature is between -30° and 71°C(-20° and 160°F).


January 2002


World Class 3000

HIGH CALGAS IN

LOW CALGAS IN

TEST GASOUT

REF AIROUT

INSTRAIR

REF AIROUT

REF AIROUT

REF AIROUT

TEST GASOUT

TEST GASOUT

TEST GASOUT

PROBE 1 PROBE 2 PROBE 3 PROBE4

21.34 (0.84)

49.78 (1.96)

106.93 (4.21)

78.49 (3.09)

133.35 (5.25)

140.72 (5.54)

355.60 (14.00) REF

304.80(12.00)

304.80(12.00)

254.00(10.00)

35870002

DIMENSIONS ARE INMILLIMETERS WITHINCHES IN PARENTHESES.

NOTE:

Figure 2-17. MPS Module

b. Gas Connections

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

1. Connect the reference air supply toINSTR. AIR IN. The air pressureregulator valve is set at the factory to

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

2. Connect the high O2 test gas to HIGHGAS. The test gas pressure should beset at 138 kPa (20 psi).



World Class 3000

HIGH CALGAS IN

LOW CALGAS IN

TEST GASOUT

REF AIROUT

INSTRAIR

REF AIROUT

REF AIROUT

REF AIROUT

TEST GASOUT

TEST GASOUT

TEST GASOUT

PROBE 1 PROBE 2 PROBE 3 PROBE4

LINE IN

SIGNAL IN

DRAIN

35870003

Figure 2-18. MPS Gas Connections

Do not use 100% nitrogen as a low(zero) gas. It is suggested that the lowgas be between 0.4% and 2.0% O2. Donot use gases with hydrocarbon con-centrations of more than 40 parts permillion. Failure to use proper gaseswill result in erroneous readings.

3. Connect the low O2 test gas to LOWGAS. The test gas pressure should beset at 138 kPa (20 psi).

4. Connect the REF AIR OUT to the ref-erence gas fitting on the probe junctionbox.

5. Connect the TEST GAS OUT to thecalibration gas fitting on the probejunction box.

6. If the MPS is configured for multipleprobes (up to four), repeat steps 4 and5 for each additional probe.

A check valve is required for eachprobe connected to an MPS to preventcondensation of flue gas in the cali-bration gas lines. The check valvemust be located between the calibra-tion fitting and the gas line.

c. Electrical Connections

Electrical connections should be made asdescribed in the electrical installation dia-gram, Figure 2-19. All wiring must conformto local and national codes. The electricalconnections will exist only between theelectronics package and the MPS to enableautomatic and semiautomatic calibration. Ifmore than one probe system is being used,the additional probes and electric packageswould be wired similarly to the first probe.

NOTEMPS power supply fuse locations andspecifications are shown in Figure2-19.


January 2002


World Class 3000

Figure 2-19. MPS Electrical Connections



World Class 3000

1. Run the line voltage through the bulk-head fitting on the bottom of the MPSwhere marked LINE IN, Figure 2-18.Refer to Figure 2-19. Connect the linevoltage to the LINE IN terminal on theMPS terminal board located inside theunit. Tighten the cord grips to providestrain relief.

2. The MPS can accommodate up to fourprobes. The terminal strips on the MPStermination board are marked PROBE1, PROBE 2, PROBE 3, and PROBE 4.

Select PROBE 1 if this is the first probeand electronic package installed on theMPS.

3. Make the connections from the MPS tothe IFT as shown in Figure 2-19. Runwires from the MPS Termination Boardinside the unit through the bulkhead fit-ting on the bottom of the unit wheremarked SIGNAL IN, Figure 2-18. Afterthe connections are made, tighten thecord grips to provide strain relief.

NOTE!

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

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

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


January 2002

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

World Class 3000

SECTION 3SETUP AND OPERATION

See Safety Data Sheet 1M03296 for safety related information.

3-1 OVERVIEW

Ensure that the oxygen analyzer, heater powersupply, and intelligent field transmitter havebeen properly connected. It is important tocheck that grounding and screening of termina-tions are correctly made to prevent the introduc-tion of ground loops. The IFT is equipped withnoise suppression circuitry on the power supplyand signal input lines. Proper grounding at in-stallation will ensure accuracy of function.

The following five languages can be selectedwithin the IFT:

English ItalianFrench SpanishGerman

The Intelligent Field Transmitter may be sup-plied with any one of three configurations.These configurations are the blind version, dis-play only version, and the deluxe version. Thethree versions differ as follows.

a. Blind Version

HART connections must be made out-side of the hazardous area. Becausethe Hart option is not protected by en-ergy limiting barriers, it must not beinterfaced from within a hazardousarea. The signal cables should berouted outside the hazardous area andthe connections made external to thehazardous area.

The blind version has no display and nokeypad. With this version, an external HARTcommunications device is required. Refer toAppendix JX regarding the HART Commu-nications option.

b. Display Only Version (LDP)

The display only version is also known asthe LED Display Panel (LDP) version. ThisIFT contains a bright LED display and afour-key pad. The LDP version provides forcalibration capability only.

c. Deluxe Version (GUI)

The deluxe version is also known as theGeneral User Interface (GUI) version. ThisIFT contains an LED display, liquid crystaldisplay panel, and an eight-key pad that al-lows probe and electronics configuration,calibration, and troubleshooting of the probeand electronics.

This section of the manual deals with operatorcontrols and displays available with the GUIequipped IFT. Operating parameters are listedand instructions are included for viewing andchanging them.

Operating instructions for the IFT equipped withthe LDP and four membrane keys are includedin Section 4.

