world class 3000 - emerson€¦ · instruction manual ib-106-300dr rev. 3.3 february 2000 world...

Instruction ManualIB-106-300DR Rev. 3.3February 2000

http://www.processanalytic.com

World Class 3000Oxygen Analyzer DirectReplacement Probe foruse with Existing SignalConditioning Electronics

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

ESSENTIAL INSTRUCTIONSREAD THIS PAGE BEFORE PROCEEDING!

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

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

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

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

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

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

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

• When replacement parts are required, ensure that qualified people use replacement partsspecified by Rosemount. Unauthorized parts and procedures can affect the product�s per-formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY.Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, exceptwhen maintenance is being performed by qualified persons, to prevent electrical shockand personal injury.

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

HIGHLIGHTS OF CHANGES

Effective June, 1996 Rev. 3

Page Summary

--- General. Updated text and illustrations to reflect probe designchanges.

Page 1-15 Added �Extended temperature by-pass arrangements� to Figure 1-15,sheet 3 of 3.

Effective December, 1996 Rev. 3.1

Page Summary

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

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

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

-1 Added WARNING regarding protective covers and grounds.

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

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

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

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

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

Effective May, 1997 Rev. 3.2

Page Summary

Page P-2 Added safety sheet.

Effective February, 1998 Rev. 3.3

Page Summary

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

Instruction ManualIB-106-300DR Rev. 3.3

February 2000

Rosemount Analytical Inc. A Division of Emerson Process Management i

World Class 3000

TABLE OF CONTENTS

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

1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-11-1 Component Checklist ..................................................................................................... 1-11-2 System Overview............................................................................................................ 1-11-3 Physical Description ....................................................................................................... 1-31-4 Probe Exterior................................................................................................................. 1-51-5 Probe Interior .................................................................................................................. 1-71-6 Junction Box .................................................................................................................... 1-81-7 Cable Assembly............................................................................................................... 1-91-8 Probe Options................................................................................................................. 1-9

2-0 INSTALLATION .............................................................................................................. 2-12-1 Locating The Oxygen Analyzer Probe.......................................................................... 2-12-2 Service Required ............................................................................................................. 2-12-3 Mechanical Installation ................................................................................................... 2-62-4 Electrical Installation........................................................................................................ 2-7

3-0 STARTUP........................................................................................................................ 3-13-1 Overview.......................................................................................................................... 3-13-2 Models 218, 225, And 132 (Analog) Electronics Setup............................................. 3-13-3 Model 218A Electronics Setup ..................................................................................... 3-23-4 Model TC200 Veritrim Electronics Setup ..................................................................... 3-33-5 Model 132 Digital Electronics Setup............................................................................ 3-43-6 The Yokogawa ZA8C And AV8C Converter Electronics Setup ................................ 3-4

4-0 MAINTENANCE AND SERVICE .................................................................................. 4-14-1 Overview.......................................................................................................................... 4-14-2 Probe Calibration............................................................................................................. 4-14-3 Cell Replacement ........................................................................................................... 4-14-4 Optional Ceramic Diffusion Element Replacement ..................................................... 4-34-5 Replacement Of Contact And Thermocouple Assembly............................................. 4-54-6 Replacement Of Heater, V-Strut And Backplate Assembly ..................................... 4-74-7 Calibration And Reference Gas Lines For High Temperature -

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

5-0 TROUBLESHOOTING.................................................................................................... 5-15-1 Overview.......................................................................................................................... 5-15-2 Probe Troubleshooting ................................................................................................... 5-1

