Emerson Electric€¦ · 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

Instruction ManualIB-106-300NC Rev. 4.4February 1998

http://www.processanalytic.com

World Class 3000Oxygen Analyzer with CRE 3000Control Room Electronics

Emerson Process Management

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


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 October, 1995 Rev. 4

Page Summary

--- General. Updated art to reflect new probe configuration.

Page 2-1 Changed installation procedure to include optional ceramic diffusorand vee deflector.

Page 3-16 Added manual block valve requirement to required equipment

Effective June, 1996 Rev. 4.1

Page Summary

Page 2-2, 2-3 Updated figure to reflect probe modification.

Page 3-13, 3-15,3-17

Added note regarding ambient air not recommended for use as hightest gas.

Effective January, 1997 Rev. 4.2

Page Summary

P-2 Added "Safety instructions for the wiring and installation of thisapparatus".

Page 1-6 Added NOTE 8 regarding fuse specifications and changed probeground lead color code to GN/YE in Figure 1-3.

Page 2-1 Added one WARNING to read new safety instructions and anotherWARNING regarding protective covers and grounds.

Page 2-8 Deleted obsolete paragraphs 2-2b.1 and 2-2b.2.

Page 2-10 Added NOTE regarding reference to Figure 2-6 for CRE unit fuse lo-cations and specifications and added NOTE regarding CRE fusespecifications to Figure 2-6.

Page 2-13 Added NOTE regarding reference to Figure 2-16 for HPS fuse loca-tions and specifications.

Page 2-14 Changed probe ground lead color code to GN/YE in Figure 2-13.

Page 2-17 Added NOTE regarding HPS fuse specifications to Figure 2-16.

Page 2-20 Added NOTE regarding reference to Figure 2-19 for MPS fuse loca-tions and specifications.

Page 2-20 Added NOTE regarding MPS fuse specifications to Figure 2-19.

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

Page 7-1 Added fuses to index listing.

HIGHLIGHTS OF CHANGES (CONTINUED)

Effective May, 1997 Rev. 4.3

Page Summary

Page P-2 Added safety sheet.

Effective February, 1998 Rev. 4.4

Page Summary

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

Page 3-15 Add note on test gas flowmeter.

HIGHLIGHTS OF CHANGESAPPENDIX A

Effective May, 1996 Rev. 3

Page Summary

-- General. Updated appendix to reflect probe design changes.

Page A-13 Added �Extended temperature by-pass arrangements� to Figure A-13(Sheet 3 of 3)

Effective June, 1996 Rev. 3.1

Page Summary

Page A-13 Updated part ordering information.

Effective August, 1996 Rev. 3.2

Page Summary

Page A-25 Updated cell replacement kit part numbers for the probe.

Effective October, 1996 Rev. 3.3

Page Summary

Page A-6 Added NOTE to Figure A-7.


Page Summary

Page A-1 Added warning to read new safety instructions.

Page A-12 Added protective covers and grounds warning.

Page A-16 Added protective covers and grounds warning.


Page Summary

Page A-18 Changed screw torque in paragraph A-11h.

Effective July, 1998 Rev. 3.6

Page Summary

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

HIGHLIGHTS OF CHANGESAPPENDIX B

Effective February, 1992 Rev. 2

Page Summary

Page B-1 Figure B-1. New HPS 3000 Optional Class 1, Division 1, Group B(IP56) Explosion-Proof Enclosure added.

Page B-11 Figure and Index No. column added to Table B-2. Replacement Partsfor Heater Power Supply.


Page Summary

Page B-3 Updated Figure B-3, Heater Power Supply Block Diagram for IBconsistency.


Page Summary

Page B-1 Added warning to read new safety instructions.

Page B-3 Corrected Table B-1 specifications list.

Page B-4 Added protective covers and grounds warning.

Page B-8 Added protective covers and grounds warning.

Page B-11 Added expanded fuse description.

HIGHLIGHTS OF CHANGESAPPENDIX C


Page Summary

Page C-4 Figure C-3. Optional Panel Mounting Kit description added.

Page C-14 Figure and Index No. column added to Table C-2. Replacement Partsfor the Master/Slave CRE 3000 Module.


Page Summary

Page C-5 Updated Figure C-4 for IB consistency.


Page Summary

Page C-5 Updated art to reflect new probe configuration.


Page Summary

Page C-1 Added warning to read new safety instructions.

Page C-6 Added protective covers and grounds warning.

Page C-6 Added reference to Table C-1 for replacement fuse specifications.

Page C-6 Amended Legend for Figure C-5.

Page C-7 Removed obsolete jumper, Item 14 from Figure C-5.

Page C-9 Deleted obsolete paragraph C-6c.

Page C-14 Revised Table C-2 to introduce new power supply and added ex-panded fuse description.

HIGHLIGHTS OF CHANGESAPPENDIX D

Effective June, 1994 Rev. 2

Page Summary

Page D-1Page D-2Page D-3Page D-4Page D-7

Page D-8Page D-10Page D-11

MPS outline drawing changed to show new MPS.MPS interior view replaced with new MPS in Figure D-2."Optional" for check valve deleted in Figure D-3.Drawing showing location of optional Z-Purge added as Figure D-4.Power supply replacement procedures in paragraph D-7 changed toreflect new design in the MPS. Solenoid valve replacement proce-dures in paragraph D-8 changed to reflect new design in the MPS.Old exploded view of MPS replaced with new MPS.Paragraph D-11, Adding Probes to the new MPS, added.Change part numbers for the power supply, solenoid valve, and testgas flowmeter assembly. Add part numbers for reference gas flow-meter assembly and all the parts in the probe adder kit.


Page Summary

Page D-1 Updated Figure D-1, MPS 3000 to include hinge.

Effective May, 1996 Rev. 2.2

Page Summary

Page D-11 Updated replacement parts list to reflect new part numbers.


Page Summary

Page D-1Page D-2Page D-5Page D-7

Page D-11

Added warning to read new safety instructions.Corrected Table D-1 Specifications listing, 1st entry.Added protective covers and grounds warning.Added protective covers and grounds warning, corrected item num-ber errors in paragraph D-6.Added expanded fuse descriptions.

Effective July, 1998 Rev. 2.4

Page Summary

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

HIGHLIGHTS OF CHANGESAPPENDIX G


Page Summary

Page G-8 Figure G-5. Optional Panel Mounting Kit description added.

Page G-16 Figure and Index No. column added to Table G-3. Replacement Partsfor the Master/Slave CRE 3000 Module.


Page Summary

Page G-6 Updated Figure G-4 for IB consistency.


Page Summary

Page G-2 Updated art to reflect new probe configuration.



Effective September, 1996 Rev. 1.3

Page Summary

Page G-2 Updated part numbers for processor board and DPI card.


Page Summary

Page G-1 Added warning to read new safety instructions.

Page G-9 Added warning to read new safety instructions and protective coversand ground warning.

Page G-13 Removed obsolete jumper, Item 14 from Figure G-8.

Page G-14 Amended Legend for Figures G-8 and G-9, Item 14.

Page G-15 Removed obsolete jumper, Item 14 from Figure G-9.

Page G-16 Added protective covers and grounds warning.

Page G-16 Revised Table G-3 to introduce new power supply and added ex-panded fuse description.

Instruction ManualIB-106-300NC Rev. 4.4

February 1998

Rosemount Analytical Inc. A Division of Emerson Process Management i

World Class 3000

TABLE OF CONTENTS

PREFACE........................................................................................................................P-1Definitions ........................................................................................................................ P-1Safety Instructions .......................................................................................................... P-2

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

2-0 INSTALLATION .............................................................................................................. 2-12-1 Oxygen Analyzer (Probe) Installation........................................................................... 2-12-2 Control Room Electronics Module Installation............................................................. 2-82-3 Heater Power Supply Installation ............................................................................... 2-132-4 Multiprobe Test Gas Sequencer Installation ............................................................. 2-172-5 Installation With Two Multiprobe Test Gas Sequencers .......................................... 2-21

3-0 OPERATION ................................................................................................................... 3-13-1 Overview.......................................................................................................................... 3-13-2 Front Panel Controls And Indicators .......................................................................... 3-13-3 Status Line...................................................................................................................... 3-23-4 Help Key ......................................................................................................................... 3-33-5 Quick Reference Chart .................................................................................................. 3-33-6 Main Menu ...................................................................................................................... 3-33-7 Data Sub-Menu............................................................................................................... 3-33-8 Calibrate Sub-Menu........................................................................................................ 3-83-9 Using The Setup Sub-Menu ......................................................................................... 3-83-10 Calibration...................................................................................................................... 3-12

4-0 TROUBLESHOOTING.................................................................................................... 4-14-1 Overview.......................................................................................................................... 4-14-2 Special Troubleshooting Notes...................................................................................... 4-14-3 Probe Troubleshooting ................................................................................................... 4-14-4 CRE Alarm Messages ................................................................................................... 4-3

5-0 RETURN OF MATERIAL ................................................................................................ 5-1

6-0 APPENDICES ................................................................................................................. 6-1Appendix A ...................................................................................................................... A-1Appendix B ...................................................................................................................... B-1Appendix C ......................................................................................................................C-1Appendix D ......................................................................................................................D-1Appendix G......................................................................................................................G-1

7-0 INDEX.............................................................................................................................. 7-1

Instruction ManualIB-106-300 NC Rev. 4.4February 1998

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. Typical System Wiring (Sheet 1 of 3) .................................................................... 1-6Figure 1-4. Control Room Electronics with 6 World Class 3000 Probes ................................. 1-9Figure 1-5. Control Room Electronics with 8 World Class 3000 Probes ............................... 1-10Figure 2-1. Probe Installation (Sheet 1 of 5) ............................................................................ 2-2Figure 2-2. Orienting the Optional Vee Deflector ..................................................................... 2-7Figure 2-3. Air Set, Plant Air Connection ................................................................................. 2-8Figure 2-4. Control Room Electronic Dimensions.................................................................... 2-9Figure 2-5. Panel Cutout for Control Room Electronic Module................................................ 2-9Figure 2-6. CRE Power, Analog Output, and Relay Output Connections.............................. 2-10Figure 2-7. Analog Output Card Jumpers .............................................................................. 2-11Figure 2-8. Relay Output Panel Jumper Configuration .......................................................... 2-11Figure 2-9. Relay Output Card Jumper Configuration ........................................................... 2-12Figure 2-10. DPI Card Jumpers ............................................................................................... 2-12Figure 2-11. Optional Trim Frame and Rear Cover ................................................................. 2-12Figure 2-12. Outline of Heater Power Supply .......................................................................... 2-13Figure 2-13. Electrical Installation of Heater Power Supply..................................................... 2-14Figure 2-14. Heater Power Supply Wiring Connections .......................................................... 2-15Figure 2-15. Jumper Selection Label ....................................................................................... 2-16Figure 2-16. Jumpers on HPS Mother Board........................................................................... 2-17Figure 2-17. MPS Module ........................................................................................................ 2-18Figure 2-18. MPS Gas Connections ........................................................................................ 2-19Figure 2-19. Typical CRE to MPS Connections ....................................................................... 2-20Figure 2-20. Typical CRE to MPS Connections, 5 or 6 Probes ............................................... 2-22Figure 2-21. Typical CRE to MPS Connections, 7 or 8 Probes ............................................... 2-24Figure 3-1. CRE Front Panel.................................................................................................... 3-1Figure 3-2. Quick Reference Chart (Sheet 1 of 2) ................................................................... 3-4Figure 3-3. Typical Calibration Setup..................................................................................... 3-14Figure 3-4. Portable Rosemount Oxygen Test Gas Kit......................................................... 3-15Figure 3-5. Typical Portable Test Calibration Setup ............................................................. 3-16Figure 3-6. Typical Automatic Calibration System ................................................................. 3-18

LIST OF TABLES

Table 2-1. Analog Output Card Jumper Configuration ......................................................... 2-11Table 2-2. DPI Card Jumper Configuration........................................................................... 2-11Table 2-3. Typical CRE SETUP Data for 5 or 6 Probe Configuration................................... 2-21Table 2-4. Typical CRE SETUP Data for 7 or 8 Probe Configuration................................... 2-23Table 3-1. Sample HELP Messages....................................................................................... 3-3Table 3-2. MAIN Menu ............................................................................................................ 3-3Table 3-3. DATA Sub-Menu.................................................................................................... 3-6Table 3-4. Perform Calibration Error Messages ..................................................................... 3-8Table 3-5. CALIBRATE Sub-Menu ......................................................................................... 3-9Table 3-6. SETUP Sub-Menu ............................................................................................... 3-10Table 3-7. Efficiency Constants. ........................................................................................... 3-12Table 4-1. Fault Finding .......................................................................................................... 4-2


February 1998

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

World Class 3000

PREFACE

The purpose of this manual is to provide information concerning the components, func-tions, installation and maintenance of this particular World Class 3000 module.

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.

DEFINITIONS

The 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.

NOTE

Highlights an essential operating procedure,condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO 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 APPARATUS

The 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.


February 1998

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

World Class 3000

13

2

4

5

6

7

8

19270001

SECTION 1DESCRIPTION

1-1 COMPONENT CHECKLIST OF TYPICALSYSTEM (PACKAGE CONTENTS)

A typical Rosemount World Class 3000 OxygenAnalyzer with CRE 3000 Control Room Elec-

tronics should contain the items shown in Figure1-1. Record the part number, serial number, andorder number for each component of your sys-tem in the table located on the first page of themanual.

1. Control Room Electronics 2. Instruction Bulletin 3. Multiprobe Test Gas Sequencer (Optional) 4. Heater Power Supply 5. Oxygen Analyzer (Probe) 6. System Cable 7. Adapter Plate with mounting hardware and gasket 8. Reference Air Set (If MPS not supplied)

Figure 1-1. Typical System Package


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

World Class 3000

1-2 SYSTEM OVERVIEW

a. Scope

This Instruction Bulletin has been designedto supply details needed to install, start up,operate, and maintain the Rosemount WorldClass 3000 Oxygen Analyzer with CRE3000 Control Room Electronics. The ControlRoom Electronic Module (CRE) can be in-terfaced with up to eight World Class 3000probes. The CRE provides all necessaryintelligence for controlling the probe and op-tional MPS 3000 Multiprobe Test GasSequencer.

Appendices, at the back of this manual,detail each component and option from thestandpoint of troubleshooting, repair, andspare parts.

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) + C0

Where:1 P2 is the partial pressure of the oxygen

in 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.

NOTE

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

When the cell is at operating temperatureand 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 is pro-portional to the logarithm of the inverse ofthe sample of the oxygen partial pressure,the output signal increases as the oxygenconcentration of the sample gas decreases.This characteristic enables the oxygenanalyzer to provide exceptional sensitivity atlow 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 Orsat appa-ratus, which provides an analysis on a "dry"gas basis, the "wet" analysis will, in general,indicate a lower percentage of oxygen. Thedifference will be proportional to the watercontent of the sampled gas stream.

c. System Configuration

The equipment discussed in this manualconsists of three major components: theoxygen analyzer (probe), the control roomelectronics (CRE), and the heater powersupply (HPS). The HPS is required whenthe cable run between the probe and theelectronics is greater than 150 feet (46 m).There is also an optional multiprobe test gassequencer (MPS) to facilitate automaticcalibration of the probes.

Probes are available in five length options,giving the user the flexibility to use an in situpenetration appropriate to the size of thestack or duct. The options on length are 18inches (457 mm), 3 feet (0.91 m), 6 feet(1.83 m), 9 feet (2.74 m), or 12 feet(3.66 m).


February 1998


World Class 3000

The CRE contains electronics that controlprobe temperature (in conjunction with theHPS), supply power, and provide isolatedoutputs that are proportional to the meas-ured oxygen concentration. The oxygensensing cell is maintained at a constanttemperature by modulating the duty cycle ofthe probe heater. The CRE accepts millivoltsignals generated by the sensing cell andproduces outputs to be used by remotelyconnected devices. The CRE output is iso-lated and selectable to provide voltage orcurrent. For a detailed description of theCRE, refer to Appendix C.

The heater power supply (HPS) provides aninterface between the CRE and the probe.The HPS contains a transformer for sup-plying proper voltage to the probe heater.The enclosure has been designed to meetNEMA 4X (IP65) specifications for watertightness; an optional enclosure to meetClass 1, Division 1, Group B (IP65) explo-sion proof is also available. For a detaileddescription of the HPS, refer to Appendix B.

Systems with multiprobe applications mayemploy an optional Multiprobe Test GasSequencer (MPS). The MPS providesautomatic test gas sequencing for up to fourprobes to accommodate automatic calibra-tion. For a detailed description of the MPS,refer to Appendix D.

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 contact-sensitive on-linehelp.

4. Field replaceable cell.

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

6. The heater power supply can be lo-cated up to 150 feet (46 m) from theprobe and up to 1200 (366 m) feet fromthe control room electronics.

7. All electronic modules are adaptable to100, 120, 220, and 240 line voltages.

8. RS-232 serial link for serial printer,baud range selectable; optional RS-232 serial link with computer interfacesuitable for an IBM Personal Computeror modem (available in the future).

e. Handling the Oxygen Analyzer

NOTE

Retain 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.

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 to shockwhen mishandled.

f. System Considerations

Prior to installation of your RosemountWorld Class 3000 Oxygen Analyzer withControl Room Electronics make sure thatyou have all of the components necessaryto make the system installation. Ensure thatall the components are properly integratedto make the system functional.

Once you have verified that you have all thecomponents, select mounting locations and



World Class 3000

determine 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 typical sys-tem wiring. For details on installing the indi-vidual components of the system, refer toSection 2, Installation. Figure 1-4 is a blockdiagram illustrating six World Class 3000Probes applied to the Control Room Elec-tronics. Figure 1-5 shows the same infor-mation but for an eight probe configuration.

After selecting the probe mounting location,provision should be made for a platformwhere the probe can be easily serviced. Theheater power supply can be located up to150 feet (46 m) cabling distance from theprobe, and up to 1200 feet (366 m) cablingdistance from the control room electronics.

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 test gas bottles will be hooked up perma-nently, a check valve must be installed nextto the calibration fittings on the probe junc-tion box. This is to prevent breathing of cali-bration gas line and subsequent flue gascondensation and corrosion. The checkvalve is in addition to the stop valve in thetest gas kit or the solenoid valve in the mul-tiprobe test gas sequencer units.

An optional Z-purge arrangement is avail-able for applications where hazardous areaclassification may be required. (See Appli-cation Data Bulletin AD 106-300B.)


February 1998


World Class 3000

STANDARD

OPTIONS

DUCT

STACK

GASES

CALIBRATIONGAS

INSTRUMENTAIR SUPPLY(REF. GAS)

PRESSUREREGULATOR

FLOWMETER

CONTROL ROOMELECTRONICS

CONTROL ROOMELECTRONICS

MULTIPROBETEST GAS

SEQUENCER

REFERENCE AIR

CALIBRATIONGAS

HEATERPOWERSUPPLY

OXYGENANALYZER(PROBE)

OXYGENANALYZER(PROBE)

ADAPTERPLATE

ADAPTERPLATE

STACK

DUCT

GASES

TE

ST

GA

S1

TE

ST

GA

S2

INS

T .A

IRS

UP

PLY

LINEVOLTAGE

LINEVOLTAGE

HEATER POWER SUPPLY

19270002

Figure 1-2. Typical System Installation



World Class 3000

Figure 1-3. Typical System Wiring (Sheet 1 of 3)


February 1998


World Class 3000

DETAIL B

PIN 16 CALINT2-PIN 15 CALINT2+PIN 14 CALINT1-PIN 13 CALINT1+PIN 12 CALRET2PIN 11 NOGAS2PIN 10 GNDPIN 9 LOGAS2PIN 8 HIGAS2PIN 7 INCAL2

PIN 7

PIN 6 CALRET1PIN 5 NOGAS1PIN 4 GNDPIN 3 LOGAS1PIN 2 HIGAS1PIN 1 INCAL1

PIN 1

PROBE 2

PROBE 1

REMOTE MOMENTARYCALIBRATION START

SWITCH BY CUSTOMER

TO DPI FORPROBES 3 AND 4IF REQUIRED

PIN

2

PIN

1

PIN

6

PIN

5

PIN

3

PIN

7

PIN

7

PIN

1

8 CONDUCTORSHIELDED CABLE#16 AWG BY CUSTOMER

DUPLICATE CONNECTIONSNOT REQUIRED

CRE AND MPS CONNECTIONS

MULTIPROBE GAS SEQUENCER (OPTIONAL) MPS 3000 TYPICAL CONFIGURATIONREFER TO MPS MODEL NUMBER FOR SPECIFIC CONFIGURATION

L

E

N

LINEVOLTAGE

J13 J14 J15 J16 J17 J18

J12

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

LOW

GA

S

LOW

GA

S

LOW

GA

S

LOW

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




World Class 3000



February 1998


World Class 3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

World Class 3000Probe


2 Pneumatic Linesby Customer

(300 Feet Max)


(300 Feet Max)

7 Conductor Cable(150 Feet Max)




Modular DesignUp to 4 Probes


Test Gasby Customer

Test Gasby Customer

8 Conductor Wire(1000 Feet Max)


Line Voltage

Line VoltageLine Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

4 Twisted Pair Plus 2 Twisted Pairfor Options (1200 Feet Max)




Test GasSequencerMPS 3000


CRE 3000Control Room

Electronics

Line Voltage100 to 120 Volt220 to 240 Volt

19270004

Figure 1-4. Control Room Electronics with 6 World Class 3000 Probes



World Class 3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000




(300 Feet Max)


(300 Feet Max)






Test Gasby Customer

Test Gasby Customer


Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage

Line Voltage







CRE 3000Control Room

Electronics

Line Voltage100 to 120 Volt220 to 240 Volt

19270005

Figure 1-5. Control Room Electronics with 8 World Class 3000 Probes


February 1998

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

World Class 3000

SECTION 2INSTALLATION

2-1 OXYGEN ANALYZER (PROBE)INSTALLATION

Before starting to install this equip-ment, read the "Safety instructions forthe wiring and installation of this ap-paratus" at the front of this InstructionBulletin. Failure to follow the safetyinstructions could result in seriousinjury or death.

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 50° to1300°F (10° to 704°C). Figure 2-1 pro-vides mechanical installationreferences.

2. Check the flue or stack for holes andair leakage. The presence of this con-dition will substantially affect the accu-racy of the oxygen reading. Therefore,either make necessary repairs or installthe probe upstream of any leakage.

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

4. If the probe is to be mounted outsideand subject to rain and snow condi-tions, make sure the back of the probe(outside of the duct) is insulated to pre-vent the formation of flue gas conden-sate in the calibration gas lines.

Do not allow the temperature of theprobe junction box to exceed 300°F(149°C) or damage to the unit may re-sult. If the probe junction box tem-perature exceeds 300°F (149°C), 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. En-sure that the system cable is therequired length. If applicable, check theoptional ceramic diffusor to ensure thatit is not damaged.

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

NOTE

An abrasive shield is recommendedfor high velocity particulate in the fluestream (such as those in pulverizedcoal kilns and recovery boilers). Verti-cal and horizontal brace clamps areprovided for 9 ft and 12 ft (2.75 m and3.66 m) probes to provide mechanicalsupport of the probe. Refer to Figure2-1, sheet 5.

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

RO

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


February 1998


World Class 3000

SN

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(P/N

353

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0008

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(8)

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9.00

(15

3)

9.25

(23

5)

9.25

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5)

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0.75

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7.48

7.48

TAB

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World Class 3000

22.5

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(mm

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92(1

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AC

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IA B

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A

2.50

0 D

IA

45o

C

B



February 1998


World Class 3000

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

INSTALLATION FOR MASONRYWALL STACK CONSTRUCTION

INSTALLATION FOR METALWALL STACK OR DUCT

CONSTRUCTION

0.50 [13]

3.75 [95]

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

MTG HOLESSHOWN ROTATED45 OUT OFTRUE POSITION

o

WELD OR BOLT ADAPTORPLATE TO METAL WALLOF STACK OR DUCT.JOINT MUST BE AIR TIGHT.

0.50 [13]

4.50 [114]O.D. REF

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

MASONRYSTACK WALL

OUTSIDE WALLSURFACE

JOINT MUSTBE AIRTIGHT

MTG HOLESSHOWN ROTATED

45 OUT OFTRUE POSITION

o

FIELD WELDPIPE TO

ADAPTOR PLATE

BOLT ADAPTORPLATE TO OUTSIDE

WALL SURFACE

NOTE: DIMENSIONS IN INCHES WITHMILLIMETERS IN PARENTHESES.

2.50 [63.5]

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

WELD OR BOLT ADAPTORPLATE TO METAL WALL

OF STACK OR DUCT.JOINT MUST BE AIR TIGHT.

FIELD WELDPIPE TOADAPTOR PLATE

3.50 [89]O.D. REF

PIPE 3.00 SCHED 40PIPE SLEEVE (NOTBY ROSEMOUNT)LENGTH BY CUSTOMER

MASONRYSTACK WALLOUTSIDE WALL

SURFACE

JOINT MUSTBE AIRTIGHT

BOLT ADAPTORPLATE TO OUTSIDE

WALL SURFACE

624038




World Class 3000

BRACE BARS(NOT BY ROSEMOUNT)

2.00(51)

NOTE: DIMENSIONS IN INCHES WITHMILLIMETERS IN PARETHESES.