Any procedures not associated with normal op-eration are included in Section 2, Installation, orSection 5, Troubleshooting.


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

World Class 3000

SETUP

ENTER

CALHELP

ESC

DATA

34990016

3

2

1

13 12 11 10

9

8

CALTGHTGL

5

6

7

4

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

3-2 IFT WITH GUI AND LDP FRONT PANELCONTROLS AND INDICATORS (See Figure3-1.)

Fig. 3-1Index

No.Control/

LED Description1 HELP Context sensitive HELP is

displayed when this key ispressed.

2 DATA DATA key is used to accessDATA menu.

3 LCDDisplay

Top line displays systemstatus, menu and probenumber.

4 LEDDisplay

Indicates current O2 or testvalue (only in LDP equippedunits).

5 CAL Calibration in progressindicator light (only in LDPequipped units).

6 TGH High test gas indicator light.High test gas is being used incalibration process (only inLDP equipped units).

7 TGL Low test gas indicator light.Low test gas is being used incalibration process (only inLDP equipped units).

8 CAL CAL key used to accessCALIBRATE menu.

9 SETUP SETUP key used to accessSETUP menu.

10 ENTER The ENTER key is used toselect a lower level menu,initiate calibration, or select aparameter to change.

11 � The increase key is used tomove the cursor (asterisk)when scrolling through lists orto increase a parametervalue.

12 � The decrease key is used tomove the cursor (asterisk)when scrolling through lists orto decrease a parametervalue.

13 ESC The escape key is used toexit to a high level menu or toabort a parameter change.

3-3 HELP KEY

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

Table 3-1. Sample HELP Messages

MENU, SUB-MENU,HELP OR

PARAMETER NAME MESSAGE

PROBE DATA Press ENTER keyto access DATAmenu.

CALIBRATE O2 The CAL menu isused to start cali-bration and viewcalibration.

SETUP The SETUP menuis used to configurethe IFT-3000.


January 2002


World Class 3000

3-4 STATUS LINE

The top line of the LCD display (3, Figure 3-1) isa status line that always displays system status,menu name, and O2 level. The system statusdisplays are:

a. OK - System is functioning correctly.

b. CAL - Calibration in progress.

c. C Err - Calibration error.

d. H Err - Heater error.

e. TGLow - Test gas is low.

f. HiO2 - O2 value is above the high alarmlimit.

g. LoO2 - O2 value is below the low alarm limit.

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

i. Off - The probe has been turned off be-cause the IFT cannot control the heatertemperature.

j. PRBE - The probe is disconnected, cold, orleads are reversed.

3-5 QUICK REFERENCE CHART

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

3-6 MAIN MENU

When power is first applied to the IFT, the MAINmenu (Table 3-2) is initially displayed. It is fromthe MAIN menu that the PROBE DATA (Table3-3), CALIBRATE O2 (Table 3-4), and SETUP(Table 3-5) menus can be accessed.

Table 3-2. Main Menu

MENU SELECTION DESCRIPTION

PROBE DATA Refer to Table 3-3.

CALIBRATE O2 Refer to Table 3-4.

SETUP Refer to Table 3-5.

Table 3-3. PROBE DATA Sub-Menu.

SUB-MENUSELECTION PARAMETER DESCRIPTION

Process Data O2 __%Efficiency ENA/DISStack Temp __DegC

O2 value for the probe.Enable/Disable efficiency display.Stack temperature.

Diagnostic Data

Temperature Cell __DegCStack __DegCCold Junct __DegC

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

Voltages Cell __mVCell T/C __mVStk T/C __mVCold Jnt __mV

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

Output Values Analog __% FSK1 State OFF/ONK2 State OFF/ON

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



World Class 3000

2

MAIN MENU

PROBE DATA CALIBRATE O

PROCESS DATA DIAGNOSTIC DATAPERFORM

CALIBRATIONVIEW

CONSTANTSCALIBRATION

STATUS

O

EFFICIENCY

STACK TEMPTEMPERATURE VOLTAGES OUTPUT VALUES

SLOPE

CONSTANT

RESIST

NEXT CAL

SLOPE

CONSTANT

RESIST

A

CELL

STACK

COLD JUNCT

CELL

CELL T/C

STK T/C

COLD JNT

ANALOG

K1 STATE

K2 STATE

2

QUICK REFERENCE CHART


January 2002


World Class 3000

22

SETUP

CALIBRATION O CALCULATION O ALARMS

HIGH GAS

LOW GAS

AUTO CAL

OUTPUT TRACKS

CAL INTRVL

NEXT CAL

GAS TIME

PURGE TIME

RES ALARM

SLOPE

CONSTANT

SET POINT

LOAD CONSTANTS

HI ALARM

LO ALARM

ALARM DB

EFFICIENCY CALC

ENABLE CALC

K1 VALUE

K2 VALUE

K3 VALUE

RELAY OUTPUT

K1 SETUP K2 SETUP

EVENT 1

EVENT 2

EVENT 3

EVENT 1

EVENT 2

EVENT 3

ANALOG OUTPUTS

SOURCE

AOUT TYPE

A



World Class 3000

3-7 PROBE DATA SUB-MENU

The PROBE DATA sub-menu is a list of all theparameters of the system as it is currently con-figured. To access the PROBE DATA sub-menu, press the DATA key at any time. The in-crease and decrease keys are used to scrollthrough the list. The PROBE DATA sub-menucan be viewed b

Documents

World Class 3000 - Emerson Electric...1993/12/14 · World Class 3000 Typical Application with Intelligent Field Transmitters - CENELEC Approved ..... 1-6 Figure 2-1. Probe Figure