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

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

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


ii Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

LIST OF ILLUSTRATIONS

Figure 1-1. Typical System Package ....................................................................................... 1-1Figure 1-2. Typical System Installation .................................................................................... 1-3Figure 1-3. Oxygen Analyzer Probe - Exploded View.............................................................. 1-4Figure 1-4. Main Probe Components ....................................................................................... 1-5Figure 1-5. Cell and Tube Assemblies ..................................................................................... 1-5Figure 1-6. Optional Ceramic Diffusor and Vee Deflector Assembly....................................... 1-7Figure 1-7. Inner Probe Assembly............................................................................................ 1-8Figure 1-8. Junction Box .......................................................................................................... 1-8Figure 1-9. Abrasive Shield Assembly ................................................................................... 1-10Figure 1-10. Ceramic Diffusion/Dust Seal Assembly ............................................................... 1-11Figure 1-11. Flame Arrestor Diffusion/Dust Seal Assembly..................................................... 1-11Figure 1-12. Ceramic Diffusion Assembly................................................................................ 1-11Figure 1-13. Flame Arrestor Diffusion Assembly ..................................................................... 1-11Figure 1-14. Snubber Diffusion/Dust Seal Assembly............................................................... 1-12Figure 1-15. Bypass Probe Option (Sheet 1 of 3) .................................................................... 1-13Figure 2-1. Probe Installation (Sheet 1 of 5) ............................................................................ 2-2Figure 2-2. Orienting the Optional Vee Deflector ..................................................................... 2-7Figure 2-3. Wiring the Direct Replacement Probe ................................................................... 2-8Figure 3-1. Temperature Controller Card Calibration Points ................................................... 3-1Figure 3-2. Main PCB (Model 218A) EPROM Replacement ................................................... 3-2Figure 3-3. Main PCB (Model TC200) EPROM Replacement ................................................. 3-3Figure 3-4. Main PCB (Model 132) EPROM Replacement...................................................... 3-4Figure 3-5. DR Probe Wired to the ZA8C or A V8C Converter................................................ 3-5Figure 4-1. Cell Wiring Connection .......................................................................................... 4-2Figure 4-2. Removal of Optional Ceramic Diffusor and Vee Deflector .................................... 4-3Figure 4-3. Cell Replacement Kit ............................................................................................. 4-3Figure 4-4. Junction Box Mechanical Connections.................................................................. 4-5Figure 4-5. Inner Probe Replacement (Heater, V-Strut, and Backplate Assembly)................ 4-6Figure 4-6. Heater, Strut, and Backplate Assembly (Inner Probe Assembly).......................... 4-6Figure 4-7. Oxygen Analyzer Probe, Cross-Sectional View .................................................... 4-8Figure 4-8. High Temperature � Corrosive Environment Kit.................................................... 4-9

LIST OF TABLES

Table 1-1. Specifications for Oxygen Analyzing Equipment1 2 ............................................... 1-6Table 5-1. Fault Finding .......................................................................................................... 5-2Table 7-1. Replacement Parts for Probe ................................................................................ 7-1


February 2000

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

World Class 3000

CAUTION!The World Class 3000 Direct Replacement Probe can be used with any of the followingmodel electronics: 218, 225, 218A, ZA8C, and TC200. Read the appropriate setpoint adjust-ment in this manual to prevent damage to the probe.

PREFACEThe purpose of this manual is to provide information concerning the components, func-tions, installation and maintenance of this particular probe.Some sections may describe equipment not used in your configuration. The user shouldbecome thoroughly familiar with the operation of this module before operating it. Readthis instruction manual completely.

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

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

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

NOTEHighlights an essential operating procedure,condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERSThe number in the lower right corner of each illustration in this publication is a manual illus-tration number. It is not a part number, and is not related to the illustration in any technicalmanner.


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

World Class 3000

IMPORTANT

SAFETY INSTRUCTIONSFOR THE WIRING AND INSTALLATION

OF THIS APPARATUSThe following safety instructions apply specifically to all EU member states. They shouldbe strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or NationalStandards.

1. Adequate earth connections should be made to all earthing points, internal and external,where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cableanchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only bemade through a circuit breaker which will disconnect all circuits carrying conductors during afault situation. The circuit breaker may also include a mechanically operated isolating switch.If not, then another means of disconnecting the equipment from the supply must be providedand clearly marked as such. Circuit breakers or switches must comply with a recognizedstandard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazard-ous voltages are likely to be present beneath. These covers should only beremoved when power is removed from the equipment � and then only bytrained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is adanger from hot surfaces beneath. These covers should only be removed bytrained service personnel when power is removed from the equipment. Cer-tain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer tothe Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the follow-ing standards: EN61010-1, IEC417, and ISO3864.


February 2000

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

World Class 3000

SECTION 1DESCRIPTION AND SPECIFICATIONS

1-1 COMPONENT CHECKLIST

The Direct Replacement (DR) Probe package ofthe World Class 3000 Oxygen Analyzer typicallyincludes the probe, the instruction bulletin, andthe mounting hardware. These three items areshown in Figure 1-1. Record the Part Number,Serial Number, and Order Number of yoursystem on the first page of this manual.

1-2 SYSTEM OVERVIEW

a. Scope

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

Replacement Probe can be interfaced to anumber of different and earlier modelelectronics packages. These electronicpackages are not covered in this manual.For specific information concerning calibra-tion and operation of the system, refer tothe Instruction Bulletin applicable to yourelectronics package.

b. System Function

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. Thesampling system is in situ rather thanextractive.