VERTICAL BRACE CLAMP ASSY.

ABRASIVE SHIELD

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

BY ROSEMOUNT}

2 HOLES - 0.625(16) DIA. FOR0.50 (12) DIA.BOLT

NOTE: BRACING IS FOR VERTICAL AND HORIZONTAL PROBE INSTALLATION.

1.00(25) MAX.

0.375(10)

1.00(25)

4.12(105)

4.12(105)

60o MAX.

30o MIN.

5.62(143)

5.62(143)

36.00 (914)

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



February 1998


World Class 3000

4. If using the optional ceramic diffusorelement, 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 probejunction box should be oriented, so thatthe system cable drops vertically fromthe probe junction box. In a vertical in-stallation, the system cable can be ori-ented in any 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,

VEEDEFLECTOR

VEEDEFLECTOR

DIFFUSIONELEMENT

SETSCREWFILTER

GAS FLOWDIRECTION

APEX

Figure 2-2. Orienting the Optional Vee Deflector

make sure that the packings are in thehub grooves as the probe slides intothe 15° forcing cone in the abrasiveshield.

7. Insert the probe through the opening inthe mounting flange and bolt the unit tothe 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 probeinside the flue or stack. See Figure 2-1,sheet 5.

c. Reference Air Package

After the oxygen analyzing (probe) unit isinstalled, connect the reference gas air setto the probe junction box. The reference gasair set should be installed in accordancewith Figure 2-3.

d. Service Required

1. Power input: 100, 115 or 220 Vacsingle phase, 50 to 60 Hz, 6 ampminimum. (See label.)

2. Compressed air: 10 psig (68.95kPag) minimum, 225 psig (1551.38kPag) maximum at 2 scfh (56.6 L/hr)maximum; supplied by one of the fol-lowing (less than 40 parts-per-milliontotal hydrocarbons). Regulator outletpressure should be set at 5 psi (35kPa).

(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.



World Class 3000

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 INCHES WITHMILLIMETERS IN PARENTHESES.

1 2 3

4.81 (122.17)

FLOW SETPOINT KNOB

0.125-27 NPT FEMALEOUTLET CONNECTION

1.19(30.22)

10.0 REF(254)

DRAIN VALVE

3.12 (79.25) MAX

8.50 MAX(215.90)

2.0(50.80) 2 MOUNTING HOLES

3.19 (81.03) LGTHROUGH BODY FOR

0.312 (7.92) DIA BOLTS1.50

(38.10)

2.250 (57.15)

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

703020

0.250 OR 6 MM OD TUBING(SUPPLIED BY CUSTOMER)

0.250 OR 6 MM ODTUBE COMPRESSION

FITTING (SUPPLIED BY WECO)

Figure 2-3. Air Set, Plant Air Connection

2-2 CONTROL ROOM ELECTRONICS MODULEINSTALLATION

a. Mechanical Installation

Install CRE in 19 inch (483 mm) rack usingrack mount brackets. Refer to Figure 2-4for CRE dimensions. If installing CRE in apanel, see Figure 2-5 for panel cutout di-mensions. If installing CRE in a wall with the

optional trim frame, refer to paragraph 2-2g,Optional Trim Frame and Rear Cover, andFigure 2-11.

b. Electrical Connections

1. The power cable used should complywith safety regulations in the user'scountry.


February 1998


World Class 3000

17.62(447,55)

16.25(412,75)

WITH CABLECLEARANCE

13.25(336,55)

19.00(482,60)

5.22(132,59)

5.22(132,59)

FRONT VIEW SIDE VIEW

TOP VIEW

DIMENSIONS IN INCHES WITH MILLIMETERS IN PARENTHESES.

NOTE:

Figure 2-4. Control Room Electronic Dimensions

17.75(450,85)

18.31(465,07)

5.36(136,14)

2.25(57,15)

CUTOUT

0.30 DIA (4 PLS)

Figure 2-5. Panel Cutout for Control Room Electronic Module



World Class 3000

2. Plug the female end of the power cableinto the AC IN plug on the back of theCRE, Figure 2-6.

3. Plug the male end of the power cableinto any acceptable power outlet forthe voltage configured.

NOTE

Refer to Figure 2-6 for CRE unit fuselocations and specifications.

c. Analog Output and Relay OutputConnections

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

2. All wiring must conform to local andnational codes.

3. Connect the analog outputs and relayoutputs as shown in Figure 2-6.

Figure 2-6. CRE Power, Analog Output, and Relay Output Connections


February 1998


World Class 3000

Table 2-1. Analog Output Card JumperConfiguration

OUTPUTNUMBER JM1 JM2

1-45-89-12

INOUT

IN

ININ

OUT

d. Analog Output Card JumperConfiguration

The CRE can have up to three analog out-put circuit boards. The jumpers on theseboards are set at the factory. Should a sys-tem ever be expanded, or in the event ofboard replacement, the jumper configura-tions for each card are given in Table 2-1.Refer to Figure 2-7 for the location of thejumpers on the analog output card.

e. Relay Output Panel JumperConfiguration

The relay output contacts can be configuredto be normally open or normally closed. Thisis done by moving jumpers on the relay out-put card.

ANALOG OUTPUT CARDJM1 JM2

21200001

Figure 2-7. Analog Output Card Jumpers

Refer to moving jumpers on the relay outputcard. Refer to Figure 2-8. The jumpers areplaced on the first two pins for normallyclosed contacts and on the last two pins fornormally open contacts. Jumpers JM1 andJM2 on the relay output card, Figure 2-9,are installed at the factory.

f. Dual Probe Interface (DPI) CardConfiguration

A CRE may be configured with up to fourDPI cards. Refer to Table 2-2 and Figure2-10 for DPI card jumper configurations.

Table 2-2. DPI Card Jumper Configuration

CARDNUMBER

JM1 JM2

1234

INOUT

INOUT

ININ

OUTOUT

16

12

8

4

NO NC

NO NC

NO NC

NO NC

JM18

JM14

JM10

JM6

15

11

7

3

14

10

6

2

13

9

5

1

JM17

JM13

JM9

JM5

JM16

JM12

JM8

JM4

JM15

JM1 1

JM7

JM3

FOR NORMALLYCLOSED CONTACTS

PLACE THEJUMPER ON THEFIRST TWO PINS.

FOR NORMALLYOPEN CONTACTS

PLACE THEJUMPER ON THELAST TWO PINS.

Figure 2-8. Relay Output Panel JumperConfiguration



World Class 3000

JM1 JM2

JM1

JM2

Figure 2-9. Relay Output Card JumperConfiguration

g. Optional Trim Frame and Rear Cover

The trim frame slides over the unit as shownin Figure 2-11. The trim frame covers wall

Figure 2-10. DPI Card Jumpers

cuts. The rear cover mounts to the back ofthe unit with the same screws holding thetrim strips, Figure 2-11. The rear cover pro-tects wires and terminals. The panelmounting kit contains a trim frame and backcover. The part number for the panelmounting kit is 1L03636G01.

Figure 2-11. Optional Trim Frame and Rear Cover


February 1998


World Class 3000

2-3 HEATER POWER SUPPLY INSTALLATION


The outline drawing of the heater powersupply enclosure in Figure 2-12, showsmounting centers and clearances. TheNEMA 4X enclosure is designed to bemounted on a wall or bulkhead. The heaterpower supply should be installed no fur-ther than 150 feet (45 m) from the probe.The heater power supply must be located ina location free from significant ambient tem-perature changes and electrical noise. Am-bient temperature must be between -20° to140°F (-30° to 60°C).

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) terminals

should 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 theterminal covers, remove two slottedscrews holding cover in place. Alwaysreinstall terminal covers after makingconnections. All wiring must conform tolocal and national codes.

NOTE

Before supplying power to the heaterpower supply, verify that jumpers JM3and JM6 are removed, and JM7 is in-stalled. JM2 is installed, if relay is notwired.

NOTE

Refer to Figure 2-16 for HPS unit fuselocations and specifications.

CLASS 1, DIVISION 1, GROUP B ENCLOSURE

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

0.13" (3.3) THK U. L. APPROVEDGASKET

7.00(177.8)

3.25(82.6)

3.63(92.2)

0.31(7.9)

NEMA 4X(NON-HAZARDOUS)

NOTE: DIMENSIONS IN INCHESWITH MILLIMETERS IN PARENTHESES.

10.39(264)

9.17(233)

9.96(253)

8.50(215.9)

6.18(156.9)4.72

(120)

8.50(215.9) 8.00

(203.2)

11.00(279.4)

6.75(171.5)

0.56 (14)DIA (2)MOUNTINGHOLES

1.00 (25.4) MINIMUM CLEARANCEFOR REMOVING COVER

4.38(111.3)

4.88(124)

0.38(9.7)

1.81(46)

6.00(152.4)

4.00(101.6)

#0.31686029

Figure 2-12. Outline of Heater Power Supply



World Class 3000

Figure 2-13. Electrical Installation of Heater Power Supply


February 1998


World Class 3000

TRANSFORMER

TRANSFORMER

TERMINALCOVERS

FRONT

SIDE

TERMINAL STRIP(FROM ELECTRONICS)

TERMINAL STRIP(FROM PROBE)

29850005

Figure 2-14. Heater Power Supply Wiring Connections



World Class 3000

2. Power Input: 120, 220 or 240 Vac. For120 Vac usage, install jumpers JM4and JM1. For 220 or 240 Vac usage,install jumper JM5 (see label, Figure 2-15).

NOTE

For 100 Vac usage, the heater powersupply is factory-supplied with a dif-ferent transformer. When using theHPS with 100 Vac transformer, installjumpers JM1 and JM4.

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

4. Before supplying power to the heaterpower supply, verify that the jumperson the mother board, Figure 2-16, areproperly configured. Jumpers JM3 andJM6 should be removed, and JM7should be installed. Additionally, makesure that the proper jumper for yourline voltage is installed, Figure 2-15.JM2 is installed if relay is not wired.

1

2

NOTES:

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

REFER TO TABLE 3-6 FOR PROPER SET POINT SELECTION.

1

2

Figure 2-15. Jumper Selection Label


February 1998


World Class 3000

3D3

080GR

EV

JM1

JM2JM3

JM4

JM5

JM6

JM7

JM8

Figure 2-16. Jumpers on HPS Mother Board

2-4 MULTIPROBE TEST GAS SEQUENCERINSTALLATION


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 than300 feet (91 m) piping distance from theprobe, and no more than 1000 feet (303 m)cabling distance from the CRE. Install theMPS module in a location where the ambi-ent temperature is between -20° to 160°F(-30° to 71°C).

b. Gas Connections

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

1. Connect the reference air supply toINSTR. AIR IN. The air pressure regu-lator valve is set at the factory to 20 psi(138 kPa). If the reference air pressureshould need readjustment, turn theknob on the top of the valve until thedesired pressure is obtained.

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

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

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. Use optional check valveif required.

A check valve is required for eachprobe connected to an MPS to preventcondensation of flue gas in the calibra-tion gas lines. The check valve mustbe located between the calibration fit-ting and the gas line.

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



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

0.84 (21,34)

1.96 (49,78)

4.21 (106,93)

3.09 (78,49)

5.25 (133,35)

5.54 (140,72)

14.00 (355,60) REF

12.00(304,80)

12.00(304,80)

10.00(254,00)

NOTE: DIMENSIONS ARE IN INCHESWITH MILLIMETERS INPARENTHESES.

Figure 2-17. MPS Module


February 1998


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

DRAIN

LINE IN

SIGNAL IN

Figure 2-18. MPS Gas Connections

c. Electrical Connections

1. Electrical connections should be madeas described in the electrical installa-tion diagram, Figure 2-19. All wiringmust conform to local and nationalcodes.

NOTE

Refer to Figure 2-19 for MPS unit fuselocations and specifications.

2. Run the line voltage through the bulk-head fitting on the bottom of the MPSwhere marked LINE IN, Figure 2-18.Connect the line voltage as shown inFigure 2-19 to J10 LINE IN terminal onthe MPS terminal board located insidethe unit. Tighten the cord grips to pro-vide strain relief.

3. The MPS can accommodate up to fourprobes. The terminal strips on the MPStermination board are marked PROBE1, PROBE 2, PROBE 3, and PROBE 4.Connect wires from these terminalstrips to the third terminal strip on aDual Probe Interface (DPI) on the backof the CRE. One DPI can accommo-date two probe connections.

NOTE

Only one HIGAS, LOGAS, CALRET,and NOGAS connection are neededper MPS unit. The HIGAS, LOGAS,CALRET, and NOGAS connection forprobe 1 will be sufficient to work for allthe probes connected to the MPS.

4. Make the connections from the MPS tothe CRE 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.

5. If more than four probes are beingused, a second MPS would be re-quired. For installations of five to eightprobes, refer to paragraph 2-5.

6. A maximum of eight MPS units may beconnected to one CRE unit, one MPSper probe. This may be necessary ifthe system has probes spread out overa great area. In this case, all wire con-nections must be made for each MPS-probe system.



World Class 3000

Figure 2-19. Typical CRE to MPS Connections


February 1998


World Class 3000

2-5 INSTALLATION WITH TWO MULTIPROBETEST GAS SEQUENCERS

When installing more than four probes, a sec-ond MPS unit is required. An installation of fiveor six probes requires that the first three probesare connected to the first MPS, the remainderare connected to the second MPS. On an in-stallation of seven or eight probes, the first fourare connected to the first MPS, the remainderare connected to the second MPS. Refer toparagraph 2-5a for five or six probe hookup, andparagraph 2-5b for seven or eight probehookup.

a. Five or Six Probe Installation.(Figure 2-20)

1. Connect probes 1 and 2 to CRE DPIpanel 1, probes 3 and 4 to DPI panel 2,and probes 5 and 6 to DPI panel 3.

2. Connect DPI panel 1 to MPS number1, probes 1 and 2, terminal blocks.

3. Connect DPI panel 2, probe 3 connec-tion, to MPS number 1, probe 3 termi-nal block.

4. Connect DPI panel 2, probe 4 connec-tion, to MPS number 2, probe 1 termi-nal block.


6. When entering the operator set vari-ables, as listed in Table 3-6, SETUPSub-menu, enter the parameters forDPI number, UNIT number, MPS num-ber, and CONTROLLED BY PRBnumber as indicated in Table 2-3.

Table 2-3. Typical CRE SETUP Data for 5 or 6 Probe Configuration

Parameter Selection forSETUP - PROBE Sub-menurefer to Table 3-4 Probe 1 Probe 2 Probe 3 Probe 4 Probe 5 Probe 6

CONFIGURE PROBESPROBE____

INTERFACEInterface TypeDPI NumberUnit Number

CALIBRATIONMPS Number

CONFIGURE MPSMPS____

Control by PRB

DPI11

1

1

DPI12

1

1

DPI21

1

1

DPI22

2

4

DPI31

2

4

DPI32

2

4



World Class 3000

Figure 2-20. Typical CRE to MPS Connections, 5 or 6 Probes


February 1998


World Class 3000

b. Seven or Eight Probe Installation(Figure 2-21)

1. Connect probes 1 and 2 to CRE DPIpanel 1, probes 3 and 4 to DPI panel 2,probes 5 and 6 to DPI panel 3, andprobes 7 and 8 to DPI panel 4.





6. When entering the operator set vari-ables, as listed in Table 3-6, SETUPSub-menu, enter the parameters forDPI number, UNIT number, MPS num-ber, and CONTROLLED BY PRBnumber as indicated in Table 2-4.

Table 2-4. Typical CRE SETUP Data for 7 or 8 Probe Configuration

Parameter Selection forSETUP - PROBESub-Menu refer toTable 3-6 Probe 1 Probe 2 Probe 3 Probe 4 Probe 5 Probe 6 Probe 7 Probe 8

CONFIGURE PROBESPROBE____

INTERFACEInterface TypeDPI NumberUnit Number

CALIBRATIONMPS Number

CONFIGURE MPSMPS____

Control by PRB

DPI11

1

1

DPI12

1

1

DPI21

1

1

DPI22

1

1

DPI31

2

5

DPI32

2

5

DPI41

2

5

DPI42

2

5



World Class 3000

L

E

N

LINEVOLTAGE

J13 J14 J15 J16 J17 J18

J12

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

LOW

GA

S

LOW

GA

S

LOW

GA

S

LOW

GA

S


L

N

L

N

LINE OUT LINE IN

J10

J11PROBE 1 PROBE 2 PROBE 3 PROBE 4

L

E

N

LINEVOLTAGE

J13 J14 J15 J16 J17 J18

J12

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

LOW

GA

S

LOW

GA

S

LOW

GA

S

LOW

GA

S


L

N

L

N

LINE OUT LINE IN

J10

J11PROBE 1 PROBE 2 PROBE 3 PROBE 4

CONTROL ROOM ELECTRONICS(REAR VIEW)

DPIPANEL 1

DPIPANEL 2

DPIPANEL 3

DPIPANEL 4

PIN 16 CALINT2-PIN 15 CALINT2+PIN 14 CALINT1-PIN 13 CALINT1+PIN 12 CALRET2PIN 11 NOGAS2PIN 10 GNDPIN 9 LOGAS2PIN 8 HIGAS2PIN 7 INCAL2PIN 6 CALRET1PIN 5 NOGAS1PIN 4 GNDPIN 3 LOGAS1PIN 2 HIGAS1PIN 1 INCAL1




PROBE1

PROBE2

PROBE3PROBE

4

PROBE5

PROBE6

MPS 2 TERMINATION BOARDMPS 1 TERMINATION BOARD

1 1

1 ALL SHIELDS CONNECTTO DPI GND (PINS 4OR 10)

NOTE:

PROBE 7PROBE 8

Figure 2-21. Typical CRE to MPS Connections, 7 or 8 Probes


February 1998


World Class 3000

NOTE!

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

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

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



World Class 3000


February 1998

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

World Class 3000

SECTION 3OPERATION

3-1 OVERVIEW

Ensure that the oxygen analyzer, heater powersupply, and control room electronics have beenproperly connected. It is important to check thatgrounding and screening of terminations arecorrectly made to prevent the introduction ofground loops. The CRE is equipped with noisesuppression circuitry on the power supply andsignal input lines. Proper grounding at installa-tion will ensure accuracy of function.

This section of the manual deals with operatorcontrols and displays available in the CRE. Op-erating parameters are listed and instructionsare included for viewing and changing them.

Any procedures not associated with normal op-eration are included in Section 2, Installation, orSection 4, Troubleshooting.

3-2 FRONT PANEL CONTROLS ANDINDICATORS

17

1 2 3 4 5

78910121516

13 14

11

6

21200002

Figure 3-1. CRE Front Panel

Fig. 3-1Index No. Control/LED Description

1 HELP Context sensitive help is displayed when this key is pressed.

2 DATA DATA key is used to access data sub-menu.

3 LCD Display Top line is a status line which displays the current probe status, current menuand current probe number. The second, third, and fourth lines display thecontents of the menu selected.

4 CAL CAL key used to access CALIBRATE O2 sub-menu.

5 SETUP SETUP key used to access SETUP sub-menu.

6 RUN/PAR Keylock switch. RUN allows the operator to examine, but not modify, anysystem parameter. Leave system in this mode except when changingparameters. PAR allows parameter change and calibration.


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

World Class 3000

Fig. 3-1 (Continued)Index No. Control/LED Description

7 ENTER The ENTER key is used to select a lower level menu, initiate calibration, orselect a parameter to change.

8 ▲ The increase key is used to move the cursor when scrolling through lists or toincrease a parameter value.

9 ▼ The decrease key is used to move the cursor when scrolling through lists or todecrease a parameter value.

10 ESC The escape key is used to exit to a high level menu or to abort a parameterchange.

11 AVERAGES LED Lights to indicate that O2 averages have exceeded operator-set high and/or lowlimits. Provided for up to four averages.

12 FAULT LED Lights to indicate fault condition. Provided for up to eight probes.

13 HIGH LED Lights to indicate that readings have risen above the high alarm limit. Providedfor up to eight probes.

14 LOW LED Lights to indicate that readings have fallen below the low alarm limit. Providedfor up to eight probes.

15 CAL LED Indicates analyzer is in calibrate mode. Provided for up to eight probes.

16 SYS. FAULT Indicates system fault condition.LED

17 AUXILIARY Two lines of eight alphanumeric LEDs. Selectable to display O2 readings of twoDISPLAY LED probes or user-specified averages.

3-3 STATUS LINE

The top line of the LCD display (3, Figure 3-1) isa status line that continuously displays currentprobe status, menu name, and current probeselected. The probe status marked by an aster-isk (*) will cause a fault condition and the faultLED to light.

a. OK. Current probe is functioning correctly.

b. CAL. Calibration in progress.

c. C Err. Calibration error.

d. *H Err. Probe heater temperature is out ofrange (±5°C).

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. Cell resistance is above the high limit.

i. *Dable. Probe disabled, no longer calcu-lated in the multiprobe averages.

j. *Off. Probe is turned off.

k. *Com-E. Communication error.

l. INACT. Interface for probe is notconfigured.

m. DPI E. CRE cannot communicate withprobe interface board.

n. PRB E. Probe is disconnected, cold, orloads reversed.


February 1998


World Class 3000

3-4 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,HLP ORPARAMETER NAME MESSAGE

DATA

PROBE DATA

O2 VALUE

"The DATA menu displaysprocess data. Press ENTERor the DATA key to accessthe DATA menu."

"The PROBE DATA menudisplays information about asingle probe."

"This is an individual probepercent O2 value."

3-5 QUICK REFERENCE CHART

The quick reference chart, Figure 3-2, is de-signed to help you get to where you want to bein the menu system. The chart shows all theavailable menu and sub-menu options for theCRE. Follow the lines to determine which menuchoices to make. To move down a level on thechart, press the ENTER key. To move up a levelon the chart, press the ESCAPE key.

3-6 MAIN MENU

When power is first applied to the CRE, themain menu is displayed under the status line.The selections in the main menu are DATA,CALIBRATE, and SETUP. These selections areaccessed by moving the cursor to the selectionand pressing the ENTER key, or pressing theappropriate direct access button. Refer to Table3-2.

Table 3-2. MAIN Menu

SUB-MENU DESCRIPTION

DATA

CALIBRATE

SETUP

Refer to Table 3-3

Refer to Table 3-5

Refer to Table 3-6

3-7 DATA SUB-MENU

The DATA sub-menu (Table 3-3) can be viewedbut not changed. The DATA sub-menu is a listof all the real time process data pertaining to thesystem as it is currently configured. To accessthe DATA sub-menu, press the DATA key onthe CRE front panel. There are three selectionsavailable on the DATA sub-menu; SYSTEMDATA, PROBE DATA, and SYSTEM STATUS.The increase and decrease keys are used toscroll through the list. The contents of the DATAsub-menu are displayed on the second, third,and fourth lines of the LCD display.



World Class 3000

MAIN MENU

A

MULTIPROBEAVERAGES

AVER 1

AVER 4

O2

VALUE 1

O2

VALUE 8

O2VALUES

EFFICIENCYVALUES

EFFVALUE 1

EFFVALUE 8

PROBEDATA

SYSTEMDATA

SYSTEMSTATUS

DATA

PROCESSDATA

O2 VALUE

EFFICIENCY

STK TEMP

DIAGNOSTICDATA

TEMPERATURES

HTR TEMP

STK TEMP

CJ TEMP

VOLTAGES

CELL

HTR T/C

STK T/C

CJ T/C

SELECTING PERFORM CALIBRATION WILLRESULT IN AUTO OR MANUAL CAL BASEDON VALUE SELECTED FOR PROBE IN PROBECAL SUB-MENU.