1

2

3

19290001

Figure 1-1. Typical System Package

1. Oxygen Analyzer Probe 2. Mounting Adapter Plate with

Mounting Hardware and Gasket

3. Instruction Bulletin


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

World Class 3000

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 sensor cell is given by thefollowing Nernst equation:

EMF = KT log10(P1/P2) + C

Where:

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

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

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

NOTEFor best results, use clean, dry,instrument air (20.95% oxygen) as areference gas.

When the cell is at operating temperature,oxygen ions will travel through the cell fromhigh to low oxygen partial pressures. Theresulting output voltage is about 50 mV perdecade. The voltage varies with the ratio ofoxygen partial pressures of the referencegas over the sample gas. Thus, the outputsignal increases as the sample oxygen leveldecreases. This property gives the analyzerhigh sensitivity at low oxygen levels.

Oxygen analyzer equipment measures netoxygen concentration in the presence of allthe products of combustion, including water

vapor. Therefore, it may be considered ananalysis on a "wet" basis. In comparisonwith older methods, such as the Orsatapparatus, which provides an analysis on a"dry" gas basis, the "wet" analysis will, ingeneral, indicate a lower percentage ofoxygen. The difference will be proportionalto the water content of the sampled gasstream.

c. System Configuration

The DR probe is similar to the ExchangeProbe (NE model) except that the DR usesa 115 V heater like most older systems. TheDR does not require a separate power sup-ply as does the NE. The DR probe (like theNE) is available in five lengths. The lengthof stack penetration depends on the size ofthe stack or duct. The length options are18 in., 3 ft, 6 ft, 9 ft, and 12 ft (457 mm, 0.9m, 1.8 m, 2.7 m, and 3.7 m).

d. Features

1. Output voltage and sensitivity increaseas the oxygen concentrationdecreases.

2. In situ, non-sampling analyzer.

3. Field replaceable cell.

4. Analyzer constructed of rugged316 LSS for all wetted parts.

5. Suitable for use in temperatures up to1300°F (700°C).

6. The DR probe uses a 115 V heaterand does not require a separate heaterpower supply.


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World Class 3000

e. Handling the Oxygen Analyzer

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

The oxygen analyzer is designed forindustrial application. Treat eachcomponent of the system with care toavoid physical damage. The probecontains components made from ce-ramics, which are susceptible toshock when mishandled.

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

f. System Considerations

Prior to installation of your RosemountWorld Class 3000 Oxygen Analyzer, makesure you have all of the componentsnecessary to make the system installation.Ensure all components are properlyintegrated to make the system functional.

Once you have verified you have all thecomponents, select mounting locations anddetermine how each component will beplaced in terms of available power supply,ambient temperatures, environmental con-siderations, convenience, and serviceability.A typical installation is illustrated in Figure1-2.

After selecting the probe mounting location,provision should be made for a platformwhere the probe can be easily serviced.

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 for

DUCT

STACK

GASES

CALIBRATIONGAS

INSTRUMENTAIR SUPPLY(REF. GAS)

PRESSUREREGULATOR

FLOWMETER

EXISTINGELECTRONICS

OXYGENANALYZER(PROBE)

ADAPTERPLATE

LINEVOLTAGE

19290002

Figure 1-2. Typical System Installation

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

NOTEAmbient air is not recommended foruse as high test gas. An 8% O2balance in nitrogen is recommendedfor high test gas.

If test gas bottles will be hooked up perma-nently, an optional check valve is recom-mended next to the calibration fittings onthe probe head. This is to prevent breathingof calibration gas line and subsequent fluegas condensation and corrosion. The checkvalve is in addition to the stop valve in thetest gas kit or the solenoid valve in themultiprobe test gas sequencer units.

1-3 PHYSICAL DESCRIPTION

The Oxygen Analyzer Probe, Figure 1-3 con-sists of three component groups: probe exterior,inner probe, and junction box, Figure 1-4.



World Class 3000

2

3

NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FORPURCHASE SEPARATELY. FOR LIST OFAVAILABLE PARTS, SEE TABLE 7-1.

29

1

27

28

25

24

30

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.35900002

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

2. Diffusion Assembly 13. Insulating Sheet 24. Label 3. Retainer Screw 14. O-Ring 25. Probe Junction Box 4. Cell and Flange 15. Terminal Block Screw 26. Ground Wires 5. Corrugated Seal 16. Terminal Block 27. Insulating Gasket 6. Probe Tube Assembly 17. Terminal Block Marker 28. Washer 7. Cover Screw 18. Terminal Block Mounting Plate 29. Screw 8. Washer 19. Probe Junction Box Screws 30. Tag 9. Cover Chain Screw 20. Hose Clamp10. Cover Chain 21. Hose

Figure 1-3. Oxygen Analyzer Probe - Exploded View


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World Class 3000

PROBEEXTERIOR(SENSING CELL INSTALLED)

PROBEINTERIOR

PROBEJUNCTION

BOX

21240006

Figure 1-4. Main Probe Components

1-4 PROBE 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 1-5, is ayttria-stabilized zirconium oxide cell. Thecell creates an electrical signal when theoxygen level on one side is out of balancewith the oxygen level on the other side. Thissignal is proportional to the difference inoxygen levels.

b. Probe Tube Assembly

Four screws secure the cell and flange as-sembly, Figure 1-5, 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 1-4).Studs on the stack flange make installationeasy. There is also a tube to carry calibra-tion gas from the junction box to theprocess side of the cell during calibration.