*

CALIBRATE

VIEWCONSTANTS

SLOPE

CONSTANT

CELLRESIST

PERFORMCALIBRATION*

AUTO MAN

CALIBRATIONSTATUS

SLOPE

CONSTANT

CELL RESIST

DIG O/PSTATUS

DIG O/P 1

DIG O/P 8

PROBESTATUS

PROBE 1

PROBE 8

ANALOGO/P STATUS

A-OUT 1

A-OUT 2

SOFTWAREVERSION

CPU

DPICARD 1

DPICARD 4

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


February 1998


World Class 3000

A

SETUP

PROBESSYSTEM

INPUTS

INPUTS

INPUT 1

INPUT 8

ALARMS

HIGH ALARM

LOW ALARM

DEADBAND

DIGITAL O/P1 . . . 8

GATE TYPE

GATEINPUT 1

GATEINPUT 16

ANALOG O/P1 . . . 12

SOURCE

RANGE

TYPE

LEDDISPLAY

LINE 1SRC

LINE 2SRC

TIME ANDDATE

TIME

DATE

O2 CALCULATIONS

SLOPE

CONSTANT

SET POINT

LOADCONSTANTS

EFFICIENCY CALC

ENABLE CALC

K1 VALUE

K2 VALUE

K3 VALUE

O2 ALARMS

HI ALARM

LO ALARM

DEADBAND

CALIBRATION

AUTO CAL

OUTPUTTRACKS

MPSNUMBER

CAL INTRVL

NEXT DATE

NEXT TIME

TEST GASTIME

PURGE TIME

RES ALARM

INTERFACE

INTERFTYPE

DPINUMBER

UNITNUMBER

CONFIGUREMPS

MPS 1 . . . 8

HIGH GAS

LOW GAS

CONTROLLEDBY PRB

CONFIGUREPROBES

ENABLEPROBES

PROBE 1ENABLED

PROBE 8ENABLED

CURRENTPROBE

CURRENTPROBE1 . . . 8

AVERAGE1 . . . 4

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



World Class 3000

Table 3-3. DATA Sub-Menu

ITEM IN SUB-MENU PARAMETER DESCRIPTION

SYSTEM DATA

MULTIPROBE AVERAGES

O2 VALUES

EFFICIENCY VALUES

AVER 1 ____%AVER 2 ____%AVER 3 ____%AVER 4 ____%

O2 Value 1 ____%O2 Value 2 ____%O2 Value 3 ____%O2 Value 4 ____%O2 Value 5 ____%O2 Value 6 ____%O2 Value 7 ____%O2 Value 8 ____%

Eff Value 1 ____%Eff Value 2 ____%Eff Value 3 ____%Eff Value 4 ____%Eff Value 5 ____%Eff Value 6 ____%Eff Value 7 ____%Eff Value 8 ____%

Average 1 valueAverage 2 valueAverage 3 valueAverage 4 value

O2 value for each probe configured

Efficiency value for each probe configured for efficiency

PROBE DATA

PROCESS DATA

DIAGNOSTIC DATA

TEMPERATURES

VOLTAGES

O2 Value ____%Efficiency ____%Stk Temp ____DegC

Htr Temp ____DegCStk Temp ____DegCCJ Temp ____DegC

Cell ____mVHtr T/C ____mVStk T/C ____mVCJ T/C ____mV

O2 value for the probe selectedEfficiency value for the probe selected (when enabled)Stack temperature for the probe selected, (when effi-ciency is enabled)

Cell temperature of the probe selectedStack temperature of the probe selectedCold junction temperature of the probe selected

Cell voltage of the probe selectedCell thermocouple voltage of the probe selectedStack thermocouple voltage of the probe selectedCold junction voltage of the probe selected


February 1998


World Class 3000

Table 3-3. DATA Sub-Menu (Continued)

ITEM IN SUB-MENU PARAMETER DESCRIPTION

SYSTEM STATUS

PROBE STATUS

DIG O/P STATUS

ANALOG O/P STATUS

SOFTWARE VERSION

PROBE 1 ____PROBE 2 ____PROBE 3 ____PROBE 4 ____PROBE 5 ____PROBE 6 ____PROBE 7 ____PROBE 8 ____

DIG OP 1 ____DIG OP 2 ____DIG OP 3 ____DIG OP 4 ____DIG OP 5 ____DIG OP 6 ____DIG OP 7 ____DIG OP 8 ____

A-Out 1 ____%A-Out 2 ____%A-Out 3 ____%A-Out 4 ____%A-Out 5 ____%A-Out 6 ____%A-Out 7 ____%A-Out 8 ____%A-Out 9 ____%A-Out 10 ____%A-Out 11 ____%A-Out 12 ____%

CPU 1.0DPI CARD 1 1.3DPI CARD 2 1.3DPI CARD 3 1.3DPI CARD 4 INACT

The status of the probes will be one of the following:OK - Functioning correctlyHIO2 - Above high O2 limitLOWO2 - Below low O2 limitINACT - Probe is not in systemCAL - Probe is being calibrated

The status of the digital outputs will be one of the following:ON - Digital output is actuatedOFF - Digital output is not actuatedINACT - Digital output is not configured

Value for each analog output

Software version of CPU cardSoftware version of DPI 1Software version of DPI 2Software version of DPI 3System does not have DPI 4



World Class 3000

3-8 CALIBRATE SUB-MENU

The CALIBRATE sub-menu is used to enter thecalibration mode. To access the CALIBRATEsub-menu, press the CAL key on the CRE keyon the CRE front panel. The increase and de-crease keys are used to scroll through the list.

At the beginning of the PERFORM CALIBRA-TION procedure, an error message may be dis-played. Unless the error is corrected,PERFORM CALIBRATION will not continue.Refer to Table 3-4 for the error messages.

The CALIBRATE sub-menu has three itemsavailable: PERFORM CALIBRATION, VIEWCONSTANTS, and CALIBRATION STATUS.Refer to Table 3-5 for contents of the sub-menus.

To abort a calibration in progress during PER-FORM CALIBRATION, press the ESC key.

3-9 USING THE SETUP SUB-MENU

The SETUP sub-menu (Table 3-6) is used toenter all operator set variables into the system.To access the SETUP sub-menu, press theSETUP key on the CRE front panel. There areitems available on the SETUP sub-menu; SYS-TEM, PROBE, and AVERAGE. To select a pa-rameter in a sub-menu to be changed, move thecursor to the desired parameter using the arrowkeys. Press ENTER to select that parameter. Tochange the value for that parameter, use the ar-row keys to increase or decrease the value.Press ENTER to save changes.

NOTE

Parameters can only be changed withthe RUN/PAR keylock (6, Figure 3-1) inthe PAR position.

Table 3-4. Perform Calibration Error Messages

Error Messages Remedy

Key required for calibration

Test gas low, can't calibrate

Heater error, can't calibrate

Turn keylock switch to the PAR position

Check test gas bottles connected to the MPS

Wait for heater to stabilize before calibrating


February 1998


World Class 3000

Table 3-5. CALIBRATE Sub-Menu

SUB-MENUSELECTION

SETUP SETTING(SEE TABLE 3-4) DATA QUEUES DESCRIPTION

PerformCalibration

Auto Cal in ProbeSetup is YES

Press ENTER to start Autocalibration.

1. "Waiting for MPS tobecome available"

2. "Starting AutomaticCalibration"

3. High Gas ____%O2

Time Left 0:00O2 Value ____%O2

4. Low Gas ____%O2

Time Left 0:00O2 Value ____%O2

5. Resistance Check

6. Returning to Process

The MPS under control of the CRE willbegin a fully automatic calibration on theprobe selected.

If MPS is in use, calibration will not beginuntil available.

After ENTER is pressed, five data queuesappear consecutively.

Value for high O2 test gasGas time runs down in min:secValue for O2

Value for low O2 test gasGas time runs down in min:secValue for O2

Resistance check in progressTime runs down in min:sec

System is purged.

Auto Cal in ProbeSetup is NO.

Press ENTER to start Man-ual Calibration

Switch on high test gas.Press ENTER when ready.

High O2 value ____%O2

Press ENTER when ready.

Switch from HIGH to LOWtest gas.


Low O2 value ____%O2


Resistance Check - waitTime Left 0:00

Switch off LOW test gas.Press ENTER when ready.

O2 value ____%O2

Press ENTER when probehas returned.

Semiautomatic calibration routine begins.

Manually turn on the high O2 test gas.Press ENTER to continue.

High O2 value.Press ENTER when O2 reading stabilizes.

Manually turn off the high O2 test gas andturn on the low O2 test gas.Press ENTER to continue.

Low O2 value.Press ENTER when O2 reading stabilizes.

Resistance check in progress.Time runs down in min:sec.

Manually turn off the low test gas.

Semiautomatic calibration is complete forthe probe selected.

ViewConstants

(N/A) Slope ____mV/DConstant ____mVCell Resist ____ohms

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

CalibrationStatus

(N/A) Slope ____Constant ____Cell Resist ____

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



World Class 3000

Table 3-6. SETUP Sub-Menu

ITEM IN SUB-MENU DISPLAY SELECTABLE OPTIONS

TIME & DATETIMEDATE

LED DISPLAY

ANALOG OUTPUTS*ANALOG O/P 1

DIGITAL OUTPUTS**DIG O/P 1

GATE TYPEGATE INPUTS

XX:XXDDMMYY

LINE 1 SRC ______LINE 2 SRC ______

SOURCE ______

RANGE __-___%

TYPE __-___mA

OR or NORINPUT 1 _______INPUT 2 _______INPUT 3 _______INPUT 4 _______INPUT 5 _______INPUT 6 _______INPUT 7 _______INPUT 8 _______INPUT 9 _______INPUT 10 _______INPUT 11 _______INPUT 12 _______INPUT 13 _______INPUT 14 _______INPUT 15 _______INPUT 16 _______

Hours 1-23; Minutes 1-59Day, Month, Year

Sources for the auxiliary LED displays can be oneof the following: AVG 1-4, PRB 1-8, or date andtime

Source can be one of the following: AVG 1-4,PRB 1-8Range can be one of the following: 0-1%, 0-5%,0-10%, 0-25%, or 0-100%Type can be either 0-20 mA, or 4-20 mA

Non-inverted or invertedData input can be one of the following:INACTIVE, SYS FAULTAV 1-4; HIGH or LOWPR 1-8; HIGH, LOW, CAL, FAIL, TG, or CAL E

PROBES

CURRENT PROBE

ENABLE PROBES

CONFIGURE PROBES**PROBE 1

CURRENT PROBE _____

*PRB 1 ENABLED _____

Select configured probe number 1-8 for LCDdisplay.

Select YES to enable, NO to disable, or OFF toturn off HPS (parameter is "OFF" when probe isinitially configured).

NOTE

Relay in HPS must be wired to the CRE.

Select probe to be configured, 1-8.

*Format is repeated for number of probes configured in system.**Format is repeated for all eight probes.


February 1998


World Class 3000

Table 3-6. SETUP Sub-Menu (Continued)

ITEM IN SUB-MENU PARAMETER SELECTABLE OPTION

PROBES (Continued)

NOTE

Once the probe is selected, the following five items are available.

INTERFACE

CALIBRATION

O2 ALARMS

O2CALCULATION

INTERF Type ______DPI Number ______UNIT Number ______

Auto Cal YES/NOOutput Tracks YES/NOMPS Number ______Cal. Intrvl XNext Date ______Next Time ______Test Gas Time 0:00

Purge Time 0:00

Res Alarm ______

Hi Alarm ______% O2Low Alarm ______% O2Deadband ______% O2

Slope ______mV/DConstant ______mV

Select type of probe interface.Select interface address.Select unit number.

If the system has an MPS, select YES, otherwise NO.Select output tracks.Select which MPS the probe is connected to.Select time between calibrations in # of days.Date of next calibration.Displays time of next calibration in hours and minutes.Amount of time for test gases to be turned on inminutes and seconds, allow enough time for signalvalue to stabilizeAmount of time for the gas lines to clear of test gas(Return to process).Resistance alarm set from 50-10000 ohms.

Set value for high alarm limit.Set value for low alarm limit.Set value for alarm deadband.

Set value between 34.5 and 57.5 mV/DECADE.Set value between -20.0 and 20.0 mV.

Ensure the correct voltage is selected when using HPS 3000 with218 probes. Refer to Figure 2-15, Jumper Selection Label forproper voltage selection. If incorrect SET POINT is selected,damage to the probe may occur.

Set Point ______°C

Load Constants

Set either 736 for World Class 3000 probes or 843 for218 probes.Press ENTER to load constants from last calibration.

EFFICIENCYCALC.

CONFIGURE MPS***MPS 1

ENABLE CALC YES/NOK1 Value _____K2 Value _____K3 Value _____

High Gas ______%O2Low Gas ______%O2Controlled by Prb _____

Select YES to enable, NO to disable.Set between 0.0000 and 1.0. (Refer to Table 3-7)Set between 0.0000 and 1.0. (Refer to Table 3-7)Set between 1.000 and 20.0. (Refer to Table 3-7)

Select the MPS unit to be configured (1 - 8).Value of high O2 test gas.Value of low O2 test gas.Select probe number wired to MPS.

**All eight probes are displayed.



World Class 3000

Table 3-6. SETUP Sub-Menu (Continued)

ITEM IN SUB-MENU DISPLAY SELECTABLE OPTIONS

AVERAGE

****AVERAGE 1ALARMS

INPUTS

HIGH ALARM ______LOW ALARM ______DEADBAND ______

INPUT 1 ______INPUT 2 ______INPUT 3 ______INPUT 4 ______INPUT 5 ______INPUT 6 ______INPUT 7 ______INPUT 8 ______

Select the average to be setup for all four averagesSet the value for high alarm.Set the value for low alarm.Set the value for deadband.

Set the probe number to any possible configuredprobe or to Inact. (Same for all eight inputs.)

***Format is repeated for each MPS selected (up to 8 selectable).****All four averages are displayed.

Table 3-7. Efficiency Constants.

UNITED STATES EUROPE

CONSTANT GAS OIL GAS OIL

K1K2K3

0.4070.05.12

0.4320.05.12

0.660.0082

12.28

0.690.00518.74

3-10 CALIBRATION

a. Overview

The primary purpose of an oxygen analyzeris to give an accurate representation of thepercentage of O2 in the gas stream. Thesystem should be calibrated periodically tomaintain an accuracy which may otherwisereduce over time due to cell aging.

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

Under normal conditions the probe shouldnot need frequent calibration. Because cali-bration is necessary, the system can beequipped with the optional MPS 3000 Multi-

probe Test Gas Sequencer for fully auto-matic calibration at regular intervals.Without an MPS, the probes must be cali-brated manually (semiautomatically).

b. Probe Calibration

There are three calibration methods: man-ual (semiautomatic), manually initiatedautomatic, and fully automatic. Manual(semiautomatic) calibration is done withoutan MPS unit. Test gases are switched onand off by the operator and the CRE is se-quenced through the calibration procedureby the operator with the front panel key-board. The CRE prompts the operator forthe correct action. Manually initiated auto-matic calibration is done with an MPS. Theoperator manually initiates the calibration at


February 1998


World Class 3000

the CRE or through a remote switch, andthe CRE controls the operation of theMPS unit and the calibration sequencing.Fully automatic calibration requires no ac-tion from the operator. The setup is thesame as semiautomatic except the CREautomatically initiates the calibration at afixed calibration interval. In this mode theoperator can also manually initiate calibra-tions between the intervals in the samemanner as semiautomatic calibrations.

c. Manual (Semiautomatic) Calibration.

1. Test Gases For Manual (Semiauto-matic) Calibration. There are two op-tions for supplying test gases to theprobe during semiautomatic calibration.The first, "A", uses refillable bottles andadjustable 2-stage pressure regulators;the second, "B", uses disposable bot-tles and a fixed single stage regulatorto provide a mixed flow. Normally, thefirst ("A") will have a higher cost andnot be portable. The second ("B") isless costly and portable, because itonly weighs about 10 pounds (4,5 kg).

Test Method "A" Fixed Tanks andManifolds.

(a) Required Equipment.

Do not use 100% nitrogen as a zerogas. It is suggested that gas for thezero 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.

NOTE

Ambient air is not recommended foruse as high test gas. An 8% O2 bal-ance in nitrogen is recommended forhigh test gas.

1 Two tanks of precision cali-bration gas mixtures. Rec-ommended calibration gasesare nominally 0.4% and 8.0%oxygen in nitrogen.

Two sources of calibrated gasmixtures are:

LIQUID CARBONICGAS CORP.SPECIALTY GASLABORATORIES

700 South Alameda StreetLos Angeles, California90058213/585-2154

767 Industrial RoadSan Carlos, California 94070415/592-7303

9950 Chemical RoadPasadena, Texas 77507713/474-4141

12054 S.W. Doty AvenueChicago, Illinois 60628312/568-8840

603 Bergen StreetHarrison, New Jersey 07029201/485-1995

255 Brimley RoadScarborough, Ontario,Canada416/266-3161

SCOTT ENVIRONMENTALTECHNOLOGY, INC.SCOTT SPECIALTYGASES

2600 Cajon Blvd.San Bernardino, CA 92411714/887-2571TWX: 910-390-1159

1290 Combermere StreetTroy, MI 48084314/589-2950

Route 611Plumsteadville, PA 18949215/766-8861TWX: 510-665-9344

2616 South Loop West,Suite 100Houston, TX 77054713/669-0469



World Class 3000

2 If gas bottles will be perma-nently hooked up to the probe,a manual block valve is re-quired at the probe (betweenthe calibration fitting and thegas line) to prevent the migra-tion of process gases downthe calibration gas line.

3 If an MPS 3000 MultiprobeGas Sequencer is used, acheck valve is required at theprobe.

4 Two, 2-stage pressure regu-lators with stainless steel dia-phragms for tanks. Maximumoutput required: 20 psi (138kPa).

5 One instrument air pressureregulator: 20 psi (138 kPa)maximum and a supply ofclean, dry instrument air.

6 Two zero-leakage shutoffvalves.

7 Miscellaneous oil-free tubingand fittings.

(b) Calibration.

For optimum accuracy, this calibrationshould be run with the process atnormal temperature and operatingconditions.

1 A typical calibration setup isshown in Figure 3-3. Caremust be taken that all fittingsare tight and free from oil orother organic contaminants.Small openings can causeback diffusion of oxygen fromthe atmosphere even thoughpositive pressures are main-tained in the lines.

NOTE

The probe calibration gas fitting has aseal cap which must be in place at alltimes except during calibration.

In addition to the precisioncalibration gas mixtures,clean, dry, oil-free instrumentair should be used forcalibration.

REFERENCE AIRCONNECTION

REFERENCEAIR SETFLOW METER

INSTR.AIR IN

LEAK TIGHTVALVES

0.4%O2

8.0%O2

2 SCFH5 SCFH

PROBE(END VIEW)

CALIBRATEIN-PLACE

FITTING

CHECKVALVE

REG

PROBE CALIBRATION GAS FITTING HAS ASEAL CAP WHICH MUST BE IN PLACE ATALL TIMES EXCEPT DURING CALIBRATION.

NOTE:

Figure 3-3. Typical Calibration Setup


February 1998


World Class 3000

When the calibration gas lineexceeds 6 feet (1,8 m) inlength from the leak tightvalves, a check valve, Rose-mount P/N 6292A97H02,should be installed next to thecalibration gas connection onthe probe to prevent breathingof the line with the processgas and subsequent gas con-densation and corrosion.

NOTE

Only set the test gas flowmeter uponinitial installation and after changingthe diffusion element. A slightly lowertest gas flow rate may indicate aplugged diffusion element.

2 Set the test gas pressureregulators and the flow meterfor a flow of 5 SCFH at 20 psi(138 kPa) for both gases. Thereference gas should beflowing as in normaloperation.

3 Refer to paragraph 2 of thissection for Manual (Semiau-tomatic) Calibration setup andprocedure using the CRE.

4 Test gases will be switched onand off using the shutoffvalves.

Test Method "B" Rosemount Oxy-gen Test Gas and Service Kit.

(a) Required Equipment.


NOTE


1 Portable Rosemount OxygenTest Gas Kits (Figure 3-4),Rosemount P/N 6296A27G01,containing 8% and 0.4%gases in a portable carryingcase with regulator, built-invalve, hose and connectingadapter to the calibration gasconnection.

TEST GASKIT #1

(P/N 6296A27G01)

629100

Figure 3-4. Portable Rosemount OxygenTest Gas Kit



World Class 3000

2 Extra gas bottles are availableat:

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

Rosemount LimitedBurymead RoadHitchin, Herts. U.K.

Rosemount ItalyVIA Guido Cavalcanti 820127 Milan, Italy

Rosemount SpainSaturnino Calleja 628002 MadridSpain

Rosemount France165 Boulevard de Vallmy92706, Colombes, France

Rosemount P/N 3530B07G01for probe 0.4% oxygen in ni-trogen in disposable bottle.

Rosemount P/N 3530B07G02for probe 8% oxygen in nitro-gen in disposable bottle.

3 A check valve or manual blockvalve is required at the probe(between the calibration fittingand the gas line) to preventthe migration of processgases down the calibrationgas line.

(b) Calibration with a Portable Rose-mount Oxygen Test Gases Kit.

1 A typical portable test calibra-tion setup is shown in Figure3-5. For Manual (semiauto-matic) calibration, remove capplug from the calibrate inplace fitting. The cap plugmust be retained to seal thisfitting after calibration is com-plete; failure to do so mayrender the probe useless if thesystem pressure is slightly

CALIBRATE INPLACE

CONNECTION

CHECKVALVE

PUSHBUTTONREGULATOR

WITH CONTENTSGAGE - SET 5 SCFH

REFERENCE AIRCONNECTION

TEST HOSECONNECTSTO CHECKVALVE

0.4%O2

8.0%O2

NOTE: PROBE CALIBRATION GASFITTING HAS A SEAL CAPWHICH MUST BE IN PLACEEXCEPT DURING CALIBRATION. 19270009

Figure 3-5. Typical Portable TestCalibration Setup

negative. The reference gasshould be flowing as in normaloperation.

2 Refer to paragraph 2 of thissection for Manual (Semiau-tomatic) Calibration setup andprocedure using the CRE.

3 Screw the pushbutton regu-lator with contents gage on tothe test gas of choice and in-ject the test gas by openingthe valve. Gas is on continu-ously when the valve isopened.

2. Manual (Semiautomatic) CalibrationProcedure. The calibration is manuallyperformed by the operator upon dataqueues from the CRE. Any systemwithout an MPS 3000 Multiprobe TestGas Sequencer must follow thesesteps.

In order for the system to calibratemanually, the following parametersfrom the Cal_Cfg menu have to beentered. This menu can be reachedfrom the top level SETUP sub-menu bymaking the following selections:Probes; Configure Probes; Probe N;Calibration. Refer to Table 3-6, SETUPSub-menu.


February 1998


World Class 3000

AutoCal YES/NOOutput Tracks

Set to NO

YES/NO Set as desired.

MPS Number

Cal Intrvl

Next Date

Next Time

Test Gas Time

Purge Time

N

DDD

DDMMMYY

HH:MM

0:00

0:00

Set the desired MPSnumber. Even thoughan MPS is not beingused, the test gas val-ues from this MPS willbe used for calibratingthis probe. Any otherprobe using thesesame test gas valuesshould reference thissame MPS.The calibration intervaltime does not apply tomanual calibrations.

The next calibrationtime does not apply tomanual calibrations.

The next calibrationdate does not apply tomanual calibrations.

The test gas time doesnot apply to manualcalibrations.

The purge time doesnot apply to manualcalibrations.

Res Alarm _____ Set the desired resis-tance alarm between50 to 10000 ohms.

The following parameters from the MPS_Cfg menumust entered. This menu can be reached from thetop level SETUP sub-menu by making the followingselections: Probes; Configure MPS; MPS N. Refer toTable 3-6, SETUP Sub-menu.High Gas

Low Gas

Controlled by Prb

X.XXXX%

X.XXXX%

N

Set the value of thehigh test gas bottle.

Set the value of the lowtest gas bottle.

Enter a value of 0.

Once these parameters have beenset, the operator will be guidedthrough a manual calibration asfollows:

1 Select the probe to be cali-brated by setting the CurrentProbe parameter in thePrb_Set menu. This menucan be reached from the toplevel SETUP sub-menu bymaking the following selec-tions: Probes. Refer to Table3-6, SETUP Sub-menu.

2 Start the calibration procedureby selecting Perform Calibra-tion from the Prb_Cal menu.This menu is the top levelCAL menu. The LCD displaywill read Press ENTER to startManual Calibration. PressENTER to start. Follow thedata queues. Refer to Table3-5, CALIBRATE Sub-menu(AUTO CAL in PROBESETUP is NO) for a list of thedata queues.

d. Fully Automatic Calibration

1. Test Gases for Fully Automatic Cali-bration. For fully automatic calibra-tion, an MPS 3000 Multiprobe TestGas Sequencer is required as well asthe two types of test gas.


NOTE




World Class 3000

(a) Two tanks of precision calibrationgas mixtures. Recommended cali-bration gases are nominally 0.4%and 8.0% oxygen in nitrogen.

(b) An MPS 3000 properly connectedto the probe and the CRE. Refer

to paragraph 2-4, Multiprobe TestGas Sequencer Installation.

A typical automatic calibration systemis shown in Figure 3-6.

PROBE(END VIEW)

TEST GASHPS

CHECKVALVE

PROBESIGNAL CONNECTIONS

MPS-CRESIGNALCONNECTIONS

MPS

INSTRUMENTAIR IN

TEST GAS 1(HIGH O2)

TEST GAS 2(LOW O2)

NOTES: THE MPS CAN BE USED WITH UP TOFOUR PROBES. ONLY ONE PROBE CANBE CALIBRATED AT A TIME. PROBECALIBRATIONS MUST BE SCHEDULEDIN MULTIPLE PROBE APPLICATIONS.

SHOWN WITH HPS OPTION.

CRE

REFERENCEAIR

Figure 3-6. Typical Automatic Calibration System


February 1998


World Class 3000

2. Fully Automatic Calibration Setup.The calibration is fully controlled by theCRE 3000 system using an MPS 3000Multiprobe Test Gas Sequencer tocontrol the application of test gas.

In order for the system to calibrateautomatically, the following parametersfrom the Cal_Cfg menu have to beentered. This menu can be reachedfrom the top level SETUP sub-menu bymaking the following selections:Probes; Configure Probes; Probe N;Calibration. Refer to Table 3-6, SETUPSub-menu.

Auto Cal YES/NO Set to YES

OutputTracks

YES/NO Set as desired.

MPSNumber

N Set the desired MPSnumber.

Cal Intrvl DDD Set the calibration in-terval in days. If auto-matic initiation ofcalibrations is not de-sired, this value shouldbe decreased under 1to DISABLED.

Next Date DDMMMYY Set the date for thenext automatic cali-bration.

Next Time HH:MM Set the time of thenext automatic cali-bration.

Gas Time 0:00 Set the amount of timefor the test gases to beturned on in seconds,allow enough time forsignal value to stabi-lize.

Purge Time 0:00 Set the amount of timefor the gas lines toclear (probe returns toprocess) in number ofminutes and seconds.

Res Alarm ____ Set the desired resis-tance alarm between50 to 10000 ohms.

The following parameters form the MPS_Cfg menumust be entered. This menu can be reached fromthe top level SETUP sub-menu by making the fol-lowing selections: Probes; Configure MPS� MPS N.Refer to Table 3-6, Setup Submenu.

High Gas X.XXXX% Set the value of thehigh test gas bottle.

Low Gas X.XXXX% Set the value of thelow test gas bottle.

Controlledby Prb

N Enter the number ofthe probe that iswired to the MPS forhigh and low testgas control. Refer toparagraph 2-4, Mul-tiprobe Test GasSequencerInstallation.

Once these parameters have been set,the system will initiate calibration with-out operator intervention as set by theCAL INTVL parameter.

3. Manually Initiated Fully AutomaticCalibration Procedure. The followingprocedure relates to an operator initi-ated calibration, either by a remoteswitch or selected at the CRE bypressing the CAL key using an MPS3000 Multiprobe Gas Sequencer.

(a) Select the probe to be calibratedby setting the Current Probe pa-rameter in the Prb_Set menu. Thismenu can be reached from the toplevel SETUP sub-menu by makingthe following selection: Probes.Refer to Table 3-6, SETUP Sub-menu.

(b) Start the calibration procedure byselecting Perform Calibration fromthe Prb_Cal menu. This menu isthe top level CAL menu. PressENTER to start AUTO; Calibrationwill appear on the LCD display.Press ENTER to start. Follow thedata queues. Refer to Table 3-5,CALIBRATE Sub-menu for a list ofthe data queues that will appear.



World Class 3000


February 1998

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

World Class 3000

SECTION 4TROUBLESHOOTING

4-1 OVERVIEW

The system troubleshooting section describeshow to identify and isolate faults which may de-velop in the oxygen analyzer system. Refer toProbe, IFT, HPS, and MPS Appendices.

4-2 SPECIAL TROUBLESHOOTING NOTES

Install all protective equipment coversand safety ground leads after trouble-shooting. Failure to replace coversand ground leads could result in seri-ous injury or death.

a. Grounding

It is essential that adequate grounding pre-cautions are taken when the system is be-ing installed. A very thorough check mustbe made at both the probe and electronicsto ensure that the grounding quality has notdegraded during fault finding. The systemprovides facilities for 100% effectivegrounding and the total elimination ofground loops.

b. Electrical Noise

The CRE has been designed to operate inthe type of environment normally found in aboiler room or control room. Noise suppres-sion circuits are employed on all field termi-nations and main inputs. When fault finding,the electrical noise being generated in theimmediate circuitry of a faulty system shouldbe evaluated.

c. Loose Integrated Circuits

The CRE uses a microprocessor and sup-porting integrated circuits. Should the elec-tronics unit receive rough handling duringinstallation in a location where it is sub-jected to severe vibration, an IntegratedCircuit (IC) could work loose. The fault find-ing guide, Table 4-1, shows the resultingvariety of failure modes. It is recommendedthat all IC's be confirmed to be fully seatedbefore troubleshooting on the system be-gins.

d. Electrostatic Discharge

Electrostatic discharge can damage the IC'sused in the electronics unit. It is essentialbefore removing or handling the processorboard or the IC's used on it, that the userensure he/she is at ground potential.

4-3 PROBE TROUBLESHOOTING

a. Probe Faults

Listed below are the three symptoms ofprobe failure.

1. The system does not respond tochanges in the oxygen concentration.

2. The system does respond to oxygenchanges, but does not give the correctindication.

3. The system does not give an accept-able indication of the value of the oxy-gen test gas being applied duringcalibration.

b. Table 4-1 provides a guide to fault findingfor the above symptoms.


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

World Class 3000

Table 4-1. Fault Finding

SYMPTOM CHECK FAULT REMEDY

1. No response tooxygen concen-tration changewhen:

Heater is coldand TC mV out-put is less thanset point

Heater is hotand T/C mV out-put is at set point+0.2 mV

Thermocouple continuity

Heater cold resistance tobe 11 ohm to 14 ohm

Triac O/P to heater

Recorder chart

Cell mV input to elec-tronics and cell mV atprobe head

Thermocouple failure

Heater failure

Failure of electronics

Recorder failure

No cell mV at probe

Probe cell mV OK, butno input to electronics

Cell MV satisfactoryboth at probe head andinput to electronics -failure of electronics

Replace thermocouple or re-turn probe to Rosemount.

Replace heater or return probeto Rosemount.

Replace faulty DPI board orHPS. Configure jumpers onnew board. See Table 2-2, DPICard Jumper Configuration.

See Recorder InstructionManual.

Replace cell or return probe toRosemount.

Check out cable connection.

Replace faulty DPI board.Configure jumpers on newboard. See Table 2-2, DPICard Jumper Configuration.

2. System re-sponds tooxygen concen-tration changes,but does notgive correctindication

Good responsewith incorrectindication

Recorder or remoteindicator

System calibration

Probe mounting andcondition of duct

Cell mV input to elec-tronics

Calibration error

Calibration error

Air ingress into duct

Failure of electronics

Recalibrate recorder or indi-cator Reference Recorder In-struction Manual.

Recalibrate system.

Stop air leaks or resite probe.

Replace faulty DPI board.Configure jumpers on newboard. See Table 2-2, DPICard Jumper Configuration.


February 1998

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

World Class 3000

Table 4-1. Fault Finding (Continued).


3. System doesnot give accu-rate indicationof applied testgas

Test gas input port

Ceramic diffusion ele-ment

Blocked port

Diffusion elementcracked, broken, ormissing

Clean port.

Replace diffusion element.

4-4 CRE ALARM MESSAGES

The CRE status line which is located on the topline of the LCD display may have one of thefollowing alarm messages. The alarm messagearea is in the upper left corner of the LCD. Themessage pertains to the current probe which isindicated by the probe number in the upper rightcorner of the LCD display.

a. *DPI E

The CRE cannot communicate with theprobe interface board. Check the probeconfiguration and probe interface board'sjumper configuration or replace the faultyinterface board.

b. *Cal E

O2 calculation constants calculated after thelast calibration were outside allowable limits.Check test gas connections and MPS con-figuration or replace faulty cell.

c. *Htr E

The probe temperature is outside allowablelimits. Check heater connections, thermo-couple, HPS triac, and heater coil in probe.

d. Tglow

The test gas pressure is low for one of thetest gases connected to this probes MPS.

e. HiO2

The O2 reading for this probe is above thehigh alarm limit.

f. LoO2

The O2 reading for this probe is below thelow alarm limit.

g. R Hi

The cell resistance measured during the lastcalibration is above the configured highalarm limit.

h. *Dable

The probe has been disabled by selectingNO in the Enable Probe menu.

i. *Off

This probe has been turned off at the HPSby selecting OFF in the Enable Probe menuor the heater has failed.

j. PRBE

The probe is disconnected, cold, or leadsare reversed.

k. COME

There is communication failure betweenMaster and Slave.

*These states cause the O2 reading to bedropped for any averages.


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

World Class 3000


February 1998

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

World Class 3000

SECTION 5RETURN OF MATERIAL

5-1 If factory repair of defective equipment is re-quired, proceed as follows:

a. Secure a return authorization number froma Rosemount Analytical Sales Office orRepresentative before returning the equip-ment. Equipment must be returned withcomplete identification in accordance withRosemount instructions or it will not be ac-cepted.

In no event will Rosemount be responsiblefor equipment returned without properauthorization and identification.

b. Carefully pack defective unit in a sturdy boxwith sufficient shock absorbing material toensure that no additional damage will occurduring shipping.

c. In a cover letter, describe completely:

1. The symptoms 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 re-moved.

4. Whether warranty or nonwarrantyservice is requested.

5. Complete shipping instructions for re-turn of equipment.

6. Reference the return authorizationnumber.

d. Enclose a cover letter and purchase orderand ship the defective equipment accordingto instructions provided in Rosemount Re-turn Authorization, prepaid, to:

Rosemount Analytical Inc.RMR Department1201 N. Main StreetOrrville, Ohio 44667

If warranty service is requested, the defec-tive unit will be carefully inspected andtested at the factory. If failure was due toconditions listed in the standard Rosemountwarranty, the defective unit will be repairedor replaced at Rosemount's option, and anoperating unit will be returned to the cus-tomer in accordance with shipping instruc-tions furnished in the cover letter.

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


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

World Class 3000


February 1998

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

World Class 3000

SECTION 6APPENDICES

APPENDIX A. WORLD CLASS 3000 OXYGEN ANALYZER (PROBE)

APPENDIX B. HPS 3000 HEATER POWER SUPPLY FIELD MODULE

APPENDIX C. CRE 3000 CONTROL ROOM ELECTRONICS MODULE

APPENDIX D. MPS 3000 MULTIPROBE TEST GAS SEQUENCER

APPENDIX G. MASTER/SLAVE CRE 3000 CONTROL ROOM ELECTRONICSMODULES

Instruction ManualAppendix A Rev. 3.6July 1998

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

World Class 3000

2

3

NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FORPURCHASE SEPARATELY. FOR LIST OFAVAILABLE PARTS, SEE TABLE A-3.

29

1

27

28

25

24

26

20

19 17

78

1513

16

18

23

2210

11

21

20

11

14

12

10

9

4

5

6

NOTE: ITEM , CALIBRATION GAS TUBE,

FITS INTO HOLES WHEN PROBE IS

ASSEMBLED.21240005

APPENDIX A 1. Heater, Strut, and Backplate Assembly 2. Diffusion Assembly 3. Retainer Screw 4. Cell and Flange 5. Corrugated Seal 6. Probe Tube Assembly 7. Screw 8. Washer 9. Cover Chain Screw 10. Cover Chain 11. Probe Junction Box Cover 12. Cover Gasket 13. Wiring Diagram 14. O-Ring 15. Terminal Block Screws 16. Terminal Block 17. Terminal Block Marker 18. Terminal Block Mounting Plate

19. Probe Junction Box Screws 20. Hose Clamp 21. Hose 22. Gas Connection 23. Seal Cap 24. Label 25. Probe Junction Box 26. Ground Wires 27. Insulating Gasket 28. Washer 29. Screw

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

Instruction ManualAppendix A Rev. 3.6

July 1998

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

World Class 3000

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

DESCRIPTION

Read the “Safety instructions for thewiring and installation of this appara-tus” at the front of this InstructionBulletin. Failure to follow the safetyinstructions could result in seriousinjury or death.

A-1 OXYGEN ANALYZER (PROBE) - GENERAL

The Oxygen Analyzer (Probe), Figure A-1, con-sists of three component groups: probe exterior,inner probe, and probe junction box, Figure A-2.

PROBEEXTERIOR(SENSING CELL INSTALLED)

PROBEINTERIOR

PROBEJUNCTION

BOX

21240006

Figure A-2. Main Probe Components



World Class 3000

Table A-1. Specifications for Oxygen Analyzing Equipment.1, 2

Probe lengths, nominal ................................................................. 18 inches (457 mm), 3 feet (0.91 m), 6 feet(1.83 m), 9 feet (2.74 m), or 12 feet (3.66 m),depending on duct dimensions

Temperature limits in processmeasurement area............................................................ 50° to 1300°F (10° to 704°C)

Standard/current output ................................................................. 4-20 mA dc signal (factory set)O2 indication (Digital display

and analog output) ............................................................ 0.1% O2 or ±3% of reading, whichever isgreater using Rosemount calibration gases

System speed of response ............................................................ less than 3 seconds (amplifier output)Resolution sensitivity...................................................................... 0.01% O2 transmitted signalHPS 3000 housing ......................................................................... NEMA 4X (IP56)Probe reference air flow................................................................. 2 scfh (56.6 L/hr) clean, dry, instrument quality

air (20.95% O2), regulated to 5 psi (34 kPa)Calibration gas mixtures ................................................................ Rosemount Hagan Calibration Gas Kit Part No.

6296A27G01 contains 0.4% O2N2 Nominal and8% O2N2 Nominal

Calibration gas flow........................................................................ 5 scfh (141.6 L/hr)HPS 3000 Power supply .............................................................. 100/110/220 ±10% Vac at 50/60 HzHPS 3000 Power requirement ..................................................... 200 VAHPS 3000 Ambient Operating Temperature................................ 32° to 120°F (0° to 50°C)Ambient operating temperature (Probe Junction Box) .................. 300°F (150°C) maxApproximate shipping weights:

18 inch (457 mm) package ............................................... 55 pounds (24.97 kg)3 foot (0.91 m) package.................................................... 60 pounds (27.24 kg)6 foot (1.83 m) package.................................................... 65 pounds (29.51 kg)9 foot (2.74 m) package.................................................... 72 pounds (32.66 kg)12 foot (3.66 m) package.................................................. 78 pounds (35.38 kg)

1All static performance characteristics are with operating variables constant.2Equipment 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.


July 1998


World Class 3000

A-2 PROBE ASSEMBLY EXTERIOR

Primary probe exterior components include aflange-mounted zirconium oxide cell, mountedon a tube assembly and protected by a snubberdiffusion assembly.

a. Cell and Flange Assembly

The primary component in the cell andflange assembly, Figure A-3, is ayttria-stabilized zirconium oxide cell. It cre-ates an electrical signal when the oxygenlevel on one side is out of balance with theoxygen level on the other side. This signalis proportional to the difference in oxygenlevels.

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 thetube.

The tube assembly includes a flange whichmates with a stack-mounted flange (shownattached to the probe flange in Figure A-2).Studs on the stack flange make installationeasy. There is also a tube to carrycalibration gas from the probe junction boxto the process side of the cell duringcalibration.

PROBE TUBE

CORRUGATEDSEAL

CELL ANDFLANGE

ASSEMBLY

21240007

Figure A-3. Cell and Tube Assemblies

c. Snubber Diffusion Assembly

The snubber diffusion assembly protectsthe cell from heavy particles and isolatesthe cell from changes in temperature. Thesnubber diffusion assembly threads ontothe cell and flange assembly. Pin spannerwrenches (probe disassembly kit3535B42G01) are applied to holes in thesnubber diffusion element hub to remove orinstall the snubber diffusion assembly.

An optional ceramic diffusor element andvee deflector, shown in Figure A-4, isavailable. The ceramic diffusor assembly isalso available in a flame arresting version tokeep heat from the cell from igniting fluegases.

Systems that use an abrasive shield requirea special snubber diffusion assembly with ahub that is grooved to accept two dust sealgaskets. This special diffusor is available inboth snubber and ceramic versions. SeeProbe Options, section A-6.

DIFFUSIONELEMENT

VEEDEFLECTOR

PINWRENCH

HUB

21240024

Figure A-4. Optional Ceramic Diffusor and VeeDeflector Assembly



World Class 3000

d. Cell - General

The components which make up the cell aremachined to close tolerances andassembled with care to provide accurateoxygen measurements. Any replacementrequires attention to detail and care inassembly to provide good results.

Failure to follow the instructions inthis manual could cause danger topersonnel and equipment. Read andfollow instructions in this manualcarefully.

The oxygen probe includes an innerelectrode for the cell assembly. It consists ofa platinum pad and a platinum/inconelcomposite wire which produces the cellconstant offset voltage described in theNernst equation.

With this pad and wire, the constant will bebetween -10 and +15 mV. The cell constantis noted in the calibration data sheetsupplied with each probe.

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

A-3 INNER PROBE ASSEMBLY

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

a. Ceramic support rod with four holes runningthrough the length. The holes serve asinsulated paths for the cell signal wire andthermocouple wires.

b. A heater that is helically wrapped on aquartz support cylinder and insulated.

c. A chromel-alumel thermocouple which actsas the sensing element for the temperaturecontroller. (Not visible in Figure A-5; locatedwithin ceramic support rod.)

d. A platinum screen pad which formselectrical contact with the inner electrode ofthe electrochemical cell. (Not visible inFigure A-5; located at end of ceramicsupport rod.) The pad is attached to aninconel wire which carries the signal to theterminal strip.

e. A V-strut assembly to give support to theinner probe assembly.

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

Turn to Service and Normal Maintenance, forrepair procedures for probe components.

HEATER

V-STRUT

CERAMICSUPPORT

ROD

INSULATINGGASKET

27270015

REFERENCEAIR TUBE

Figure A-5. Inner Probe Assembly


July 1998


World Class 3000

CALIBRATIONGAS FITTING

PROBEJUNCTION BOX

COVERTERMINALSTRIP

REFERENCEAIR FITTING

27270016

Figure A-6. Probe Junction Box

A-4 PROBE JUNCTION BOX

The probe junction box, Figure A-6, ispositioned at the external end of the probe andcontains a terminal strip for electricalconnections and fittings for reference air andcalibration gases. Fittings are for 0.250 inchstainless steel tubing on American units and6 mm on European units. The calibration fittinghas a seal cap which must remain in placeexcept during calibration. A tubing fitting is alsosupplied to be used with the calibration gassupply during calibration.

If the calibration gas bottles will be permanentlyhooked up to the probe, a manual block valve isrequired at the probe (between the calibrationfitting and the gas line) to prevent condensationof flue gas down the calibration gas line.

During operation and calibration, reference air issupplied through the reference air fitting to thereference side of the cell. This gives the systema known quantity of oxygen with which tocompare the oxygen level in the process gas.Though ambient air can be used for thispurpose, accuracy can only be assured if areference air set is used.

During calibration, two gases of different knownoxygen concentrations are injected one at atime through the calibration gas fitting. Stainlesssteel tubing delivers this gas to the process sideof the cell. In a healthy cell, the difference inoxygen pressure from the process side to thereference side of the cell will cause a millivoltoutput proportional to the difference in oxygenlevels. The electronics unit can use the twomillivolt outputs caused by the two calibrationgases for either automatic or semi-automaticcalibration.

Do not attempt to remove a processgas sample through either gas fitting.Hot gases from the process woulddamage gas hoses in the probejunction box.

A-5 CABLE ASSEMBLY

The system uses a 7-conductor cable toconnect 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 pairof wires for the cell millivolt signal, one shieldedpair of type K wires for the thermocouple, andthree individual 16-gauge wires for the heaterand for ground. The assembled conductors arewrapped by a type K TeflonTM jacket andbraided stainless steel shield. The TeflonTM andstainless steel jacketing is suitable for hightemperature use. All metal shields are isolatedat the probe end and connect by drain wires toground at the electronics.

A-6 PROBE OPTIONS

a. Abrasive Shield Assembly

The abrasive shield assembly, Figure A-7,is a stainless-steel tube that surrounds theprobe assembly. The shield protects theprobe against particle abrasion andcorrosive condensations, provides a guidefor ease of insertion, and acts as a probeposition support, especially for longer lengthprobes. The abrasive shield assembly usesa modified diffusor and vee deflectorassembly, fitted with dual dust seal packing.



World Class 3000

VIEW A VIEW B

A

B

A

B

15o

2.187

1

ON INSIDE BREAKFOR SMOOTHROUNDED EDGE ONBOTH ENDSOF CHAMFER

.187

6.00

12

5

.45 MIN

90o

3.5843.554

SKIN CUT FACE FOR 90o

22.5o

DIA ON A 7.50 DIA B.C. (REF).745.755

0.75 THRU 4 PLS,EQ SP ON 4.75 B.C.

NOTES: 1 WELD ON BOTH SIDES WITH EXPANDINGCHILL BLOCK.

2 BEFORE WELDING, BUTT ITEM 2 OR 4 WITHITEM 1 AS SHOWN.

.187

16860033

Figure A-7. Abrasive Shield Assembly

NOTE

In highly abrasive applications, rotate the shield 90 degrees at normalservice intervals to present a new wear surface to the abrasive flow stream.


July 1998


World Class 3000

P0010

Figure A-8. Ceramic Diffusion/Dust Seal Assembly

These modified diffusion and vee deflectorassemblies are available in standard, FigureA-8, and flame arrestor version, Figure A-9.

b. Ceramic Diffusion Assembly

The ceramic diffusion assembly, FigureA-10, is the traditional design for the probe.Used for over 25 years, the ceramic diffu-sion assembly provides a greater filter sur-face area for the probe.

P0011

Figure A-9. Flame Arrestor Diffusion/DustSeal Assembly

19280010

Figure A-10. Ceramic Diffusion Assembly

c. Flame Arrestor Diffusion Assembly

Where a high concentration of unburnedfuel is present in the exhaust gases, a flamearrestor diffusion assembly, Figure A-9 andFigure A-11 is recommended.

The flame diffusion assembly includes a setof baffles between the cell and the stackgases. This keeps 1500°F (816°C) cell tem-peratures from igniting unburned fuel in thestack.

P0012

Figure A-11. Flame Arrestor Diffusion Assembly



World Class 3000

Figure A-12. Snubber Diffusion/DustSeal Assembly

d. Snubber Diffusion/Dust Seal Assembly

The snubber diffusion/dust seal assembly,Figure A-12, is used in applications wherean abrasive shield is to be used with asnubber type diffusion element. The dustseal consists of two rings of packing to pre-vent abrasive dust from collecting inside theabrasive shield.

e. Bypass Probe Options

For processes where the flue gas exceedsthe maximum allowable temperature of1300°F (704°C) a bypass sensor packagecan be employed. The bypass system uses

an 18 inch (457 mm) or 3 foot (0.92 m)probe mounted externally on the stack orduct. The process or exhaust gases are di-rected out to the probe through a passivesampling system using inconel tubes. Fluegas flow induces the movement of gasesinto, through, and out of the bypass unit.The bypass arrangement does not requirethe use of aspiration air and the gas whichflows past the probe is returned to the stackor duct.

The bypass probe package is normally usedfor process temperatures of 1300°F (704°C)to 2000°F (1094°C). A higher temperatureversion of the bypass provides for operationat temperatures up to 2500°F (1372°C). Inthis version the pick up tubes are made of aspecial high-temperature alloy.

Overall dimensions and mounting details ofthe American and European bypass sys-tems are shown in Figure A-13.

f. Probe Mounting Jacket Options

A probe mounting jacket option is availableto allow the probe to operate at tempera-tures of up to 2000°F (1095°C). A separateinstruction bulletin is available for thisoption.


July 1998


World Class 3000

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



World Class 3000N

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July 1998


World Class 3000

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

PART NO.GROUPCODE DESCRIPTION

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



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



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






World Class 3000

PROBE TROUBLESHOOTING

A-7 OVERVIEW

The probe troubleshooting section describeshow to identify and isolate faults which may de-velop in the probe assembly.

Install all protective equipment andsafety ground leads after trouble-shooting. Failure to replace coversand ground leads could result in seri-ous injury or death.

A-8 PROBE TROUBLESHOOTING

a. Probe Faults

Listed below are the four symptoms ofprobe failure.

1. The system does not respond tochanges in the oxygen concentration.

2. The system responds to oxygenchanges but does not give the correctindication.

3. The system does not give an accept-able indication of the value of the oxy-gen calibration gas being appliedduring calibration.

4. The system takes a long time to returnto the flue gas value after the calibra-tion gas is turned off.

b. Table A-2 provides a guide to fault findingfor the above symptoms.

c. Figure A-14 and Figure A-15 provide an al-ternate approach to finding probe relatedproblems.

Table A-2. Fault Finding

Symptom Check Fault Remedy

1. No response to oxy-gen concentrationchange when:

Thermocouple continuity Thermocouple failure Replace thermocoupleor return probe toRosemount.

Heater cold resistance tobe 11 ohm to 14 ohm

Heater failure Replace heater or returnprobe to Rosemount.

Heater is cold and TCmV output is less thanset point

Triac O/P to heater Failure of electronics Check HPS and electron-ics package.

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

Recorder chart Recorder failure See Recorder InstructionManual.

Cell mV input to electron-ics and cell mV at probejunction box

No cell mV at probe whencalibration gas applied

Replace cell or returnprobe to Rosemount.

Probe cell mV OK but noinput to electronics

Check out cableconnection.

Cell mV satisfactory bothat probe junction box andinput to electronics - fail-ure of electronics

Check electronicspackage.


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World Class 3000

Table A-2. Fault Finding (Continued)

Symptom Check Fault Remedy

2. System responds tooxygen concentrationchanges but does notgive correct indication

Recorder or remoteindicator

Calibration error Recalibrate recorder orindicator. Reference Re-corder Instruction Manual.