PROBE TUBE

CORRUGATEDSEAL

CELL ANDFLANGE

ASSEMBLY

21240007

Figure 1-5. Cell and Tube Assemblies



World Class 3000

Table 1-1. Specifications for Oxygen Analyzing Equipment1 2

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

Temperature limits in processmeasurement area ....................................................................... 50° to 1300°F (10° to 704°C)Standard/current output................................................................ 4-20 mA dc signal (factory set)

O2 indication (Digital displayand analog output)........................................................................ 0.1% O2 or ±3% of reading, whichever is greater

using Rosemount test gasesSystem speed of response................................................................ less than 3 seconds (amplifier output)Resolution sensitivity ......................................................................... 0.01% O2 transmitted signalProbe reference air flow .................................................................... 2 scfh (56.6 L/hr) clean, dry, instrument

quality air (20.95% O2), regulated to5 psi (34 kPa)

Calibration gas mixtures .................................................................... Rosemount Hagan Test Gas Kit Part No.6296A27G01 contains 0.4% O2N2 Nominaland 8% O2N2 Nominal

Calibration gas flow ........................................................................... 5 scfh (141.6 L/hr)Power supply ..................................................................................... 115 ±10% Vac at 50/60 HzPower requirement ............................................................................ 200 VAAmbient operating temperature (Junction Box)................................. 300°F (149°C) [160°F (71°C) max for YEW

replacement]Approximate shipping weights:

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

1 All static performance characteristics are with operating variables constant.2 Equipment ordered utilizing this document as reference will be supplied to the USA standard design.Customers requiring the EEC standard design should request the EEC documentation and utilize its ordering data. Temperatures over 1000°F (537°C) may affect the ease of field cell replaceability.

c. Snubber Diffusion Assembly

The snubber diffusion assembly protectsthe cell from heavy particles and isolatesthe cell from changes in temperature. Thesnubber assembly threads onto the cell andflange assembly. Pin spanner wrenches(probe disassembly kit 3535B42G01) areapplied to holes in the diffusion element hubto remove or install the snubber assembly.

An optional ceramic diffusor element andvee deflector shown in Figure 1-6, is avail-able. The ceramic diffusor assembly is alsoavailable in a flame arresting version tokeep heat from the cell from igniting fluegases.


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World Class 3000

DIFFUSIONELEMENT

VEEDEFLECTOR

PINWRENCH

HUB

21240024

Figure 1-6. Optional Ceramic Diffusor and VeeDeflector Assembly

Systems that use an abrasive shield requirea special diffusor assembly with a hub thatis grooved to accept two dust seal gaskets.This special diffusor is available in bothsnubber and ceramic versions. See ProbeOptions, paragraph 1-8.

d. Cell � General

The components which make up the cell aremachined to close tolerances and assem-bled with care to provide accurate oxygenmeasurements. Any replacement requiresattention to detail and care in assembly toprovide 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 inner elec-trode for the cell assembly. It consists of aplatinum pad and a platinum/inconel com-posite wire which produces the cell constantoffset voltage described in the Nernst equa-tion.

With this pad and wire, the constant will bebetween -10 and +15 mV. The cell constant

is noted in the calibration data sheet sup-plied 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.

There are two styles of the heater/strutinner probe assembly. P/Ns3D39441G06 through G10 identify the44 V heater design. P/Ns 3D39441G01through G05 and G11 through G15identify the 115 V heater design. Bothstyles look the same. When replacinga strut, be sure the replacement hasthe same part number as the original.A stainless steel tag is attached to theinner probe assembly to identify the115V design. Operating a probe on thewrong heater voltage can cause injuryor severe damage to equipment.

1-5 PROBE INTERIOR

The inner probe assembly, Figure 1-7, consistsof six main parts:

a. Ceramic support rod with four holes runningthrough the length. The holes serve as in-sulated 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 1-7; locatedwithin ceramic support rod.)

d. A platinum screen pad which forms electri-cal contact with the inner electrode of theelectrochemical cell. (Not visible in Figure1-7; located at end of ceramic support rod.)The pad is attached to an inconel/stainlesssteel wire which carries the signal to theterminal strip.

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



World Class 3000

HEATER

V-STRUT

CERAMICSUPPORT

ROD

INSULATINGGASKET

21220004

REFERENCEGAS TUBE

TAG

Figure 1-7. Inner Probe Assembly

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

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

1-6 JUNCTION BOX

The junction box, Figure 1-8, is positioned at theexternal end of the probe and contains a termi-nal strip for electrical connections and fittings forreference and calibration gases. Fittings are for0.250 inch stainless steel tubing on Americanunits, and 6 mm tubing on European units. Thecalibration fitting has a seal cap which must re-main in place except during calibration. A tubingfitting is also supplied to be used with thecalibration gas supply 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 gasis supplied through the reference gas fitting tothe reference side of the cell. This gives the

TERMINALSTRIP

PROBEJUNCTION BOX

COVER

REFERENCEGAS FITTING

CALIBRATIONGAS FITTING 21240029

Figure 1-8. Junction Box

system a known quantity of oxygen with whichto compare the oxygen level in the process gas.Though ambient air can be used for this pur-pose, accuracy can only be assured if areference gas air set is used.

During calibration, two gases of different knownoxygen concentrations are injected one at atime through the calibration gas fitting. Stain-less steel tubing delivers this gas to the processside of the cell. In a healthy cell, the differencein oxygen 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 two mil-livolt outputs caused by the two calibrationgases for either automatic or semi-automaticcalibration.


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World Class 3000

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

1-7 CABLE ASSEMBLY

The Westinghouse and Rosemount systemsuse a 7-conductor cable to connect the probe tothe electronics package. Standard length for thiscable is 20 ft (6 m), but lengths up to 150 ft(45 m) are available. The seven conductorsinclude one shielded pair of wires for the cellmillivolt signal, one shielded pair of type K wiresfor the thermocouple, and three individual16-gauge wires for the heater and for ground.The assembled conductors are wrapped by aTeflonTM jacket and braided stainless steel

shield. The TeflonTM and stainless steel jacket-ing is suitable for high temperature use. Allmetal shields are isolated at the probe end andconnect by drain wires to ground at theelectronics.

1-8 PROBE OPTIONS

a. Abrasive Shield Assembly

The abrasive shield assembly, Figure 1-9, isa stainless-steel tube that surrounds theprobe assembly. The shield protects theprobe against particle abrasion and corro-sive condensations, provides a guide forease of insertion, and acts as a probe posi-tion support, especially for longer lengthprobes. The abrasive shield assembly usesa modified diffusion and vee deflector as-sembly fitted with dual dust seal packing.



World Class 3000

VIEW AVIEW B

A

B

A

B

15o

0.7450.755

0.1870.187

03.58403.554

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

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

/

/

NOTES: WELD ON BOTH SIDES WITH EXPANDINGCHILL BLOCK.

BEFORE WELDING, BUTT ITEM 2 WITHITEM 1 AS SHOWN.

2

0.45 MIN

125

SKIN CUT FACE FOR 90o

ON INSIDE BREAKFOR SMOOTHROUNDED EDGE ONBOTH ENDS OFCHAMFER.

2

90o

0.187

1

6.00

22.5o

P0009

oo

Figure 1-9. Abrasive Shield Assembly


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World Class 3000

P0010

Figure 1-10. Ceramic Diffusion/Dust SealAssembly

These modified diffusion and vee deflectorassemblies are available in standard, Figure1-10, and flame arrestor version, Figure1-11.

b. Ceramic Diffusion Assembly

The ceramic diffusion assembly, Figure1-12, is the traditional design for the probe.Used for over 25 years, the ceramic diffu-sion assembly provides a greater filtersurface area for the probe.

P0011

Figure 1-11. Flame Arrestor Diffusion/Dust SealAssembly

19280010

Figure 1-12. 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 1-11 andFigure 1-13 is recommended.

The flame diffusion assembly includes a setof baffles between the cell and the stackgases. This keeps 1500°F (816°C) celltemperatures from igniting unburned fuel inthe stack.

P0012

Figure 1-13. Flame Arrestor Diffusion Assembly



World Class 3000

P0014

Figure 1-14. Snubber Diffusion/Dust SealAssembly

d. Snubber Diffusion/Dust Seal Assembly

The snubber diffusion/dust seal assembly,Figure 1-14, 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 package

can be employed. The bypass system usesan 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 1-15.

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.