System calibration Calibration error Recalibrate system.

Probe mounting and con-dition of duct

Air ingress into duct Stop air leaks or resiteprobe.

Good response, withincorrect indication

Cell mV input toelectronics

Failure of electronics Check electronicspackage.

Calibration gas input port Blocked port Clean port. If the flue gasis condensing in the cali-bration gas line, insulatethe back of the probe.Make sure that the cali-bration gas line is cappedbetween calibrations, or acheck valve is installed.

3. System does not giveaccurate indication ofapplied calibration gas

Ceramic diffusion element Diffusion element cracked,broken, or missing

Replace diffusion element.

4. System takes a longtime to return to fluegas value after calibra-tion gas is turned off

Diffusion element Plugged diffusion element Change diffusion elementor snubber diffusionelement.



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Figure A-14. Flowchart of Probe Related Problems, #1


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Figure A-15. Flowchart of Probe Related Problems, #2



World Class 3000

NOTE!

SERVICE AND NORMAL MAINTENANCE

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 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.

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

A-9 OVERVIEW

This section describes routine maintenance ofthe oxygen analyzer probe. Spare parts referredto are available from Rosemount. Probe disas-sembly kit 3535B42G01 contains the requiredspanner and hex wrenches. Refer to the follow-ing section of this appendix for part numbersand ordering information.

Install all protective equipment coversand safety ground leads after equip-ment repair or service. Failure to in-stall covers and ground leads couldresult in serious injury or death.

A-10 PROBE RECALIBRATION

The oxygen analyzer system should be cali-brated when commissioned. Under normal cir-cumstances the probe will not require frequentcalibration. When calibration is required, followthe procedure described in the Instruction Bulle-tin applicable to your electronics package.

A-11 CELL REPLACEMENT

This paragraph covers oxygen sensing cell re-placement. Do not attempt to replace the celluntil all other possibilities for poor performancehave been considered. If cell replacement isneeded, order cell replacement kit, Table A-3.

The cell replacement kit contains a cell andflange assembly, corrugated seal, setscrews,socket head cap screws, and anti-seize com-pound. Items are carefully packaged to preserve

precise surface finishes. Do not remove itemsfrom packaging until they are ready to be used.Spanner wrenches and hex wrenches needed forthis procedure are part of an available specialtools kit, Table A-3.

Wear heat resistant gloves and cloth-ing to remove probe from stack. Nor-mal operating temperatures of diffusorand vee deflector are approximately600° to 800°F (316° to 427°C). Theycould cause severe burns.

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

Do not remove cell unless it is certainthat replacement is needed. Removalmay damage cell and platinum pad. Gothrough complete troubleshootingprocedure to make sure cell needs re-placement before removing it.

a. Disconnect and lock out power to electron-ics. Shut off and disconnect reference airand calibration gas supplies from probejunction box, Figure A-16. Wearing heat re-sistant gloves and clothing, remove probeassembly from stack carefully and allow tocool to room temperature. Do not attempt towork on unit until it has cooled to a comfort-able working temperature.


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World Class 3000

CELL EXTENSIONWIRE (ORANGE)

BOMB TAILCONNECTOR

INCONELCELL WIRE

(CLEARSLEEVING)

HEATERWIRES(BLACK

SLEEVING)THERMOCOUPLE -

(RED ALUMEL)

THERMOCOUPLE +(YELLOW CHROMEL)

CALIBRATIONGAS FITTING

REFERENCEAIR FITTING

PROBE JUNCTIONBOX COVER

CABLE

27270019

Figure A-16. Cell Wiring Connection

b. If the probe uses the standard diffusionelement, use a spanner wrench to removethe diffusion element.

c. If equipped with the optional ceramic diffusorassembly, remove and discard setscrews,Figure A-17, and remove vee deflector. Usespanner wrenches from probe disassemblykit, Table A-3, to turn hub free from retainer.Inspect diffusion element. If damaged, re-place element.

d. Loosen four socket head cap screws fromthe cell and flange assembly and removethe assembly and the corrugated seal. Thecell flange has a notch which may be used

to gently pry the flange away from theprobe. Note that the contact pad inside theprobe will sometimes fuse to the oxygensensing cell. If the cell is fused to the con-tact pad, push the cell assembly back intothe probe (against spring pressure), andquickly twist the cell assembly. The cell andcontact pad should separate. If the contactpad stays fused to the cell, a new con-tact/thermocouple assembly must be in-stalled. Disconnect the cell and thethermocouple wires at the probe junctionbox, and withdraw the cell with the wires stillattached (see paragraph A-13).



World Class 3000

OPTIONAL CERAMICDIFFUSION ELEMENT

VEEDEFLECTOR

HUB

PINWRENCH

SETSCREW

RETAINER

CEMENTPORT

CEMENTFILLET

21240026

Figure A-17. Removal of Optional Diffusorand Vee Deflector

PROBE TUBE(NOT INCLUDED

IN KIT)

SOCKET HEADCAP SCREWS

CORRUGATEDSEAL

CELL ANDFLANGE

ASSEMBLY

CALIBRATION GASPASSAGE

21240009

Figure A-18. Cell Replacement Kit

e. If contact assembly is damaged, replacecontact and thermocouple according toparagraph A-13, Replacement of Contactand Thermocouple Assembly.

f. Remove and discard corrugated seal. Cleanmating faces of probe tube and retainer.Remove burrs and raised surfaces withblock of wood and crocus cloth. Cleanthreads on retainer and hub.

g. Rub a small amount of anti-seize on bothsides of new corrugated seal.

h. Assemble cell and flange assembly, corru-gated seal, and probe tube. Make sure thecalibration tube lines up with the calibrationgas passage in each component. Apply asmall amount of anti-seize compound toscrew threads and use screws to secureassembly. Torque to 55 in-lbs (4 N•m).

i. Apply anti-seize compound to threads ofcell assembly, hub, and setscrews. Reinstallhub on cell assembly. Using pin spannerwrenches, torque to 10 ft-lbs (14 N•m). Ifapplicable, reinstall vee deflector, orientingapex toward gas flow. Secure withsetscrews and anti-seize compound.Torque to 25 in-lbs (2.8 N•m).

j. On systems equipped with an abrasiveshield, install dust seal gaskets, with joints180o 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 asthey enter 15o reducing cone.

l. Turn power on to electronics and monitorthermocouple output. It should stabilize at29.3 ±0.2 mV. Set reference air flow at 2 scfh(56.6 L/hr). After probe stabilizes, calibrateprobe per Instruction Bulletin applicable toyour electronics package. If new componentshave been installed, repeat calibration after24 hours of operation.

A-12 OPTIONAL CERAMIC DIFFUSIONELEMENT REPLACEMENT

a. General

The diffusion element protects the cell fromparticles in process gases. It does not nor-mally need to be replaced because the veedeflector protects it from particulate erosion.In severe environments the filter may bebroken or subject to excessive erosion. Ex-amine the diffusion element whenever re-moving the probe for any purpose. Replaceif damaged.


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World Class 3000

Damage to the diffusion element may be-come apparent during calibration. Compareprobe response with previous response. Abroken diffusion element will cause a slowerresponse to calibration gas.

Hex wrenches needed to remove setscrewsand socket head screws in the following pro-cedure are available as part of a special toolkit, Table A-3.

Wear heat resistant gloves and cloth-ing to remove probe from stack. Nor-mal operating temperatures of diffusorand vee deflector are approximately600° to 800°F (300° to 425°C). They cancause severe burns.

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

It is not necessary to remove the cellunless it is certain that replacement isnecessary. Cell cannot be removed forinspection without damaging it. Referto paragraph A-11, Cell Replacement.

b. Replacement Procedure

1. Shut off power to electronics. Discon-nect cable conductors and remove ca-ble, Figure A-16. Shut off anddisconnect reference air and calibrationgas supplies from probe junction box.Wearing heat resistant gloves andclothing, carefully remove probe as-sembly from stack and allow to cool toroom temperature. Do not attempt towork on unit until it has cooled to acomfortable working temperature.

2. Loosen setscrews, Figure A-17, usinghex wrench from special tools kit,Table A-3, and remove vee deflector.Inspect setscrews. If damaged, replacewith M-6 x 6 stainless setscrewscoated with anti-seize compound.

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

4. Use spanner wrenches from specialtools kit, Table A-3, to turn hub freefrom retainer.

5. Put hub in vise. Break out old diffusionelement with chisel along cement lineand 3/8 inch (9.5 mm) pin punchthrough cement port.

6. Break out remaining diffusion elementby tapping lightly around hub withhammer. Clean grooves with pointedtool if necessary.

7. Replace diffusion element, using re-placement kit listed in Table A-3. Thisconsists of a diffusion element, ce-ment, setscrews, anti-seize compoundand instructions.

8. Test fit replacement element to be sureseat is clean.

Do not get cement on diffusion ele-ment except where it touches the hub.Any cement on ceramic elementblocks airflow through element. Wip-ing wet cement off of ceramic onlyforces cement into pores.

9. Thoroughly mix cement and insert tipof squeeze bottle into cement port. Tiltbottle and squeeze while simultane-ously turning diffusion element intoseat. Do not get any cement on upperpart of diffusion element. Ensure com-plete penetration of cement aroundthree grooves in hub. Cement shouldextrude from opposite hole. Wipe ex-cess material back into holes and wipetop fillet of cement to form a uniformfillet. (A Q-Tip is useful for this.) Cleanany excess cement from hub withwater.

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



World Class 3000

11. Wipe a heavy layer of anti-seize com-pound onto the threads and matingsurfaces of the diffusion hub andretainer.

12. Assemble retainer and diffusion hubwith two pin spanner wrenches. Torqueto 10 ft-lbs (14 N·m).

13. On systems equipped with abrasiveshield, install dust seal gaskets withjoints 180° apart.

14. Reinstall vee deflector, orienting apextoward gas flow. Apply anti-seize com-pound to setscrews and tighten withhex wrench.

15. Reinstall probe on stack flange.

16. Turn power on to electronics andmonitor thermocouple output. It shouldstabilize at 29.3 ±0.2 mV. Calibrateprobe per Instruction Bulletin applica-ble to your electronics package.

A-13 REPLACEMENT OF CONTACT ANDTHERMOCOUPLE ASSEMBLY

Use heat resistant gloves and cloth-ing when removing probe junction boxand inner probe assembly. Do not at-tempt to work on these componentsuntil they have cooled to room tem-perature. Probe components can be ashot as 800°F (427°C). This can causesevere burns.


a. Disconnect and lock out power to electron-ics. Using heat resistant gloves and cloth-ing, remove probe junction box cover.

Squeezing tabs on hose clamps, removehoses from probe junction box, Figure A-19.Remove four screws in corners of probejunction box. Pull probe junction box and in-ner probe assembly free from probe tube.Set on bench and allow to cool to roomtemperature.

b. Disconnect cell extension wire (orange),thermocouple wire (red alumel), and ther-mocouple wire (yellow chromel) by cuttingbomb tail connections from the terminalstrip, Figure A-16.

c. Remove two screws, Figure A-19, lock-washers, and flat washers that connectprobe junction box to inner probe assembly.Pull heater, V-strut and backplate assemblyaway from probe junction box. Inspect allO-rings and insulating gasket; replace if wornor damaged.

PROBE JUNCTION BOXINNER PROBE ASSEMBLYTO PROBE TUBE SCREWS

PROBE JUNCTION BOX TO HEATER,STRUT, AND BACKPLATE

ASSEMBLY SCREW

PROBEJUNCTION

BOX

HOSECLAMP

HOSE

21240027

Figure A-19. Probe Junction Box MechanicalConnections


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World Class 3000

d. Use a pencil to mark locations of spring clipon ceramic rod, Figure A-20.

e. Pry or squeeze tabs on spring clips, and pullcontact and thermocouple assembly out ofprobe assembly. Retain spring clips andspring; replace if damaged.

Be very careful when handling contactand thermocouple assembly. The ce-ramic rod in this assembly is fragile.

f. While very carefully handling new contactand thermocouple assembly, lay old as-sembly next to new one. Transfer pencilmarks to new rod.

21240010

MOUNTING SCREW(REAR VIEW)

CONTACT ANDTHERMOCOUPLER

ASSEMBLY

V-STRUT

HEATER SCREWS(NOT SHOWN)

HEATERCERAMIC ROD

SPRINGCLIP

INSULATINGGASKET

Figure A-20. Inner Probe Replacement(Heater, V-Strut, and Backplate Assembly)

g. Note wire lengths of old assembly as an aidfor trimming new lengths in step (j). Trim-ming of wires will not always be necessary.Throw away old contact and thermocoupleassembly.

h. Carefully guide new contact and thermo-couple assembly through V-strut assemblyleaf spring (4, Figure A-21), spring (9),spring clip (10) (held open by squeezingtabs), and tube supports (11, 13) untilspring clip reaches pencil mark.

i. Reinstall insulating gasket on backplate, re-place two screws, O-rings, lockwashers andflat washers connecting probe junction boxto inner probe assembly.

Do not trim new wiring shorter thanexisting (old) wiring. Excessive wiretrim will prevent connections frombeing properly made and will require anew replacement kit.

j. Trim wires, if necessary, as noted instep (g).

k. Connect color coded wires to proper termi-nals as shown in Figure A-16. Rosemountrecommends connecting the thermocouplewires directly to the terminal strip. This isbecause the junction of different metals atthe wires and lugs and at the lugs and the

1 3 45

4

8

6

78

9101111213

12

1. Heater Ceramic Rod 2. Contact and Thermocouple Assembly 3. Strut 4. Leaf Spring

5. Ring Lug 6. Butt Connector 7. Extension 8. 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)



World Class 3000

terminal strip could act as additional ther-mocouple junctions. This could produce avoltage that would affect the thermocoupleoutput signal.

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

l. Slide assembled probe junction box and in-ner probe assembly into probe tube. Toalign calibration gas tube with correspond-ing hole in backplate (A, B, Figure A-1), in-sert scriber through hole in backplate andinto calibration gas tube. Secure withscrews. Reinstall hoses and probe junctionbox cover.

m. Power up system. Monitor thermocoupleoutput. It should stabilize at set point mV±0.2 mV. Recalibrate probe per InstructionBulletin applicable to your electronicspackage.

A-14 REPLACEMENT OF HEATER, V-STRUTAND BACKPLATE ASSEMBLY (INNERPROBE ASSEMBLY; INCLUDES CONTACTAND THERMOCOUPLE ASSEMBLY)

Use heat resistant gloves and clothingwhen removing probe junction boxand inner probe assembly. Do not at-tempt to work on these componentsuntil they have cooled to room tem-perature. Probe components can be ashot as 800° (427°C). This can causesevere burns.


NOTE

This replacement may be done withoutremoving the probe from the duct.

a. Disconnect and lock out power to electron-ics. Using heat resistant gloves and cloth-ing, remove probe cover. Squeezing tabson hose clamps and remove hoses fromprobe junction box, Figure A-19. Removefour screws and lockwashers (7, 10, FigureA-22) that hold probe junction box and innerprobe assembly to probe tube. Pull probejunction box and inner probe assembly freefrom probe tube. Set on bench and allow tocool to room temperature.

b. Disconnect cell extension wire (orange),thermocouple wire (red alumel), and ther-mocouple wire (yellow chromel) by cuttingbomb tail connections from the terminalstrip, Figure A-16.

c. Remove two screws, lockwashers, and flatwashers that connect probe junction box toinner probe assembly. Remove and discardinner probe assembly (heater, V-strut, andbackplate assembly). Replace with new in-ner probe assembly. Reinstall screws, lock-washers and flat washers.

d. Connect color coded wires to proper termi-nals as shown in Figure A-16. Rosemountrecommends connecting the thermocouplewires directly to the terminal strip. This isbecause the junction of different metals atthe wires and lugs and at the lugs and theterminal strip could act as additional ther-mocouple junctions. This could produce avoltage that would affect the thermocoupleoutput signal.

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


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World Class 3000

1 2 4

3

11

5

6 7 8 9

1021240012

1. Snubber Diffusion Element 2. Socket Hd Cap Screw [0.25 in.-28 x 0.063 (16 mm)] 3. Cell and Flange Assembly 4. Corrugated Seal 5. Probe Tube Assembly

6. Gasket [4.0 in. (102 mm) x 4.0 in. x 0.12 in. (3 mm)] 7. Fillister Hd Screw [8-32 x 0.5 in. (12.7 mm)] 8. Cover Head Assembly 9. Hose Clamp 10. Lockwasher (#8 Split) 11. 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. Toalign calibration gas tube with correspond-ing hole in backplate (A, B, Figure A-1), in-sert aligning tool (included in probedisassembly kit, P/N 3535B42G01) throughhole in backplate and into calibration gastube, while sliding the heater strut into theprobe tube. Secure with screws. Reinstallhoses and probe junction box cover.

f. Power up system. Monitor thermocoupleoutput. It should stabilize at set point ±0.2mV. Recalibrate probe per Instruction Bulle-tin applicable to your electronics package.

A-15 CALIBRATION GAS AND REFERENCE AIRLINES FOR HIGH TEMPERATURE -CORROSIVE ENVIRONMENT OPERATION

A high temperature, corrosive environment kit isavailable when the probe is exposed to thesetypes of operating conditions. The kit includesstainless steel tubing and teflon fittings for in-side the probe junction box. The kit part numberis 4843B93G01.

a. Installation Procedure

Use heat resistant gloves andclothing when removing probe junc-tion box and inner probe assembly.Do not attempt to work on these com-ponents until they have cooled toroom temperature. Probe componentscan be as hot as 800°F (427°C). Thiscan cause severe burns.


1. Disconnect and lock out power to digi-tal electronics. Using heat resistantgloves and clothing, remove probecover. Squeezing tabs on hose clamps,remove hoses from probe junction box(Figure A-19).



World Class 3000

Do not use sealant when installing thestainless steel tubes. Gas samplesmay become contaminated.

2. First install the stainless steel tubing onthe fitting at the bottom of the probejunction box. Install the other end of thestainless steel tube onto the tube goingto the probe (Figure A-23).

NOTE

If abrasive conditions of high ash con-tent and high velocity exist, an abra-sive shield is recommended. Tobalance out the wear on the shield, ro-tate the shield 90° every time theprobe is powered down for service.

STAINLESSSTEEL

TUBING

TEFLONSLEEVES

21240028

Figure A-23. High Temperature - CorrosiveEnvironment Kit


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REPLACEMENT PARTS

Table A-3. Replacement Parts for Probe

Figure andIndex No. Part Number Description

Figure A-20Figure A-20Figure A-20Figure A-20Figure A-20Figure A-21, 2Figure A-21, 2Figure A-21, 2Figure A-21, 2Figure A-21, 2Figure A-7Figure A-7Figure A-7Figure A-7Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-18Figure A-10Figure A-8

3D39441G061

3D39441G071

3D39441G081

3D39441G091

3D39441G101

3534B56G042

3534B56G052

3534B56G062

3534B56G072

3534B56G082

3D39003G013

3D39003G023

3D39003G073

3D39003G083

4847B61G014847B61G024847B61G034847B61G044847B61G054847B61G064847B61G074847B61G084847B61G094847B61G104847B61G114847B61G124847B61G134847B61G144847B61G154847B61G164847B61G174847B61G183535B42G013534B18G013535B60G01

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 WireCell Replacement Kit, ANSI 18 in. (45.6 cm)Cell Replacement Kit, ANSI 3 ft (0.9 m)Cell Replacement Kit, ANSI 6 ft (1.8 m)Cell Replacement Kit, ANSI 9 ft (2.7 m)Cell Replacement Kit, ANSI 12 ft (3.6 m)Cell Replacement Kit, JIS, No Lead WireCell 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 WireCell 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 KitDiffuser AssemblyDiffuser Dust Seal Hub Assembly (For use with Abrasive Shield)



World Class 3000

Table A-3. Replacement Parts for Probe (Continued)

Figure andIndex No. Part Number Description

Figure A-10Figure A-9Figure A-11Figure A-4

Figure A-17

Figure A-23Figure A-1, 2

Figure A-12

4841B03G023535B63G013535B62G013534B48G01

6292A74G021537B70G03

4843B93G014843B37G01

4843B38G02

Stainless Steel Diffuser AssemblyFlame Arrestor Diffuser Dust SealFlame Arrestor DiffuserVee Deflector Assembly (For use with standard or dust seal type ceramic diffusers)Diffusion Element Replacement KitHorizontal and Vertical Brace Clamp Assembly, 9 and 12 foot (2.7 and 3.6 m) probeHigh Temperature - Corrosive Environment KitSnubber Diffusion Assembly

Dust Seal/Snubber Diffusion Assembly1Heater, V-strut, and backplate assembly includes contact and thermocouple assembly.2Contact and thermocouple assembly includes platinum pad and inconel wire.3Abrasive shield assembly includes accessories necessary for its use and a mounting plate and gasket.

Instruction ManualAppendix B Rev. 2.2

January 1997

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

World Class 3000

APPENDIX B, REV. 2.2HPS 3000 HEATER POWER SUPPLY

DESCRIPTION


B-1 DESCRIPTION

The Rosemount HPS 3000 Heater Power Sup-ply Field Module acts as an interface betweenprobe and electronics, and supplies power tothe probe heater. The unit allows the use ofprobes with a number of different electronicspackages.

The HPS is available in a NEMA 4X (IP56)non-hazardous enclosure or an optionalClass 1, Division 1, Group B (IP56) explo-sion-proof enclosure, Figure B-1.

The heater power supply, Figure B-2, consistsof a mother board, daughter board, and atransformer for supplying correct voltage to theprobe heater. The mother and daughter boardscontain terminal strips for connecting probe,electronics, and power supply.

The HPS is jumper configurable for 120, 220, or240 Vac. For 100 Vac usage, the HPS is fac-tory-supplied with a special transformer. The100 Vac transformer can also be easily field in-stalled. Refer to paragraph B-7, TransformerReplacement for installation procedure; refer toTable B-2, for transformer part numbers.

35730001

Figure B-1. HPS 3000 Heater Power Supply Field Module

Instruction ManualAppendix B Rev. 2.2January 1997

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

World Class 3000

TRANSFORMER

TRANSFORMER

TERMINALCOVERS

FRONT

SIDE

TERMINAL STRIP(FROM ELECTRONICS)

TERMINAL STRIP(FROM PROBE)

35730002

Figure B-2. Heater Power Supply, Interior


January 1997


World Class 3000

Table B-1. Specifications for Heater Power Supply

Environmental Classification ..................................................NEMA 4X (IP56) Optional - Class 1, Division 1,Group B (IP56)

Electrical Classification ..........................................................Category IIHumidity Range .....................................................................95% Relative HumidityAmbient Temperature Range ................................................-20° to 140°F (-30° to 60°C)Vibration .................................................................................5 m/sec2, 10 to 500 xyz planeCabling Distance Between 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 Weight ................................................12 pounds (5.4 kg)

B-2 THEORY OF OPERATION

The HPS 3000 Heater Power Supply may per-form slightly different functions, depending uponwhich electronics package it is used with. FigureB-3 shows a functional block diagram of theunit. The HPS contains a transformer for con-verting line voltage to 44 volts needed to powerthe probe heater. The relay, Figure B-3, can beused to remotely turn the probe on or off manu-ally. A triac module is used to turn the heater onor off, depending on probe temperature.

When used with the CRE 3000 Control RoomElectronics or IFT 3000 Intelligent Field Trans-mitter, the HPS uses a cold junction tempera-ture compensation feature. This allows for the

use of a less expensive cable between the HPSand CRE or HPS and IFT. The HPS and elec-tronics package can be located up to 1200 feet(364 m) apart.

The standard cable, between probe and HPS, isthermocouple compensated. This prevents theadditional junctions between thermocouple andcable from producing a voltage which would af-fect the thermocouple output signal. A tem-perature sensor in the HPS monitors thetemperature at the junction and sends a voltagesignal to the CRE and IFT. The CRE and IFTuses this signal to compensate the probe ther-mocouple reading for the temperature at thejunction between the compensated and uncom-pensated cables.

TO HEATER

PROBE TC

STACK TC

CELL

LINE

RELAY

TRIAC

AD590

PROBE TC

STACK TC

CELL MV

FROMIFT

TOPROBE

686015

Figure B-3. Heater Power Supply Block Diagram



World Class 3000

In operation, when connected to the CRE 3000Control Room Electronics, line voltage passesthrough the relay (when on) and is convertedinto 44 volts by the transformer. If the probethermocouple indicates that the probe hasdropped below operating temperature, a signalfrom the CRE triggers the triac. The triac thensupplies voltage to the probe heater, warmingthe cell. Conversely, if the probe thermocoupleindicates that the probe heater has reached theupper limit of operating temperature, the CREdeactivates the triac, shutting off power to theheater.

NOTE

When using the HPS 3000 with an ex-isting electronics package, such asModels 218, 218A, 225, or TC200, theelectronics will not have the in-put/output capacity to support all ofthe functions mentioned in this sec-tion. Refer to Instruction Bulletin IB-106-300NE.

HPS 3000 TROUBLESHOOTING

B-3 OVERVIEW

The HPS 3000 troubleshooting section de-scribes how to identify and isolate faults whichmay develop in the HPS 3000 assembly.


B-4 HPS 3000 TROUBLESHOOTING

The HPS 3000 troubleshooting may overlapwith the probe in use in the system. Faults ineither system may cause an error to be dis-played in the electronics package. Figure B-4,Figure B-5, and Figure B-6 provide trouble-shooting information.


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World Class 3000

HEATER DOES NOT HEATUP (DOES NOT INCREASEIN OUTPUT).

SET METER* FOR 50 VAC.PLACE PROBES ONTERMINAL BLOCK J2,“FROM PROBE”, PROBEHEATER.

METER INDICATESPULSATING NOMINAL44 VAC.

DISCONNECT POWER FROMHPS & PROBE ELECT. SETMETER ON RX1.

MEASURE RESISTANCE OFHEATER BY PLACINGPROBES ON TERMINALBLOCK J2, “FROM PROBE”,PROBE HEATER.

RESISTANCE MEASUREDSHOULD BE NOMINALLY12 OHMS.

SET METER TO 250 VAC.PLACE METER PROBES ONJ2, “FROM ELECTRONICS”,ANALOG HEATER.

METER SHOULD REGISTERA PULSATING NOMINAL115 VAC.

YES

DISCONNECT POWER TOHPS AND PROBEELECTRONICS. CHECKALL FOUR FUSES IN HPS.

FUSES BLOWN IN HPS.NO

NO

CHECK THAT LINE VOLTAGEIS CORRECT BY SELECTINGCORRECT JUMPERSACCORDING TO CHART ONINSIDE OF HPS COVER.

REPLACE BLOWN FUSES.

HEATER IS OPEN.REPLACE HEATER.

NO

YES YES

YES

NO

CHECK JUMPER JM2 ISINSTALLED.

IF FUSES OK, POSSIBLEPROBE ELECTRONICS TRIACFAILURE.

CHECK FUSES IN PROBEELECTRONICS.

POSSIBLE TRIAC FAILURE.REPLACE HPSMOTHERBOARD.

SYMPTOM

*SIMPSON MODEL 260 OREQUIVALENT MULTIMETER.

35730004

Figure B-4. HPS Troubleshooting Flowchart, #1



World Class 3000

HEATER OVERHEATS.NOTE: ON INITIAL STARTUP THE

TEMPERATURE OF THE PROBE MAYOVERHEAT TO A NOMINAL TEMP OF800°C.

CHECK IF THE YELLOW WIRE IS CONNECTEDTO POSITIVE AND THE RED TO NEGATIVEON BOTH “FROM ELECTRONICS” AND “FROMPROBE” TERMINAL BLOCKS. (MODELS 218AND 225 ONLY)

SET METER* ON 250 VAC SCALE.

CHECK “FROM ELECTRONIC”, ANALOGHEATER TERMINALS IF THERE IS APULSATING NOMINAL 115 VAC.

CHECK “FROM PROBE”, TERMINALS ATPROBE HEATER IF THERE IS A PULSATINGNOMINAL 44 VOLTS.

CHECK PROBE ELECTRONICS SETPOINTHAS BEEN CHANGED ACCORDING TOAPPLICABLE ELECTRONICS PACKAGE IB.

SET METER* ON 50 VAC SCALE.

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

CONNECT THE WIRINGACCORDING TO THEDECALS ON THE TERMINALCOVERS.

IF THE VOLTAGE ISCONSTANTLY ON, THENTHE TRIAC IN THE PROBEELECTRONICS IS SHORTED.

IF THE VOLTAGE ISCONSTANTLY ON, THENTHE TRIAC MODULE INTHE HPS IS SHORTED.

NO

NO

NO

YES

YES

YES

SYMPTOM

*SIMPSON MODEL 260 OR EQUIVALENT MULTIMETER. 35730003



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World Class 3000

PROBE HEATER START TO HEAT UP ANDTHEN LOOSES TEMPERATURE. (MODELTC200 ONLY)

CHECK PARAMETER 35 ON TC200. IF THENUMBER IS NEGATIVE THEN SOMEWHERETHE THERMOCOUPLE WIRES ARE REVERSED.

SYMPTOM

35730005




World Class 3000


B-5 OVERVIEW

This section describes service and routinemaintenance of the HPS 3000 Heater PowerSupply Field Module. Replacement parts re-ferred to are available from Rosemount. Refer toTable B-2 of this manual for part numbers andordering information.


B-6 FUSE REPLACEMENT

The heater power supply mother board (12,Figure B-7) contains four identical 5 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 headscrewdriver and remove fuse. After checking orreplacing a fuse, reinstall fuseholder top.

B-7 TRANSFORMER REPLACEMENT


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 oftransformer assembly. Remove retainingplate (24) and gasket (22).

d. Disconnect transformer harness plug frommother board.

e. Remove old transformer. Place new trans-former in position and reconnect harnessplug as noted in step d.

f. Place gasket and retaining plate on trans-former.

g. Tighten hex nut only enough to firmly holdtransformer in place.

h. Reinstall HPS cover.

B-8 MOTHER BOARD REPLACEMENT




c. Remove hex nut (25, Figure B-7) from top oftransformer assembly. Remove retainingplate (24) and gasket (22).

d. Disconnect transformer harness plug frommother board.

e. Remove screws on either side of terminalstrip covers (2). Remove terminal strip cov-ers (4 and 8).

f. Unplug ribbon cable from the receptacle onthe daughter board (7).

g. Unscrew stand offs on either side of thedaughter board. Remove daughter board(7).

h. Unscrew four stand offs that supported thedaughter board.


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World Class 3000

i. Making a note of the location and color ofeach wire, disconnect wires from terminalstrip on mother board.

j. Remove four screws (9) holding motherboard to stand offs (10) on subplate (14).

k. Remove mother board (12).

l. Position new mother board on stand offsand 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 andreinstall stand offs removed in step g.

o. Plug ribbon cable back into receptacle ondaughter board. Reinstall terminal covers.

p. Reinstall transformer, tightening hex nutonly enough to hold transformer firmly inposition. Reconnect transformer harnessplug to mother board.

q. Reinstall HPS cover.

B-9 DAUGHTER BOARD REPLACEMENT

When turning power off at the HPS,also turn off the respective probe atassociated electronics. When serviceon the HPS is completed, restorepower at the HPS and the associatedelectronics.



c. Remove screws on either side of terminalstrip covers (2, Figure B-7). Remove termi-nal strip covers (4 and 8).

d. Making a note of the location and color ofeach wire, disconnect wires from the termi-nal strip on the daughter board (7).

e. Unplug ribbon cable from receptacle ondaughter board.

f. Unscrew two stand offs from daughterboard. Remove daughter board (7).

g. Position new daughter board on four standoffs on mother board. Reinstall the standoffs removed in step f.

h. Plug ribbon cable into receptacle ondaughter board.

i. Reconnect wires to terminal strip in posi-tions noted in step d. Reinstall terminalcovers.

j. Reinstall HPS cover.



World Class 3000

35730006

NOTE: NOT ALL PARTS SHOWN ARE AVAILABLEFOR PURCHASE SEPARATELY. FOR LIST OFAVAILABLE PARTS SEE TABLE B-2.

Figure B-7. Heater Power Supply, Exploded View


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LEGEND FOR FIGURE B-7

1. Enclosure Cover 2. Screw 3. Lockwasher 4. Terminal Cover 5. Stand Off 6. Lockwasher 7. Daughter Board 8. Terminal Cover 9. Screw 10. Stand Off 11. Hex Nut 12. Mother Board 13. Fuse

14. Subplate 15. Enclosure Box 16. Lockwasher 17. Stand Off 18. Screw 19. Lockwasher 20. Mounting Plate 21. Screw 22. Gasket 23. Transformer 24. Retaining Plate 25. Hex Nut

REPLACEMENT PARTS

Table B-2. Replacement Parts for Heater Power Supply

FIGURE and INDEX NO. PART NUMBER DESCRIPTION

Figure B-1Figure B-1Figure B-1Figure B-1Figure B-1Figure B-1Figure B-7, 13

Figure B-7, 12Figure B-7, 7Figure B-7, 23Figure B-7, 23

3D39129G013D39129G023D39129G031U05667G011U05667G021U05667G031L01293H02

3D39080G023D39078G011M02961G011M02961G02

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, casesize; 5 x 20 mm, type T to IEC127,SchurterMother BoardDaughter BoardTransformer (120, 220, 240 Vac)Transformer (100 Vac)



World Class 3000

Instruction ManualAppendix C Rev. 2.3

January 1997

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

World Class 3000

APPENDIX C, REV. 2.3CRE 3000 CONTROL ROOM ELECTRONICS MODULE

DESCRIPTION

Read the �Safety instructions for thewiring and installation of this appara-tus� at the front of this InstructionBulletin. Failure to follow the safetyinstructions could result in seriousinjury or death.

C-1 DESCRIPTION

The Rosemount CRE 3000 Control Room Elec-tronics Module (CRE), Figure C-1, provides allnecessary intelligence for controlling probes andthe optional Multiprobe Test Gas Sequencer.The CRE provides a user-friendly, menu-drivenoperator interface with context-sensitive, on-linehelp. The CRE can be interfaced with up toeight probes.

The CRE is based on a modular design. Thereare a total of nine slots for PC boards available.The CRE contains a processor board (CPU),analog and relay output boards, and dual probeinterface (DPI) boards.

The CRE front panel consists of a General UserInterface (GUI) and an Auxiliary Display Panel(ADP) mounted in a standard 19 inch (482 mm)cabinet. All operator-set variables are input us-ing the LCD screen and keyboard on the GUI.

The number of DPI boards and input/outputconnections on the rear termination panel mayvary depending on the input/output require-ments and number of probes in the user's sys-tem. Each DPI termination panel hasconnections for two probes. There can be up tofour DPI termination boards per CRE unit. Therecan be up to two Analog Output Panels and oneRelay Output Panel (Figure C-2).

HIGHLOW

CALFAULT

1 2 3 4 5 6 7 8 1 2 3 4AVERAGEANALYZER HELP DATA CAL SETUP

ENTERESC

CRE 3000

21240016

Figure C-1. CRE 3000 Control Room Electronics Module

Instruction ManualAppendix C Rev. 2.3January 1997

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

World Class 3000

DPI PANELS (UP TO 4)ANALOG OUTPUTPANELS (UP TO 2)

RELAY OUTPUTPANELRSC-232

CONNECTION

POWERSWITCH

ACIN

Figure C-2. CRE 3000 Rear Panel

a. CPU Board

The CPU board contains EEPROM, RAM,and a real time clock. The board is con-nected to a battery back-up. The batteryback-up is located off the board, on the rightpanel of the enclosure; if the CPU is re-placed or the battery disconnected, the op-erator will have to reset the clock. Theprogram software is contained in the non-volatile memory of the EEPROM.

The CPU card also controls the probe heat-ers. This configuration requires the use ofthe HPS 3000 Heater Power Supply thatcontains a transformer and control circuitryfor providing power to the heater.

b. Dual Probe Interface Board

Each dual probe interface board (DPI) cansupport two probes and one test gas se-quencer. The CRE can hold up to four DPIboards, for a maximum of eight probes. TheDPI provides analog inputs for the cell volt-age signal, heater thermocouple signal, andthermocouple cold junction temperaturesensor for each probe.

An output for the heater drive circuit, locatedin the Heater Power Supply, is also pro-vided by the DPI. This signal is used to tellthe HPS when to energize or de-energizethe probe heater.

The DPI controls the Multiprobe Test GasSequencer (MPS). Control is through opencollector type digital outputs that directlydrive the solenoids in the MPS.

c. Analog Outputs

The analog outputs are user-configurableusing the GUI screen and keypad, and canbe sent to a strip chart recorder, data acqui-sition system or similar recording device.Output data can be used as a permanentrecord of oxygen readings.

The outputs are configurable to be eithervoltage or current by means of a jumper onthe analog output board. If set to current,the outputs can be configured to be 0-20mA or 4-20 mA using the GUI screen andkeypad. The user can then select whetherthe output is to represent high or low O2

readings or an averaged reading for one toeight probes. The high and low limits, aswell as the time period and number ofprobes used in determining an average, areuser-selectable.

Each analog output board holds two out-puts, with an additional two being addedthrough the use of a piggyback board. TheCRE can hold up to twelve analog outputs(three boards with piggybacks). Each ana-log output rear termination panel containsterminals for up to eight outputs.


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d. Relay Outputs

The relay output board contains a total ofeight relays (Form-C, 48 V max, 100 mAmax). These outputs can control signals upto 48 volts and can be configured to benormally open or normally closed.

The analog outputs are user-configurable torepresent high or low values of either cur-rent or averaged readings of up to eightprobes. The outputs can be used to operateauxiliary equipment such as an annunciator.The rear termination panel is the same asthat used for the analog outputs, and pro-vides terminals for eight outputs.

e. General User Interface

The GUI has a 4-line by 20-character liquidcrystal display (LCD) and eight membrane

keys. All operator-set variables are inputusing the LCD screen and keyboard.

f. Auxiliary Display Panel

The ADP has two rows of eight 16-segmentlight emitting diodes (LED) which can beconfigured to display any two readings (ei-ther current or averaged O2 from any two ofeight probes). Indicating LEDs for HIGH,LOW, CAL, and FAULT are provided for upto eight analyzers. HIGH and LOW indicatorLEDs are provided for four averages. Thereis also a SYSTEM FAULT indicator thatlights to indicate system malfunction.

g. Run/Par Keylock Switch

The RUN/PAR keylock prevents accidentalchanges to system parameters while in theRUN position. Turning the key to PAR al-lows parameter change and calibration.

Table C-1. Specifications for Control Room Electronics

Ambient Environment Requirements .......................... Clean, dryAmbient Temperature Range...................................... 40° to 120°F (4° to 50°C)VibrationSlight ............................................................. 30 degree drop testNumber of Probes....................................................... 8 maximum, expandable to 16 with slave CRE 3000*Communications........................................................ 1 RS-232 for control room communication (printer,

modem) IBM PC or slave CRE 3000 max 50 ft (15 m)1 RS-485 for field communications (IFT 3000) max180 feet (55 m)

Analog Outputs ........................................................... 2-12 isolated outputs: 0-20 mAdc or 4-20 mAdc into950 ohms max, 0-10 Vdc into 2K min ohms

Output Resolution ....................................................... 11 bits (1 bit = 0.05% of output F.S.)Programmable Contact Outputs ................................. 8 available, Form-C, 48 V max, 100 mA maxIndicators..................................................................... LED indicators for system failure (failure description

available on LED panel), calibration in progress foreach of 8 probes, O2 Hi/Lo alarm for each of eightprobes, probe failure for each of eight probes

Programmable Display................................................ 2, 0.8 inch (20 mm) high, 8-digit alphanumeric LEDdisplays

Operator Interface....................................................... 4-line by 20-character backlit LCD alphanumeric dis-play; 8-key general purpose keyboard

Approximate Shipping Weight .................................... 35 pounds (16 kg)

*Available at future date



World Class 3000

h. Optional Panel Mounting Kit

The panel mounting kit consists of a trimframe, back cover, trim strips, and screws.The trim frame slides over the CRE unit asshown in Figure C-3. The trim frame coverswall cuts. The rear cover mounts to the backof the unit with the same screws holding thetrim strips, protecting wires and terminals.The part number for the panel mounting kitis 1L03636G01.

C-2 THEORY OF OPERATION

A functional block diagram of the CRE, con-nected to the HPS and probe, is shown inFigure C-4. In operation, the CRE monitors thetemperature of the cell by means of the probethermocouple. If the temperature of the cell hasexceeded the operator-set high or low limits, theCRE sends a signal to the heater power supply.The heater power supply then either energizes

or de-energizes the probe heater to maintain theproper operating temperature.

A cold junction temperature compensation fea-ture ensures an accurate probe thermocouplereading. A temperature sensor in the heaterpower supply monitors the temperature at thejunction between the compensated cable run-ning to the probe and the uncompensated cablerunning to the CRE. The voltage from this sen-sor is used by the CRE to compensate theprobe thermocouple readings for the tempera-ture at the junction.

The cell signal is a voltage proportional to theoxygen concentration difference between thetwo sides of the cell. The CRE receives this sig-nal and translates it into a user-specified formfor display and/or output. The readings can beconfigured to be a current oxygen percentagefor each (up to eight) probes or an average of anumber of probes for a specific period of time.

Figure C-3. Optional Panel Mounting Kit


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World Class 3000

PROBE

ZEROCROSSINGDETECTOR

TRIACRELAYTO HEATER

COLDJUNCTION

TEMP.PROBE TC

STACK TC

CELL

LINE

RELAY

TRIAC

AD590

PROBE TC

STACK TC

CELL MV

HEATER POWER SUPPLY(OPTIONAL)

TRANSFORMER

CONTROL ROOM ELECTRONICS

19270010

Figure C-4. System Block Diagram



World Class 3000


C-3 OVERVIEW

This section describes service and routinemaintenance of the CRE Control Room Elec-tronics Module. Service and routine mainte-nance on replacement parts referred to areavailable from Rosemount. Refer to Replace-ment Parts of this Appendix for part numbersand ordering information.


C-4 MAINS FILTER ASSEMBLY FUSEREPLACEMENT

The mains filter assembly (30, Figure C-5) con-tains two identical 5 amp fuses (29). Refer toTable C-1 for replacement fuse specifications.Perform the following procedure to check or re-place a fuse (29).

Disconnect and lock out power beforeworking on any electrical components.

1. Turn off power to the CRE.

2. Remove the power cord (39) from theAC IN plug on the mains filter assem-bly (30) to gain access to thefuseholder.

3. With your finger, pull out the fuseholderwhich is located between the AC INplug and the mains power switch onthe mains filter assembly (30).

4. When the fuseholder drawer is fullyextended, the drawer will swing downmaking the fuses (29) accessible.

5. After checking or replacing a fuse,swing the fuseholder drawer into placeand press firmly back into the mainsfilter assembly.

LEGEND FOR FIGURE 2-1

1. Lithium Battery 2. Battery Holder 3. Front Card Support 4. Rear Card Support 5. Flat Washer 6. Lock Washer 7. Screw 8. Spacer 9. Backplane 10. Top Cover 11. Power Supply Assembly 12. Harness Assembly 13. Not Used 14. Not Used 15. Not Used 16. Power Supply 17. 3 Amp Fuse 18. Mains Wire Assembly 19. Power Supply Mounting Plate 20. Screw

21. Relay/Analog Output Assembly 22. Relay/Analog Output Assembly 23. Back Panel Plate 24. DPI Assembly 25. Terminal Strip 26. Shield 27. Back Panel Plate 28. RS-232 Ribbon Cable Assembly 29. 5 Amp Fuses 30. Mains Filter Assembly 31. Back Panel Mounting Plate 32. Nut 33. Screw 34. Retaining Strip 35. Screw 36. Side Panel Strip 37. Bottom Panel 38. Foot 39. Power Cord 40. CRE Enclosure

41. Tip Up Foot 42. GUI/ADP Ribbon Cable

Assembly 43. GUI Assembly 44. Retaining Nut 45. Front Panel 46. Allen Screw 47. Run/Par Keylock Switch 48. ADP Assembly 49. PCB Shield 50. PCB Retainer 51. GUI PCB Ribbon Cable

Assembly 52. Processor Board 53. Relay Output Card 54. Analog Output Card 55. DPI Card 56. Card Guides 57. Driver PCB Cable

Assembly


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Figure C-5. CRE 3000 Control Room Electronics Module, Exploded View



World Class 3000

C-5 BATTERY REPLACEMENT

A lithium type battery (1, Figure C-5) is installedin the CRE to ensure that current operating pa-rameters are not lost during power failure. Toreplace the battery, perform the followingprocedure.


1. Turn off power to the CRE.

2. Remove the two screws (35) on eachof the retaining strips (34) on the CREback panel. Remove the retainingstrips (34).

3. Slide the top panel (10) off of the unit.

4. Note the color and position the twobattery connectors and remove themfrom their terminals on the backplane(9).

5. Remove the two screws (7), lockwashers (6), and flat washers (5)holding the battery holder (2) to therear card support (4).

6. The battery (1) is fastened to the bat-tery holder (2) with velcro. Remove theold battery.

7. Place the new battery in the batteryholder (2) and attach to the rear cardsupport (4) with two screws (7), lockwashers (6), and flat washers (5).

8. Attach the two battery connectors totheir respective terminals on the back-plane (9) as noted in step 4.

9. Slide the top panel (10) back onto theunit.

10. Reinstall both retaining strips (34) withtwo screws (35).

C-6 POWER SUPPLY MAINTENANCE

a. Power Supply Fuse Replacement

There is a 3 amp fuse (17, Figure C-5) lo-cated on the rear portion of the power sup-ply (16). Proceed with the followingprocedure to check or replace a fuse.


1. Turn off power to the CRE module.

2. Remove the two screws (35) on eachof the retaining strips (34) on the CREback panel. Remove the retainingstrips (34).


4. With a plastic fuse puller, remove thefuse (17) from the power supply (16).

5. After checking or replacing the fuse,slide the top panel (10) back onto theunit.

b. Power Supply Replacement



2. Remove the two screws (35, FigureC-5) on both retaining strips (34) on theCRE back panel. Remove the retainingstrips.


4. With a 5/32 Allen wrench, remove thetwo Allen screws (46) and washers (6)retaining the CRE front panel (45).


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World Class 3000

5. Disconnect the GUI PCB ribbon cableassembly (51) from the GUI assembly(43) and the driver PCB cable assem-bly (57) from the ADP assembly (48).Place the CRE front panel away fromthe work area to avoid damage.

6. Disconnect the mains wire assembly(18) by carefully pulling the connectorsfrom their terminals on the mains filterassembly (30).

7. Slide the two right side panel strips(36) out to expose the four screws (33)and lock washers (6) which retain thepower supply mounting plate (19). Ifthe side panels (36) will not slide outeasily, use a padded pair of pliers orchannel locks to pull them out.

8. Remove the four screws (33) and lockwashers (6) retaining the power supplymounting plate (19). Turn the powersupply right side up for better access tothe harness assembly (12) connectionson the front of the power supply.

9. Noting the color and positions of theharness assembly connections, dis-connect the harness assembly (12)from the power supply terminal board(16). Remove the power supply (11)from the CRE enclosure (40).

10. Remove the four screws retaining thepower supply mounting plate (33) tothe power supply (16).

11. Disconnect the mains wire assembly(18) from the power supply.

12. Connect the mains wire assembly (18)to the new power supply.

13. Attach the new power supply onto thepower supply mounting plate (19) withfour screws (33) and place into theCRE enclosure (40).

14. Connect the harness assembly asnoted in step 9. Refer to Figure C-6 forpower supply to harness assemblyconnections.

15. Reinstall the power supply assembly(11) in the CRE enclosure (40) withfour screws (33) and lock washers (6).

16. Slide the side panel strips (36) backinto the CRE enclosure (40). If the sidepanel strips do not slide easily, use arubber mallet or a small block of woodand hammer to butt the panels intoplace.

17. Reconnect the GUI PCB ribbon cableassembly (51) to the GUI assembly(43) and the driver PCB cable as-sembly (57) to the ADP assembly (48)on the CRE front panel (45).

18. Reinstall the CRE front panel (45) withtwo Allen screws (46) and washers (5).

19. Slide the top panel (10) back onto theunit.

20. Reinstall both retaining strips (34) ontothe CRE back panel with two screws(35).

Figure C-6. Power Supply � Harness AssemblyConnections



World Class 3000

C-7 CIRCUIT BOARD REPLACEMENT

Perform the following to gain access to the cir-cuit boards inside the CRE module.



2. With a 5/32 Allen wrench, remove thetwo Allen screws (46, Figure C-5) andwashers (5) retaining the CRE frontpanel (45).

3. Disconnect the GUI PCB ribbon cableassembly (46) from the GUI assembly(43) and the driver PCB cable assem-bly (57) from the ADP assembly (48).Place the CRE front panel (45) awayfrom the work area to avoid damage.

4. Proceed to the following paragraphs forspecific circuit board replacement:

(a) Processor Board(b) Relay Output Card(c) Analog Output Card(d) DPI Card

a. Processor Board Replacement

1. Carefully disconnect the GUI PCB rib-bon cable assembly (51) and the RS-232 ribbon cable assembly (28) fromtheir pin terminals on the processorboard (52).

2. Disengage the processor board (52)from the backplane board (9) bypressing down on the PCB retainer(50) and firmly pulling the processorboard out. The board will slide out eas-ily along the grooves in the card guides(56) once the pin plug on the processorboard is separated from its terminal onthe backplane board.

3. Align the top and bottom edge of thenew processor board in the grooves inthe top and bottom card guides (56)and slide the processor board back into

the backplane board (9). Press firmlyon the front edge of the processorboard to completely seat the pin plug inthe terminal connector.