February 2000


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



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February 2000


World Class 3000

FLANGESTYLE ANSI JIS DIN

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

3D39004 GROUP

ITEMPART NAME

SIZE-REFERENCEINFORMATION

MAIL CODEPART NUMBEROR REF DWG G01 G02 G03 G04 G05 G06 G07 G08 G09

01 WORLD CLASS3000

DWG PROBE 18 IN. ORDER FROMMATRIX

02 GAS PICK-UP DWG 3 FT 4507C26G01 103 GAS PICK-UP DWG 6 FT 4507C26G02 104 GAS PICK-UP DWG 9 FT 4507C26G03 105 ANALYZER

HOUSINGDWG FOR WORLD CLASS

3000 ANSI3D39005G01 1 1 1

06 MTG HARDWARE DWG FOR ANSI FLANGE 3535B58G01 1 1 107 MTG HARDWARE DWG FOR JIS 3535B58G03 1 1 108 MTG HARDWARE DWG FOR DIN 3535B58G05 1 1 109 ANALYZER

HOUSINGDWG FOR JIS 3D39005G02 1 1 1

10 ANALYZERHOUSING

DWG FOR DIN 3D39005G03 1 1 1

11 GAS PICK-UP DWG FOR JIS 3 FT 4507C26G04 112 GAS PICK-UP DWG FOR JIS 6 FT 4507C26G05 113 GAS PICK-UP DWG FOR JIS 9 FT 4507C26G06 1

14 GAS PICK-UP DWG FOR DIN 3 FT 4507C26G07 1



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


February 2000

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

World Class 3000

SECTION 2INSTALLATION

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.

2-1 LOCATING THE OXYGEN ANALYZERPROBE

The location of the probe in the stack or flue ismost important for maximum accuracy in theoxygen analyzing process. The probe must bepositioned so that the gas it measures is repre-sentative of the process. Best results are nor-mally obtained if the probe is positioned nearthe center of the duct (40 to 60% insertion). Apoint too near the edge or wall of the duct maynot provide a representative sample because ofthe possibility of gas stratification. In addition,the sensing point should be selected so that theprocess gas temperature falls within a range of50° to 1300°F (10° to 704°C). Figure 2-1 pro-vides mechanical installation references.

a. Check the flue or stack for holes and airleakage. The presence of this condition willsubstantially affect the accuracy of the oxy-gen reading. Therefore, either make neces-sary repairs or install the probe upstream ofany leakage.

b. Ensure that the area is clear of obstructions,internal and external, that will interfere withinstallation. Allow adequate clearance forremoval of probe (Figure 2-1).

The junction box temperature mustnot exceed 300°°°°F (149°°°°C). If used withthe Yokogawa ZA8C electronics, junc-tion box temperature is limited to160°°°°F (71°°°°C). To meet these limits, theuser may need to make a heat shieldor provide cooling air to the junctionbox. The temperature limit is due tothe thermocouple "cold reference"device.

2-2 SERVICE REQUIRED

a. Power input: 115 ±10% Vac single phase,50 to 60 Hz, 3 amp minimum. (See label.)

b. Compressed air: 10 psig (69 kPa gauge)minimum, 225 psig (1551 kPa gauge)maximum at 2 scfh (56.6 L/hr) maximum;supplied by one of the following (less than40 parts-per-million total hydrocarbons).Regulator outlet pressure should be set at 5psi (35 kPa).

1. Instrument air - clean, dry.

2. Bottled standard air with step-downregulator.

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

4. Other equivalent clean, dry, oil-free airsupply.


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

World Class 3000

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


February 2000


World Class 3000

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World Class 3000

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February 2000


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 ROTATED

22.5o OUT OFTRUE POSITION

WELD OR BOLT MOUNTINGPLATE TO METAL WALL

OF STACK OR DUCT. JOINT MUST BE AIRTIGHT.

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

22.5o

OUT OFTRUE POSITION

FIELD WELDPIPE TO

ADAPTOR PLATE

BOLT ADAPTORPLATE TO OUTSIDE

WALL SURFACE

NOTE: DIMENSIONS IN INCHES WITHMILLIMETERS IN PARENTHESES.

3.25 (82.5)

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

WELD OR BOLT MOUNTINGPLATE TO METAL WALL

OF STACK OR DUCT.JOINT MUST BE AIRTIGHT.

FIELD WELDPIPE TOADAPTOR PLATE

4.0 (102)O.D. REF

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

MASONRYSTACK WALLOUTSIDE WALL

SURFACE

JOINT MUSTBE AIRTIGHT

BOLT MOUNTINGPLATE TO OUTSIDE

WALL SURFACE

ABRASIVE SHIELD MOUNTING

PROBE MOUNTING P0038




World Class 3000

BRACE BARS(NOT BY ROSEMOUNT)

2.00(51)

NOTE: DIMENSIONS IN INCHES WITHMILLIMETERS IN PARETHESES.