4. Reconnect the RS-232 ribbon cableassembly (28) and the GUI PCB ribboncable assembly (51) to the processorboard (52).

5. Reconnect the GUI PCB ribbon cableassembly (51) to the GUI assembly(43) and the driver PCB cable assem-bly (57) to the ADP assembly (48) onthe CRE front panel (45).


b. Relay Output Card Replacement

1. Carefully disconnect the relay outputribbon cable assembly (21) from its pinterminal on the relay output board (53).

2. Disengage the relay output board (53)from the backplane board (9) bypressing down on the PCB retainer(50) and firmly pulling the relay outputboard out. The board will slide out eas-ily along the grooves in the card guides(56) once the pin plug on the relay out-put board is separated from its terminalon the backplane board.

3. Align the top and bottom edge of thenew relay output board in the groovesin the top and bottom card guides (56)and slide the relay output board backinto the backplane board (9). Pressfirmly on the front edge of the relayoutput board to completely seat the pinplug in the terminal connector.

4. Reconnect the relay output ribbon ca-ble assembly (21) to the relay outputboard (52).




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World Class 3000

c. Analog Output Card Replacement

A CRE may contain up to 3 analog outputboards (54).

1. Carefully disconnect the relay outputribbon cable assembly (21) from its pinterminal on the relay output board (53)to gain access to the analog outputboard(s) (54).

2. Carefully disconnect the analog outputribbon cable assembly (22) from itsterminal on the analog output board(54) to be replaced.

3. Disengage the analog output board(54) from the backplane board (9) bypressing down on the PCB retainer(50) and firmly pulling the analog out-put board out. The board will slide outeasily along the grooves in the cardguides (56) once the pin plug on theanalog output board is separated fromits terminal on the backplane board.

4. Align the top and bottom edge of thenew analog output board in thegrooves in the top and bottom cardguides (56) and slide the analog outputboard back into the backplane board(9). Press firmly on the front edge ofthe analog output board to completelyseat the pin plug in the terminalconnector.

5. Reconnect the analog output ribboncable assembly (22) to the new analogoutput board.




d. DPI Board Replacement

A CRE may have up to 4 DPI boards (55).

1. Carefully disconnect the relay outputribbon cable assembly (21) from its pinterminal on the relay output board (53)to gain access to the DPI board(s) (55).

2. Carefully disconnect the analog outputribbon cable assembly(ies) (22) fromtheir terminal(s) on the analog outputboard (54) to gain access to the DPIboard(s) (55).

3. Carefully disconnect the DPI ribboncable assembly (24) from the DPIboard (55) to be replaced.

4. Disengage the DPI board (55) from thebackplane board (9) by pressing downon the bottom retainer (50) and firmlypulling the DPI board out. The boardwill slide out easily along the groovesin the card guides (56) once the pinplug on the DPI board is separatedfrom its terminal on the backplaneboard.

5. Align the top and bottom edge of thenew DPI board in the grooves in thetop and bottom card guides (56) andslide the DPI board back into the back-plane board (9). Press firmly on thefront edge of the DPI board to com-pletely seat the pin plug in the terminalconnector.

6. Reconnect the DPI ribbon cable as-sembly (24) to the new DPI board.

7. Reconnect the analog output ribboncable assembly(ies) (22) to the analogoutput board(s) (54).






World Class 3000

C-8 FRONT PANEL COMPONENTREPLACEMENT

The CRE front panel consists of a General UserInterface (GUI), an Auxiliary Display Panel(ADP), and a Run/Par Keylock Switch.

a. GUI Assembly Replacement




3. Disconnect the GUI PCB ribbon cableassembly (51) from the GUI assembly(43) and the driver PCB cable assem-bly (57) from the ADP assembly (48).

4. Disconnect the GUI/ADP ribbon cableassembly (42) from the GUI assembly(43).

5. Disconnect the Run/Par keylock switch(47) plug from its terminal connectionon the GUI assembly (43).

6. Remove the four screws (7) and lockwashers (6) that retain the GUI assem-bly (43) to the CRE front panel (45).Remove the GUI assembly.

7. Attach the new GUI assembly to theCRE front panel (45) with four screws(7) and lock washers (6).

8. Reconnect the Run/Par switch (47)plug to its terminal connection on thenew GUI assembly (43).

9. Reconnect the GUI/ADP ribbon cableassembly (42) from the ADP assembly(48) to the GUI assembly (43).



b. ADP Assembly Replacement




3. Disconnect the GUI PCB ribbon cableassembly (51) from the GUI assembly(43) and the driver PCB cable assem-bly (57) from the ADP assembly (48).

4. Disconnect the GUI/ADP ribbon cableassembly (42) from the ADP assembly(48).

5. Remove the four screws (7) and lockwashers (6) that retain the ADP as-sembly (48) to the CRE front panel(45).

6. Attach the new ADP assembly to theCRE front panel with four screws (7)and lock washers (6).

7. Reconnect the GUI/ADP ribbon cableassembly (428) from the ADP assem-bly (48) to the GUI assembly (43).

8. Reconnect the GUI PCB ribbon cableassembly (51) to the GUI assembly(43) and the driver PCB cable as-sembly (57) to the GUI assembly (43)on the CRE front panel (45).



January 1997


World Class 3000

c. Run/Par Keylock Switch Replacement




3. Disconnect the GUI PCB ribbon cableassembly (51) from the GUI assembly(43) and the driver PCB cable assem-bly (57) from the ADP assembly (48)so the CRE front panel can be movedto a suitable work area.

4. Disconnect the Run/Par keylock switch(47) plug from its terminal connectionon the GUI assembly (43).

5. Remove the retaining nut (44) holdingthe Run/Par switch (47) onto the CREfront panel (45). Remove the switch.

6. Place the new Run/Par keylock switchinto position through the front of theCRE front panel (45). Secure with theretaining nut (40).

7. Reconnect the Run/Par keylock switch(47) plug to its terminal connection onthe GUI assembly (43).


9. Reinstall the CRE front panel (45) withtwo Allen screws (46) and washers



World Class 3000

REPLACEMENT PARTS

Table C-2. Replacement Parts for the CRE Control Room Electronics Module

FIGURE andINDEX NUMBER PART NUMBER DESCRIPTION

C-5, 52 1L03635G01 Processor BoardC-5, 53 3D39203G01 Relay Output CardC-5, 54 3D39097G01 Analog Output CardC-5, 54 3D39097G02 Analog Output and A/O Daughter CardsC-5, 54 3D39099G01 Analog Output Daughter CardC-5, 55 3D39072G01 DPI CardC-5, 16 1N04858 Power SupplyC-5, 1 1L03391G02 BatteryC-5, 47 1M03055G01 Run/Par Keylock SwitchC-5, 43 1N04956G02 GUI AssemblyC-5, 48 1N04957G02 ADP AssemblyC-3 1L03636G01 Panel Mounting KitC-5, 24 1N04873G02 DPI Rear Termination PanelC-5, 22, 21 1M03068G02 Relay/Analog Output Rear Termination PanelsC-5, 29 1L01293H02 Fuse, 5A @ 250 Vac, anti-surge, case size;

5 x 20 mm, type T to IEC127, Schurter

Instruction ManualAppendix D Rev. 2.4

July 1998

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

World Class 3000

APPENDIX D, REV 2.4MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER

DESCRIPTION


D-1 DESCRIPTION

The Rosemount MPS 3000 Multiprobe Calibra-tion Gas Sequencer provides automatic calibra-tion gas sequencing for up to four probes. TheMPS routes calibration gas to the selectedprobe under control of the CRE, IFT, or digitalelectronics package. The electronics packagecan be preprogrammed by the user for auto-matic periodic recalibration, or manually initiatedcalibration through the keypad on the front ofthe electronics package. The calibration pa-rameters held in the electronics package can beselected to automatically update after eachcalibration.

The MPS is housed in a NEMA 4X (IP56) non-hazardous enclosure, Figure D-1.

NOTE

A single multichannel MPS cannot beshared among a number of CREelectronics.

The MPS, Figure D-2, consists of: an air pres-sure regulator, a terminal board, a flowmeterassembly (one for each probe, up to four perMPS), HI GAS solenoid, LO GAS solenoid, amanifold, and a power supply. Each flowmeterassembly contains a probe solenoid.

An optional Z-purge arrangement is available forhazardous area classification. See ApplicationData Bulletin AD 106-300B.

16860013

Figure D-1. MPS 3000 Multiprobe Calibration GasSequencer

D-2 THEORY OF OPERATION

A typical automatic calibration setup is shown inFigure D-3. The MPS 3000 Multiprobe Calibra-tion Gas Sequencer operates under the controlof the CRE, IFT, or digital electronics package.When the electronics package initializes auto-matic calibration, the solenoid controlling theselected probe is energized. Next, the solenoidcontrolling calibration gas 1 (high O2) energizesallowing calibration gas 1 to flow to that probe.After the probe measures the oxygen concen-tration of calibration gas 1, the gas solenoid isdeenergized. An operator selected time delayallows the gas to clear the system. Next, thesolenoid controlling calibration gas 2 (low O2)energizes and allows calibration gas 2 to flow tothe probe. After the probe measures the oxygenconcentration of calibration gas 2, the gas andprobe solenoids deenergize. The automaticcalibration is now complete for the probeselected.

Instruction ManualAppendix D Rev. 2.4July 1998

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

World Class 3000

POWERSUPPLY

REGULATOR

TUBE

SOLENOID MANIFOLD HOSEADAPTER

CABLEGRIP

TERMINATIONBOARD

FLOWMETER

27270024

Figure D-2. Multiprobe Calibration Gas Sequencer, Interior

Table D-1. Specifications for Multiprobe Calibration Gas Sequencer.

Environmental Classification ................................................................ NEMA 4X (IP56)Humidity Range .................................................................................... 95% Relative HumidityHumidity Range .................................................................................... 95% Relative HumidityAmbient Temperature Range ............................................................... -20° to 160°F (-30° to 71°C)Vibration................................................................................................ 5 m/sec2, 10 to 500 xyz planeExternal Electrical Noise....................................................................... Minimum InterferencePiping Distance Between MPS 3000 and Probe.................................. Maximum 300 feet (91 m)Cabling Distance Between MPS 3000 and Electronics Package......... Maximum 1000 feet (303 m)In Calibration Status Relay................................................................... 48V max, 100 mA maxCabling Distance Between MPS 3000 and Status Relay Indicator ...... Maximum 1000 feet (303 m)Approximate Shipping Weight .............................................................. 35 pounds (16 kg)


July 1998


World Class 3000

CALIBRATIONGAS 1

(HIGH O )2

CALIBRATIONGAS 2

(LOW O )2

PROBE(END VIEW)

ELECTRONICPACKAGE

CALIBRATION GAS

CHECKVALVE

PROBESIGNAL CONNECTIONS

MPS ELECTRONICSPACKAGE SIGNALCONNECTIONS

NOTE: THE MPS CAN BE USED WITH UPTO FOUR PROBES AND FOURELECTRONIC PACKAGES. ONLYONE PROBE CAN BE CALIBRATEDAT A TIME. PROBE CALIBRATIONSMUST BE SCHEDULED IN MULTIPLEPROBE APPLICATIONS.

MPS

INSTRUMENTAIR IN

REFERENCEAIR

27270022

Figure D-3. Typical Automatic Calibration System



World Class 3000

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Figure D-4. MPS with Z-Purge


July 1998


World Class 3000

MPS 3000 TROUBLESHOOTING

D-3 OVERVIEW

This section describes troubleshooting for theMultiprobe Calibration Gas Sequencer. Addi-tional troubleshooting information can be foundin the Instruction Bulletin for the electronicspackage.


D-4 TROUBLESHOOTING

Table D-2 provides a guide to fault finding fail-ures within the MPS. The flowchart in FigureD-5 provides an alternate approach to faultfinding MPS related problems.

Table D-2. Fault Finding


1. Power to solenoid,calibration gas notreleased to probe.

Calibration gas Insufficient calibrationgas

Install new calibration gastanks.

Solenoid Solenoid failure Replace solenoid.

2. No power tosolenoid.

Power supply output Power supply failure Replace power supply.

Fuses in powersupply

Fuse blown Replace fuse.

Main power source Main power off Reestablish power.



World Class 3000

YES YES

NO NO

SYMPTOM

SOLENOID ISOPERATING NORMALLY.

ENSURE THAT ASUFFICIENT SUPPLY OFCALIBRATION GAS ISAVAILABLE.

CALL FOR FACTORYASSISTANCE.

SET METER* FOR 50 VDC.PLACE PROBES ONTERMINAL BLOCK J2, CALRET, AND J1 HI GAS.

INSTALL NEW CALIBRATIONGAS BOTTLES.

SOLENOID IS RECEIVING24 VDC.

YESREPLACE SOLENOID.

NO

PLACE PROBES FROMMETER ON J11.

METER INDICATES24 VDC.

YES REPLACE TERMINALBOARD.

NO

FUSES BLOWN IN MPS.NO

PLACE PROBES FROMMETER ON J1, LINE 1,AND LINE 2. SET METERFOR 200 VAC.

YES

REPLACE BLOWN FUSES.METER INDICATES 110VAC AT J1.

YESREPLACE POWER SUPPLY.

NO

CHECK MAIN POWERSOURCE.

*SIMPSON MODEL 260 OREQUIVALENT MULTIMETER. 27270023

Figure D-5. MPS Troubleshooting Flowchart


July 1998


World Class 3000


D-5 OVERVIEW

This section describes service and routinemaintenance of the MPS 3000 Multiprobe Cali-bration Gas Sequencer. Replacement parts re-ferred to are available from Rosemount. Refer toTable D-3 for part numbers and orderinginformation.


D-6 FUSE REPLACEMENT

Power supply (58, Figure D-6) contains twoidentical 1 amp fuses (3). Perform the followingprocedure to check or replace a fuse.


a. Turn off power to the system.

b. Unscrew top of fuseholder (40) and removethe fuse. Refer to Table D-3 for replacementfuse specifications. After checking or re-placing a fuse, reinstall top of fuseholder.

D-7 POWER SUPPLY REPLACEMENT



b. Loosen two captive screws holding the MPScover (15, Figure D-6). Open the MPScover.

c. Loosen two captive screws holding the innercover (16). Lower the inner cover.

d. Disconnect the 24V connector from J11 onthe termination board (34).

e. Remove two screws (39) and washers (38)holding the terminal cover (37). Remove theterminal cover.

f. Tag and remove wires from terminals 1 and4 or 5 of the transformer in the power supply(58).

g. Remove two nuts (60) and washers (59)from the screws holding the power supply(58). Remove the power supply.

h. Mount the new power supply onto thescrews with two nuts (60) and washers (59).Make sure the ground wires are connectedto the upper mounting screw.

i. Reconnect the wires removed in step f.

j. Install the terminal cover (37) with twoscrews (38) and washers (39).

k. Connect the 24V connector to J11 on thetermination board (34).

l. Close and secure the inner cover (16) withtwo captive screws. Close and secure theouter cover (15) with two captive screws.

D-8 SOLENOID VALVE REPLACEMENT

An MPS 3000 will always have a HI GAS sole-noid (63, Figure D-6) and a LOW GAS solenoid(64) mounted to the manifold (11). Each probewill also have a solenoid valve (9) mounted onthe manifold.



b. Loosen two captive screws holding the MPScover (15, Figure D-6). Open the MPScover.

c. Loosen two captive screws holding the innercover (16). Lower the inner cover.

d. Disconnect the HI GAS (J17), LOW GAS(J18), or Probe (J13-J16) plug from its re-ceptacle on the termination board (34).



World Class 3000

49

49

50

53

53

41

31

54

14

34

54

1

17

16

18

15

26

2742

48 46

42

40

30

30

22

35

36

37

21

32

4

33

5857

59

60

56

21

44

45

19

20

42

51

43

52

47

62

61

55

2

3

3839

2524

23

28

29

5

63

64

6

7

9

8

13

12

11

10

Figure D-6. Multiprobe Calibration Gas Sequencer, Exploded View


July 1998


World Class 3000

LEGEND FOR FIGURE D-6

1. Enclosure 2. Screw 3. Plug 4. Cable Grip 5. Fitting 6. Hose Adapter 7. Pressure Switch 8. Plug 9. Solenoid Valve 10. Screw 11. Manifold 12. Washer 13. Screw 14. Gasket 15. Outer Cover 16. Inner Cover 17. Flowmeter, 10 SCFH 18. Flowmeter, 2.0 SCFH 19. Bracket 20. Screw 21. Hose Adapter 22. 1/8 in. Hose

23. Nut 24. Lockwasher 25. Washer 26. Washer 27. Screw 28. Nut 29. Washer 30. Washer 31. Cover Stop Slide 32. Screw 33. Washer 34. Termination Board 35. Standoff 36. Mounting Bracket 37. Cover Plate 38. Washer 39. Screw 40. Fuseholder 41. Plastic Nut 42. Bushing 43. Pressure Gauge 44. Bolt

45. Washer 46. Drain Valve 47. 1/8 in. Impolene Tubing 48. Connector 49. Elbow 50. Pressure Regulator 51. Hose Adapter 52. 1/4 in. Tube 53. Screw 54. Washer 55. Inner Enclosure 56. Washer 57. Screw 58. Power Supply 59. Washer 60. Nut 61. Screw 62. Washer 63. Solenoid 64. Solenoid

e. Loosen the retaining ring in the middle ofthe solenoid and remove the top part.

f. With a spanner wrench or padded pliers,remove the remaining part of the solenoidfrom the manifold (11).

g. Separate the new solenoid and screw thesmaller part into the manifold.

h. Place the top part of the solenoid into posi-tion and tighten the retaining ring.

i. Connect the plug to the proper receptacleon the termination board (34).

j. Close and secure the inner cover (16) withtwo captive screws. Close and secure theouter cover (15) with two captive screws.

D-9 PRESSURE REGULATOR MAINTENANCE

a. Pressure Adjustments

Pressure regulator (50, Figure D-6) is fac-tory set to 20 psi (138 kPa). Should thepressure need to be changed or adjusted,use the knob on top of the pressureregulator.

b. Condensation Drain

To drain excess moisture from the internalgas circuit of the MPS, periodically loosendrain valve (46) on the bottom of pressureregulator (50). The moisture will flowthrough vinyl tubing drain (47) on the bottomof pressure regulator (50) and exit the bot-tom of MPS enclosure (1).



World Class 3000

D-10 FLOWMETER ADJUSTMENTS

There are two flowmeters per flowmeter assem-bly. The top flowmeter is factory set to 5 scfh.The bottom flowmeter is set to 2 scfh. Shouldthe flow need to be changed or adjusted, useknob on the bottom of the respective flowmeter.

D-11 ADDING PROBES TO THE MPS

This procedure is used to add a probe to theMPS.



b. Loosen the two captive screws holding theMPS cover (15). Lift the cover.

c. Loosen the two captive screws that hold theinner cover (16) and lower the cover.

d. From the backside of the inner cover, locatethe flowmeter positions next to the existingunit(s). Insert a hacksaw blade into the slotssurrounding the positions for two flowme-ters, and saw out the knockout tabs.

e. From the front of the inner cover, install aflowmeter (P/N 771B635H01) into the tophole and a flowmeter (P/N 771B635H02)into the bottom hole. From the backside se-cure with brackets provided.

f. Remove four brass screw plugs (CAL GASIN, CAL GAS OUT, REF AIR IN, and REFAIR OUT) for the next probe position in themanifold.

g. Install 1/8" hose adapters (P/N1A97553H01) into the empty holes using asuitable pipe dope. Attach the tubing.

h. Remove a brass screw plug (P/N1A97900H01) and install a solenoid (P/N3D39435G01). Make sure the O-ring sealsproperly.

i. Attach the hoses to the flowmeter using theexisting installation as a guide. Support theflowmeter while attaching the hose.

j. Install the solenoid wire connector into theproper position (J14-J16) on the terminationboard (34).

k. Close and secure the inner cover (16) withtwo captive screws. Close and secure theouter cover (15) with two captive screws.


July 1998


World Class 3000

REPLACEMENT PARTS

Table D-3. Replacement Parts for the Multiprobe Test Gas Sequencer

FIGURE andINDEX No.

PART NUMBER DESCRIPTION

Figure D-6, 58 1A97909H01* Power SupplyFigure D-6, 9 3D39435G01** Solenoid ValveFigure D-6, 40 138799-004 Fuse, fast acting, 1A @ 250 Vac, size: 1/4" Dia.

x 1-1/4” Lg., glass body, non time delay, Buss-man part no. BK/AGC-1

Figure D-6, 40 138799-014 Fuse, fast acting, 0.5A @ 250 Vac, size: 1/4"Dia. x 1-1/4” Lg., glass body, non time delay,Bussman part no. BK/AGC-1/2

Figure D-6, 17 771B635H01** Flowmeter Assembly - Calibration GasFigure D-6, 18 771B635H02** Flowmeter Assembly - Reference Air

1A98631 Probe Adder KitFigure D-6, 51 1A97953H01** Hose Adapter

4847B46H01** Tubing Length4847B46H02** Tubing Length4847B46H03** Tubing Length4847B46H04** Tubing Length

Figure D-3 7307A56G02 Check Valve

*Specify line voltage and probe type when ordering.**These items are included in the probe adder kit.



World Class 3000

Instruction ManualAppendix G Rev. 1.4

January 1997

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

World Class 3000

APPENDIX G, REV. 1.4MASTER/SLAVE CRE 3000 CONTROL ROOM

ELECTRONICS MODULE

DESCRIPTION

Read the �Safety instructions for thewiring and installation of this appara-tus� at the front of this InstructionBulletin. Failure to follow the safetyinstructions could result in seriousinjury or death.

G-1 DESCRIPTION

This appendix provides the basic system infor-mation for CRE 3000 systems configured asMaster/Slave Control Room Electronics. Thisappendix, along with information contained inWorld Class 3000 Oxygen Analyzer with CRE3000 Control Room Electronics, IB-106-300NC,and related appendices as specified, providesthe user with the information necessary to in-stall, operate, and maintain the Master/SlaveCRE 3000 Control Room Electronics. TheRosemount Master/Slave CRE 3000 ControlRoom Electronics (CRE) Modules, Figure G-1,provide the necessary intelligence for control-

ling up to 16 probes. The Master CRE 3000 in-terfaces with probes 1 through 8; the Slave CRE3000 interfaces with probes 9 through 16,Figure G-2.

The Master CRE is based on a modular design.There are a total of 12 slots for PC boardsavailable. The Master CRE contains a CPUboard, analog and relay output boards, DualProbe Interface (DPI) boards, and a memoryboard to provide the additional memory for in-terfacing with the Slave CRE. The front panelconsists of a General User Interface (GUI) andan Auxiliary Display Panel (ADP). The MasterCRE provides the necessary intelligence forcontrolling probe numbers 1 through 8 and forthe operation of the multiple test gas sequencerfor these probes. In addition, the operator-setvariables for all 16 probes, numbers 1 through 8on the Master CRE, and numbers 9 through 16on the Slave CRE, are input using the GUI key-board on the Master CRE. The Master CREalso calculates all 8 averages.

HIGH

HIGH

LOW

LOW

CAL

CAL

FAULT

FAULT

1

9

2

10

3

11

4

12

5

13

6

14

7

15

8

16

1

5 6 7 8

2 3 4AVERAGE

AVERAGE

ANALYZER

ANALYZER

HELP DATA CAL SETUP

ENTERESC

MASTER CRE 3000

SLAVE CRE 3000 35840017

Figure G-1. Master/Slave CRE 3000 Modules

Instruction ManualAppendix G Rev. 1.4January 1997

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

World Class 3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

HPS3000

WORLD CLASS 3000PROBE




2 PNEUMATIC LINESBY CUSTOMER[300 FEET MAX]




7 CONDUCTOR CABLE[150 FEET MAX]








MODULAR DESIGNUP TO 4 PROBES




TEST GASBY CUSTOMER

TEST GASBY CUSTOMER

TEST GASBY CUSTOMER

TEST GASBY CUSTOMER

8 CONDUCTOR WIRE[1000 FEET MAX]




4 TWISTED PAIR PLUS 2 TWISTED PAIRFOR OPTIONS [1200 FEET MAX]LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINEVOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINE VOLTAGE

LINEVOLTAGE

LINE VOLTAGE

LINEVOLTAGE

LINEVOLTAGE

4 TWISTED PAIR PLUS 2 TWISTED PAIRFOR OPTIONS [1200 FEET MAX]







TEST GAS

SEQUENCER

MPS 3000

TEST GAS

SEQUENCER

MPS 3000

TEST GAS

SEQUENCER

MPS 3000

TEST GAS

SEQUENCER

MPS 3000

LINE VOLTAGE100 TO 120 VOLT220 TO 240 VOLT

MASTERCRE 3000

SLAVECRE 3000LINE VOLTAGE

100 TO 120 VOLT220 TO 240 VOLT

FOR COMPLETE WIRING HOOK UP INFORMATIONREFER TO IB-106-300NC

35840011

Figure G-2. Master/Slave CRE 3000 Multiprobe Applications


January 1997


World Class 3000

The Slave CRE is based on the same modulardesign as the Master CRE. However, the SlaveCRE only has a total of 9 slots for PC boards.The slave module contains the same CPUboard, analog and relay output boards, and dualprobe interface (DPI) boards; there is no mem-ory board. The Slave CRE front panel does notcontain a GUI interface panel but does have anADP panel. The Slave CRE provides the neces-sary intelligence for controlling probe numbers 9through 16 and for operation of the Multiple TestGas Sequencer for these probes. The operator-set variables for probe numbers 9 through 16are input using the GUI on the Master CRE.