VERTICAL BRACE CLAMP ASSY.

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)

60 MAX.o

30 MIN.o

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.

ABRASIVE SHIELD

P0039


2-3 MECHANICAL INSTALLATION

a. Ensure that all components are available forinstallation of the probe. If equipped with theoptional ceramic diffusor, check to ensurethat it is not damaged. Ensure that the sys-tem cable is the required length.

b. The probe may be installed intact as it is re-ceived. It is recommended that you disas-semble the adapter plate for eachinstallation.

NOTEAn abrasive shield is recommendedfor high velocity particulate in the fluestream (such as those in coal firedboilers, kilns, and recovery boilers).Vertical and horizontal brace clampsare provided for 9 ft and 12 ft (2.75 mand 3.66 m) probes to provide me-chanical support of the probe. Refer toFigure 2-1, sheet 5.

c. Weld or bolt adapter plate (Figure 2-1) ontothe duct. Existing stack penetration andmounting hardware may be revised, or newmounting flanges may be installed (seeFigure 2-1, sheets 3 and 4).


February 2000


World Class 3000

d. If using the optional ceramic diffusor ele-ment, the vee deflector must be correctlyoriented. Before inserting the probe, checkthe direction of gas flow in the duct. Orientthe vee deflector on the probe so that theapex points upstream toward the flow (Fig-ure 2-2). This may be done by loosening thesetscrews, and rotating the vee deflector tothe desired position. Retighten thesetscrews.

VEEDEFLECTOR

VEEDEFLECTOR

DIFFUSIONELEMENT

SETSCREWFILTER

GAS FLOWDIRECTION

APEX

P0017

Figure 2-2. Orienting the Optional Vee Deflector

e. In horizontal installations, the probe covershould be oriented so the system cabledrops vertically from the probe cover. In avertical installation, the system cable can beoriented in any direction.

f. If the system has an abrasive shield, checkthe diffusion element dust seal packings.The joints in the two packings must bestaggered 180°. Also, make sure that thepackings are in the hub grooves as theprobe slides into the 15° forcing cone in theabrasive shield.

g. Insert the probe through the opening in themounting flange and bolt the unit to theflange When probe lengths selected are 9or 12 ft (2.74 or 3.66 m), special bracketsare supplied to provide additional supportfor the probe inside the flue or stack. SeeFigure 2-1, sheet 5.

2-4 ELECTRICAL INSTALLATION

Figure 2-3 shows the junction box wiring for thedirect replacement probe including the 115 Vhookup. Consult the electronics manual for theconnections to power and the existing signalconditioning electronics.



World Class 3000

1 2 3 4 5 6 7 8

BL

CE

LL-V

EB

L

OR

CE

LL+

VE

OR

YE

CH

RO

ME

LY

E

RD

ALU

ME

LR

D

GN

GN

WH

TW

HT

BK

BK

}115V

HE

AT

ER

JUNCTION BOXWIRING

PROBETEST GAS INPUT

AT 2-3 L/MIN(4-7 SCFH)

NOTE: FOR YOKOGAWA (YEW) ZA8C,REFER TO SECTION 3-6.

REF. GAS SUPPLYINPUT AIR AT

1 L/MIN (2 SCFH)

CHECKVALVE

19290007

Figure 2-3. Wiring the Direct Replacement Probe

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.


February 2000

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

World Class 3000

SECTION 3STARTUP

3-1 OVERVIEW

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

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

For Models 218, 225, and 132 (analog), refer toparagraph 3-2. Additional information can befound in IB-106-101.

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

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

For Model 132 (digital), refer to paragraph 3-5.Additional information can be found in IB-106-106A.

For Yokogawa Model ZA8C, refer to paragraph3-6.

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

Before beginning operation, it is important thatthe probe heater setpoint of the existing elec-tronics be changed to support the World Class3000 probe. The setpoint adjustment procedurerequired for Models 218, 225, and 132 analogelectronics is as follows:

a. Open electronics enclosure.

b. On temperature controller card, Figure 3-1,connect jumper wire from TP3 to either Pin2 or Pin 7.

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

d. Attach voltmeter with positive (+) lead onTP1 and negative (-) on either Pin 2 or 7.