The number of DPI boards and input/outputconnections on the rear termination panel of theSlave and Master CRE may vary depending onthe input/output requirements and the number ofprobes in the user's system. Each DPI termina-tion panel has connections for two probes.

There can be up to four DPI termination boardson either the Master or Slave CRE. There canbe up to two analog output panels and one relayoutput panel for either the Master or Slave CRE,Figure G-3. Regardless of the number of probesin the master/slave system, probe numbers 1through 8 must be connected to the MasterCRE and probe numbers 9 through 16 must beconnected to the Slave CRE.

a. CPU Board

The CPU board contains EEPROM, RAM,and a real-time clock. The board is con-nected to a battery backup. The batterybackup is located off the board, on the rightpanel of the enclosure; if the CPU is re-placed or the battery disconnected, the op-erator must reset the clock. The programsoftware is contained in the non-volatilememory of the EEPROM.

RSC-232CINTERCONNECTION

WITH MASTER CRE 3000

RSC-232CCONTROL ROOM

COMMUNICATIONS

RSC-232CINTERCONNECTION

WITH SLAVE CRE 3000

POWERSWITCH

POWERSWITCH

SLAVE CRE 3000(REAR VIEW)

MASTER CRE 3000(REAR VIEW)

ACIN

ACIN

DPI PANELS(UP TO 4)

DPI PANELS(UP TO 4)

ANALOG OUTPUTPANELS

(UP TO 2)

ANALOG OUTPUTPANELS

(UP TO 2)

RELAY OUTPUTPANEL

RELAY OUTPUTPANEL

Figure G-3. Master/Slave CRE 3000 Rear Panels



World Class 3000

b. Dual Probe Interface Board

Each dual probe interface board (DPI) cansupport two probes and two test gas se-quencers. The Master and Slave CREs caneach hold up to four DPI boards, for amaximum of 8 probes per unit, or a total of16 probes per master/slave system. TheDPI provides analog inputs for the cell volt-age signal, heater thermocouple signal, andthermocouple cold junction temperaturesensor for each probe.

An output for the heater drive circuit, locatedin the Heater Power Supply (HPS), is alsoprovided by the DPI. This signal is used totell the HPS when to energize or de-energize the probe heater.

The DPI controls the Multiprobe Test GasSequencer (MPS). Control is through opencollector type digital outputs that directlydrive the solenoids in the MPS.

c. Analog Output Board

The analog outputs of both the Master andSlave CREs are user-configurable using theGUI screen and keypad located on the frontpanel of the Master CRE. The Master CREcontains outputs 1 to 12 and the Slave CREcontains outputs 13 to 24. Signals can besent to a strip chart recorder, data acquisi-tion system, or similar recording device.Output data can be used as a permanentrecord of oxygen readings.

Outputs are configurable to be either volt-age or current by means of a jumper on theanalog output board; refer to IB-106-300NCfor jumper configurations. If set to current,the outputs can be configured to be 0-20mA or 4-20 mA using the GUI screen andkeypad on the Master CRE. Any output maybe configured to represent any of the six-teen probe values or eight averaged values.The user can also select the O2 range theoutput represents to be 0 to 1, 5, 10, 25, or100%.

Each analog output board holds two out-puts, with an additional two added through

the use of a piggyback board. Each Masteror Slave CRE can hold up to 12 analog out-puts (three boards each with piggybacks).Each Master or Slave CRE analog outputrear termination panel contains terminals forup to eight outputs.

d. Relay Output Board

The relay output boards in both the Masterand Slave CRE contain a total of eight re-lays each (Form-C, 48V max, 100 mA max).The master contains outputs 1 to 8 and theslave contains outputs 9 to 16. These out-puts can control signals up to 48 volts andcan be configured to be normally open ornormally closed; refer to relay output jumperconfigurations in IB-106-300NC.

The relay outputs are user-configurablefrom the Master CRE to represent high orlow alarms of any of the eight averages.They can also be configured to representhigh or low alarms, in calibration, calibrationerror, low test gas, or fault of up to any ofthe sixteen probes for either the Master orSlave CRE. As many as 16 of these eventscan be configured together in a logical ORarrangement to actuate the output. The out-puts can be used to operate auxiliaryequipment such as annunciators. The reartermination panel is the same as that usedfor analog outputs, and provides terminalsfor eight outputs.

e. Memory Board

The memory board is located in the MasterCRE next to the relay board. This boardprovides the added memory for communi-cation with the Slave CRE.

f. General User Interface (GUI)

The GUI on the Master CRE has a 4-line by20-character liquid crystal display (LCD)and eight membrane keys. All operator-setvariables for all 16 probes interfaced withboth the Master CRE and Slave CRE areinput using the LCD screen and keyboardlocated on the Master CRE.


January 1997


World Class 3000

g. Auxiliary Display Panel (ADP)

The ADP on the Master CRE has two dis-play lines, two rows of eight 0.8 inch (20mm) alphanumeric characters, which can beconfigured to display any two readings (ei-ther individual or averaged O2 from any twoof the Master/Slave CRE systems 16probes). The ADP on the Slave CRE alsohas two display lines; these can be config-ured as display lines 3 and 4 to provide anadditional two lines of information in con-junction with display lines 1 and 2 on themaster ADP display.

Indicating LEDs for HIGH, LOW, CAL, andFAULT are provided for up to eight analyz-ers each for both the Master and SlaveCREs. HIGH and LOW indicator LEDs areprovided for four averages. There is also asystem fault indicator that lights to indicatesystem malfunction. LEDs on the MasterCRE provide data for probes 1 through 8;LEDs on the Slave CRE provide data forprobes 9 through 16.

h. Run/Par Keylock Switch

The RUN/PAR keylock switch on the MasterCRE prevents accidental changes to systemparameters for both the Master and SlaveCRE while in the RUN position. Turning thekey to PAR allows parameter changes and

calibration of all 16 probes in the completeMaster/Slave CRE system.

G-2 THEORY OF OPERATION

A functional block diagram of a Master or SlaveCRE, connected to an HPS and probe, is shownin Figure G-4. In operation, the CRE monitorsthe temperature of the cell by means of theprobe thermocouple. If the temperature of thecell deviates from the set point, the CRE eitherenergizes or de-energizes the probe heaterthrough the HPS to maintain the proper operat-ing temperature.

A cold junction temperature compensation fea-ture ensures an accurate probe thermocouplereading. A temperature sensor in the heaterpower supply monitors the temperature at thejunction between the compensated cable run-ning to the probe and the uncompensated cablerunning to the CRE. The voltage from this sen-sor is used by the CRE to compensate theprobe thermocouple readings for the tempera-ture at the junction.

The cell signal is a voltage proportional to theoxygen concentration difference between thetwo sides of the cell. The Master or Slave CREreceives this signal and translates it into a user-specified form for display and/or output. Thereadings can be configured to be a current oxy-gen percentage for each probe or an average ofa number of probes.



World Class 3000

PROBE

ZEROCROSSINGDETECTOR

TRIACRELAYTO HEATER

COLDJUNCTION

TEMP.PROBE TC

STACK TC

CELL

LINE

RELAY

TRIAC

AD590

PROBE TC

STACK TC

CELL MV

HEATER POWER SUPPLY(OPTIONAL)

TRANSFORMER

MASTER OR SLAVE CRE

19270012

Figure G-4. Master or Slave CRE to Probe, System Block Diagram


January 1997


World Class 3000

Table G-1. Specifications for Master/Slave CRE 3000

Ambient Environment Requirements .............. Clean, dryAmbient Temperature Range.......................... 40° to 120°F (4° to 50°C)Vibration .......................................................... Slight: 30 degree drop testNumber or Probes........................................... 16 maximum:

Probes 1 through 8- Master CREProbes 9 through 16 - Slave CRE

Communications ............................................. Master and Slave CREs - RS-232 for interconnection be-tween the Master and Slave CREsMaster CRE - a second RS-232 is provided on the MasterCRE only for control room communication (printer, modem)or IBM PC

Analog Outputs ............................................... 12 to 24 isolated outputs on the Master and Slave CREs:0-20 mAdc or 4-20 mAdc into 950 ohms max, 0-10 Vdcinto 2K min ohms

Output Resolution ........................................... 11 bits (1 bit = 0.05% of output F.S.)Programmable Contact Outputs A total of 16 available on both the Master and Slave CREs:

Form-C, 48 V max, 100 mA maxIndicators......................................................... Master CRE:

LED indicators for system failure (failure description avail-able on LED panel), calibration in progress for probes 1through 8, O2 Hi/Lo alarm for probes 1 through 8, Hi/Loalarms for alarms 1 through 4, probe failure for probes 1through 8Slave CRE:LED indicators for system failure (failure description avail-able on Master CRE panel), calibration in progress forprobes 9 through 16, O2 Hi/Lo alarm for probes 9 through16, Hi/Lo alarms for alarms 5 through 8, probe failure forprobes 9 through 16

Programmable Display.................................... LED display with two, 0.8 inch (20 mm) high, 8 digit alpha-numeric rowsMaster CRE: lines 1 and 2 primary displaySlave CRE: lines 3 and 4 additional display (if operatorselected)

Operator Interface ........................................... Master CRE: 4-line by 20-character backlit LCD alphanu-meric display; 8-key general purpose keyboard

Approximate Shipping Weight......................... 70 pounds (32 kg) - combined weight of both the masterand slave CREs (35 pounds each)



World Class 3000

a. Optional Panel Mounting Kit

The panel mounting kit consists of a trimframe, back cover, trim strips, and screws.The trim frame slides over the CRE MAS-TER or SLAVE unit as shown in Figure G-5.The trim frame covers wall cuts.

The rear cover mounts to the back of theunit with the same screws holding the trimstrips, protecting wires and terminals. Thepart number for the panel mounting kit is1L03636G01.

Figure G-5. Optional Panel Mounting Kit


January 1997


World Class 3000

INSTALLATION

G-3 GENERAL

Procedures for the mechanical and electrical in-stallation of both the Master CRE 3000 and theSlave CRE 3000 are identical and can be foundin the World Class 3000 Oxygen Analyzer withCRE 3000 Control Room Electronics InstructionBulletin, IB-106-300NC. In addition, an RS-232cable is required to connect the Master CRE3000 to the Slave CRE 3000. Instruction for thatcable is provided in paragraph G-4. General in-formation in regard to probe hookup is providedin paragraph G-5.

Before starting to install this equip-ment read the "Safety instructions forthe wiring and installation of this ap-paratus" at the front of this InstructionBulletin. Failure to follow the safety in-structions could result in serious in-jury or death.

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

G-4 MASTER TO SLAVE 3000 INTER-CONNECTION

An RS-232 cable, maximum 50 feet (15 m), isused between the Master CRE and the SlaveCRE. Refer to Figure G-6 for connection points.Table G-2 provides the pin and cabling require-ments for making an RS-232 cable.

MASTER 2 --------------- 3CRE 3000 5 --------------- 5 SLAVECONNECTOR 3 --------------- 2 CRE 3000

7 --------------- 8 CONNECTOR8 --------------- 7

NOTE

This cable is essentially an IBM AT toAT cable available from any PC orcommunication supplier.

RS-232 INTERCONNECTIONCABLING DIAGRAM

RS-232C CABLE(50 FOOT MAX)

MASTER CRE 3000SLAVE CRE 3000

Figure G-6. RS-232 Interconnection Between Master and Slave CRE 3000 Modules



World Class 3000

Table G-2. RS-232 Pin Connections

MASTER CRE 3000

PIN NO. DESCRIPTION

SLAVE CRE 3000

PIN NO. DESCRIPTION

1 N/C 1 N/C2 Receive Data 2 Receive Data3 Transmit Data 3 Transmit Data4 N/C 4 N/C5 Signal Ground 5 Signal Ground6 N/C 6 N/C7 Request to Send 7 Request to Send8 Clear to Send 8 Clear to Send9 N/C 9 N/C

G-5 PROBE CONNECTIONS

It is important to note that when connectingprobes to either the Master or Slave CRE 3000,probes number 1 through 8 must connect to theMaster CRE 3000, and probes number 9through 16 must connect to the Slave CRE3000.

For example, in a 12-probe configuration, wherethe 12 probes would be divided between the

master and slave modules (six to each module)probes 1 through 6 are connected to the MasterCRE 3000 and referred to as probes 1 through6; probes 7 through 12 are connected to theSlave CRE 3000 and are now referred to asprobes 9 through 14. Refer to Figure G-7. for atypical 12-probe installation using the Mas-ter/Slave CRE 3000 Modules. You will noticethat the 12-probes are now referred to as probenumbers 1, 2, 3, 4, 5, 6, 9, 10, 11, 12, 13, and14.


January 1997


World Class 3000

SLAVECRE 3000

MASTERCRE 3000

MULTIPROBETEST GAS

SEQUENCER

MULTIPROBETEST GAS

SEQUENCER

REFERENCE AIRREFERENCE AIR

CALIBRATIONGAS

CALIBRATIONGAS

HEATERPOWERSUPPLY

HEATERPOWERSUPPLY

PROBENUMBERS9 THROUGH 14

PROBENUMBERS1 THROUGH 6

ADAPTERPLATE

ADAPTERPLATE

STACKSTACK

DUCTDUCT

GASESGASES

TE

ST

GA

S1

TE

ST

GA

S1

TE

ST

GA

S2

TE

ST

GA

S2

INS

T .A

IRS

UP

PL Y

INS

T .A

IRS

UP

PL Y

LINEVOLTAGE

LINEVOLTAGE

19270013

Figure G-7. Typical Master/Slave CRE 3000 System Installation



World Class 3000

OPERATION

G-6 GENERAL

Operation of the 16-probe Master/Slave CRE3000 system is identical to the operation of the8-probe CRE 3000 Control Room Electronicssystem. These operating procedures will befound in World Class 3000 Oxygen Analyzerwith CRE 3000 Control Room Electronics In-struction Bulletin, IB-106-300NC.

When operating the Master/Slave CRE 3000,please keep in mind the following points:

a. Probes 1 through 8 are interfaced to theMaster CRE 3000 and probes 9 through 16are interfaced to the Slave CRE 3000.

b. Analog outputs 1 through 12 are in theMaster CRE and 13 through 24 are in theSlave CRE.

c. Digital outputs 1 through 8 are in the MasterCRE and 9 through 16 are in the SlaveCRE.

d. All operator set variables for all 16 probesare set using the GUI panel on the MasterCRE.

e. LED fault readouts for probes 1 through 8are displayed on the Master CRE and all

LED fault readouts for probes 9 through 16are displayed on the Slave CRE.

f. The ADP panel on the Master CRE displaysO2 readings for all 16 probes. The ADPpanel on the Slave CRE is user pro-grammed to provide an additional two linesof data display to the Master CRE ADPpanel. These two additional display lines arereferred to in the menu as display lines 3and 4.

g. When referencing IB-106-300NC for opera-tion procedures, only probes 1 through 8are mentioned. In the Master/Slave CRE3000 system the GUI will automatically dis-play all probes 1 through 16. After probe 8,probe 9 will appear followed by probe 10,probe 11, etc. The menus look and functionthe same as the CRE, except they are ex-tended; the analog outputs now go to 24,the digital outputs now go to 16, and theprobes now go to 16.

h. If the system fault light on the Slave CRElights, there is a communication failure be-tween the Master CRE and the Slave CRE.

i. The data display from the Slave CRE willappear a bit sluggish. This is normal in aMaster/Slave configuration due to theamount of data being processed and doesnot indicate a system problem.


January 1997


World Class 3000

Figure G-8. Master CRE 3000, Exploded View



World Class 3000

LEGEND FOR FIGURES G-8 AND G-9

1. Lithium Battery 2. Battery Holder 3. Front Card Support 4. Rear Card Support 5. Flat Washer 6. Lockwasher 7. Screw 8. Spacer 9. Backplane 10. Top Cover 11. Power Supply Assembly 12. Harness Assembly 13. Mesh Screen 14. Not Used 15. Screw 16. Power Supply 17. 3 Amp Fuse 18. Mains Wire Assembly 19. Power Supply Mounting Plate 20. Screw 21. Relay/Analog Output Assembly 22. Relay/Analog Output Assembly 23. Back Panel Plate 24. DPI Assembly 25. Terminal Strip 26. Shield 27. Back Panel Plate 28. RS-232 Ribbon Cable Assembly 29. 5 Amp Fuses 30. Mains Filter Assembly

31. Back Panel Mounting Plate 32. Nut 33. Screw 34. Retaining Strip 35. Screw 36. Side Panel Strip 37. Bottom Panel 38. Foot 39. Power Cord 40. CRE Enclosure 41. Tip Up Foot 42. GUI/ADP Ribbon Cable Assembly 43. GUI Assembly (Master CRE) 44. Retaining Nut 45. Front Panel 46. Allen Screw 47. Run/Par Keylock Switch 48. ADP Assembly 49. PCB Shield 50. PCB Retainer 51. GUI PCB Ribbon Cable Assembly 52. Processor Board 53. Relay Output Card 54. Analog Output Card 55. DPI Card 56. Card Guides 57. Driver PCB Cable Assembly 58. GUI Assembly (Slave CRE) 59. Memory Board (Master CRE)


January 1997


World Class 3000

Figure G-9. Slave CRE 3000, Exploded View



World Class 3000



G-7 GENERAL

The service and normal maintenance on theMaster/Slave CRE 3000 is identical to that per-formed on the CRE Control Room ElectronicsModule. This information can be found in Ap-pendix C to IB-106-300N Series. Explodedviews of both the Master CRE 3000, Figure G-8,and Slave CRE 3000, Figure G-9, have beenincluded for reference. The index numbering onthese two figures is identical to the index num-

bering on the CRE 3000 Control Room Elec-tronics Module in Appendix C to make it easierto compare the differences. This also will help inreferencing the service instructions in AppendixC when using these instructions to service theMaster/Slave CRE 3000 Modules.

You will note that the Master CRE 3000 Moduleis identical to the CRE 3000 Control RoomElectronics Module except for the addition of thememory board and 12 connector backplane toaccommodate the addition of this board.

The Slave CRE 3000 Module is identical to theCRE 3000 Control Room Electronics Modulewith the exception that the GUI display and key-board panel has been removed; the GUI boardremains in the slave module. Also the Run/ParKeylock Switch has been deleted.

REPLACEMENT PARTS

Table G-3. Replacement Parts for the Master/Slave CRE 3000 Modules

INDEX ANDFIGURE NUMBER PART NUMBER DESCRIPTION

G-8, 52 3D39072G01 Processor BoardG-8, 53 3D39203G01 Relay Output CardG-8, 54 3D39097G01 Analog Output CardG-8, 54 3D39097G02 Analog Output and A/O Daughter CardsG-8, 54 3D39099G01 Analog Output Daughter CardG-8, 55 3D39097G01 DPI CardG-8, 59 1M03196G01 Memory BoardG-8, 16 1N04858 Power SupplyG-8, 17 N/A Fuse, 5A @ 250 Vac, fast blow, case size; 5x20 mmG-8, 1 1L03391G02 BatteryG-8, 47 1M03055G01 Run/Par Keylock SwitchG-8, 43 1N04956G02 GUI Assembly (Master CRE)G-9, 58 3D39029G03 GUI PC Board (Slave CRE)G-8, 48 1N04957G02 ADP AssemblyG-5 1L03636G01 Panel Mounting KitG-8, 24 1N04873G02 DPI Rear Termination PanelG-8, 22, 21 1M03068G02 Relay/Analog Output Rear Termination PanelsG-8, 29 1L01293H02 Fuse, 5A @ 250 Vac, antisurge, case size; 5 x 20

mm, type T to IEC127, Schurter


February 1998

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

World Class 3000

SECTION 7INDEX

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 locationin the manual by one or more page numbers.

AAdapter Plate, 1-1, 2-4ANALOG O/P Status, 3-7Analog Output Card, 2-11AUXILIARY DISPLAY LED, 3-2AVERAGES LED, 3-2

CC Err, 3-2CAL, 3-1, 3-2CAL LED, 3-2CALIBRATE Sub-Menu, 3-8Check Valve, 1-4, 3-18Com-E, 3-2

DDable, 3-2DATA, 3-1, 3-3DATA Sub-Menu, 3-3DIAGNOSTIC DATA Temperatures, 3-6DIG O/P STATUS, 3-7DPI Card, 2-11

EEFFICIENCY VALUES, 3-6ENTER, 3-2ESC, 3-2

FFAULT LED, 3-2Front Panel, 3-1Fuses

CRE Unit, 2-10HPS Unit, 2-17MPS Unit, 2-20

HH Err, 3-2HELP, 3-1HIGH LED, 3-2HiO2, 3-2

IINACT, 3-2

JJumper Selection, 2-16

LLCD Display, 3-1LoO2, 3-2

LOW LED, 3-2

MMULTIPROBE AVERAGES, 3-6

NNEMA 4X, 1-3Nernst Equation, 1-2

OO2 VALUE, 3-3OK, 3-2Optional Trim Frame, 2-12

PPower Cable, 2-10Power Requirements, 2-16PROBE STATUS, 3-7PROCESS DATA, 3-6

RR Hi, 3-2Rear Cover, 2-12Relay Output Panel Jumper Configuration, 2-11RUN/PAR, 3-1

SSETUP, 3-1, 3-8SOFTWARE VERSION, 3-7SYS. FAULT LED, 3-2SYSTEM DATA, 3-6


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

World Class 3000

TTGLow, 3-2Transformer, 2-16Trim Frame, 2-12

VVOLTAGES, 3-6

ZZirconia Disc, 1-2

24612857/2-98

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free fromdefects in workmanship and material under normal use and service for a period of twelve (12)months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquidjunctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship andmaterial under normal use and service for a period of ninety (90) days from date of shipment bySeller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/ormaterial shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that thegoods, part(s) or consumables are returned to Seller's designated factory, transportation chargesprepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and inthe case of consumables, within the ninety (90) day period of warranty. This warranty shall be ineffect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) daywarranty 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) andconsumables 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 directlyor indirectly, arising from the use of the equipment or goods, from breach of any warranty, or fromany other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS,SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WAR-RANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIEDWARRANTIES 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 STANDARDWARRANTY 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 SPECIFICGOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYERAGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDEN-TAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUTARE 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 MANNERNOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMSCOVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TOBUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDEDHEREUNDER.

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

Instruction ManualIB-106-300NC Rev. 4.4February 1998

© Rosemount Analytical Inc. 2001

World Class 3000

Emerson Process Management

Rosemount Analytical Inc.Process Analytic Division1201 N. Main St.Orrville, OH 44667-0901T (330) 682-9010F (330) 684-4434E [email protected]

ASIA - PACIFICFisher-RosemountSingapore Private Ltd.1 Pandan CrescentSingapore 128461Republic of SingaporeT 65-777-8211F 65-777-0947


Fisher-Rosemount GmbH & Co.Industriestrasse 163594 HasselrothGermanyT 49-6055-884 0F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICAFisher-Rosemount Ltd.Heath PlaceBognor RegisWest Sussex PO22 9SHEnglandT 44-1243-863121F 44-1243-845354

LATIN AMERICAFisher - RosemountAv. das Americas3333 sala 1004Rio de Janeiro, RJBrazil 22631-003T 55-21-2431-1882

World Class 3000 Probe

Part No._______________

Serial No.______________

Order No.______________


Part No._______________

Serial No.______________

Order No.______________


Part No._______________

Serial No.______________

Order No.______________


Part No._______________

Serial No.______________

Order No.______________


Part No._______________

Serial No.______________

Order No.______________


Part No._______________

Serial No.______________

Order No.______________


Part No._______________

Serial No.______________

Order No.______________


Part No._______________

Serial No.______________

Order No.______________

HPS 3000

Part No._______________

Serial No.______________

Order No.______________

HPS 3000

Part No._______________

Serial No.______________

Order No.______________

HPS 3000

Part No._______________

Serial No.______________

Order No.______________

HPS 3000

Part No._______________

Serial No.______________

Order No.______________

HPS 3000

Part No._______________

Serial No.______________

Order No.______________

HPS 3000

Part No._______________

Serial No.______________

Order No.______________

HPS 3000

Part No._______________

Serial No.______________

Order No.______________

HPS 3000

Part No._______________

Serial No.______________

Order No.______________

MPS 3000

Part No._______________

Serial No.______________

Order No.______________

MPS 3000

Part No._______________

Serial No.______________

Order No.______________

MPS 3000

Part No._______________

Serial No.______________

Order No.______________

MPS 3000

Part No._______________

Serial No.______________

Order No.______________

CRE 3000

Part No._______________

Serial No.______________

Order No.______________

If your system includes more components than there is space for on this chart, photocopy this page. Record the serial numbers of the othercomponents on the copy and insert this copy in the manual for reference.

Documents

Emerson Electric€¦ · 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