NOTEThe voltage given above is for an am-bient (machinery space) temperatureof 77°F (25°C). For each degree of am-bient temperature above or below 77°F(25°C), add or subtract 0.242 mV fromthe nominal. Example: at 87°F (31°C),the nominal voltage of -322.3 Mvshould be increased (made less nega-tive) by 10 x 0.242 or 2.42 mV, makingthe adjusted nominal -319.9 Mv.e. Adjust potentiometer M110-1 to read -322.3

millivolts nominal.

f. Remove voltmeter leads.

g. Remove jumper wire.

2 3 5 6 7 10 12

TP1 M110-1

TP3

PIN 2(PSC)

PIN 7 (PSC) P0019

Figure 3-1. Temperature Controller CardCalibration Points


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

World Class 3000

3-3 MODEL 218A ELECTRONICS SETUP

Before beginning operation, it is important thatthe probe heater setpoint of the existing elec-tronics be changed to support the World Class3000 probe. To convert the Model 218A DigitalElectronics Package for use with the DR probe,an EPROM change is necessary. Remove MainPCB and check back of board to identify unit asG02 or G04. The replacement EPROM neededis as identified below:

G02 G04United States 1M03192G01 1M02982G01United Kingdom 1M03192G02 1M02982G02Germany 1M03192G03 1M02982G03France 1M03192G04 1M02982G04Italy 1M03192G05 1M02982G05

NOTEThe replacement EPROM when using amultiprobe averager unit is1M02982G10.

To replace the EPROM, proceed as follows:

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

b. Open electronics enclosure.

c. On the Main PCB, Figure 3-2, locate andremove old EPROM.

d. Replace with new EPROM.

e. Close electronics enclosure and power upsystem.

MAIN PCB

EPROM

P0020

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


February 2000


World Class 3000

3-4 MODEL TC200 VERITRIM ELECTRONICSSETUP

Before beginning operation, it is important thatthe probe heater setpoint of the existing elec-tronics be changed to support the World Class3000 Probe. To convert the Model TC200 Elec-tronics Package for use with the DR probe, anEPROM change is necessary. The replacementEPROM needed is part number 1M03154G02.

a. EPROM Replacement


1. Shut off and lock out power to theelectronics package.

2. Open electronics enclosure.

3. On the main PCB, Figure 3-3, locateand remove old EPROMs U11 andU12.

4. Replace with new EPROMs (part num-ber 1M03154G02) being careful to in-stall U11 and U12 in their properlocations.

5. Close electronics enclosure and powerup system.

b. Heater SetPoint Adjustment

The adjustment procedure required for theModel TC200 Electronics Package is asfollows:

1. Open keylocked enclosure to accessmembrane keyboard.

2. Put controller in PAR (parameter)mode by depressing "LOCK" "�""%O2" "INC" "ACK" in sequence.

3. Depress "ACK" pushbutton to cleardisplay.

DIS A/M

U11

U12

EPROMSU11 AND U12

P0021

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



World Class 3000

4. Press "NUM" pushbutton.

5. Using "INC", "DEC" buttons, displayparameter 125.

6. Press "VAL" button.

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

8. Press "ENT" to save new value.

3-5 MODEL 132 DIGITALELECTRONICS SETUP

Before beginning operation, it is important thatthe probe heater setpoint of the existing elec-tronics be changed to support the World Class3000 Probe. To convert the Model 132 DigitalElectronics Package for use with the DR probe,an EPROM change is necessary. The replace-ment EPROM needed is as identified below:

United States IM03222G01United KingdomGermanyFranceItaly


a. Shut off and lock out power to theelectronics package.

b. Open electronics enclosure.

c. On the Main PCB, Figure 3-4, locate andremove old EPROM.

d. Replace with new EPROM.

e. Close electronics enclosure and power upsystem.

3-6 THE YOKOGAWA ZA8C AND AV8C CON-VERTER ELECTRONICS SETUP

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

Connect the cabling from the ZA8C or AV8Cterminal to the probe terminal in the junction boxas shown in Figure 3-5.

C1

3

28

28

28

28

28

28

28

28

C4

2C

43

LE

D1

U1

0

20

O1

8

P2

8

P6

1

R8

C4

8

U2 C4

4U

7R

27

XT1

C2

7C

26

U1

R38

C38

C3

7

C2

9C

28

LM

80403

TP

1

J1

R4

8

C3

4

CR

18

CR

17

M5

5

C39 C3

0

R4

7R

49

R8

6C

R1

8

R3

8R

43

C1

0

U1

4

C3

1

C41

U3

R6

8

R6

4

P2

9

R6

1P

2209

CR

15

CR

16

R4

2

U13

R4

1R

48

U9

R6

2

R6

3

R5

4R

5308

1

RP

1

R4

6R

48

P6

2

U1

2

C11

C4

8C

47

U2

C3

2

R9

C3 C2

C1

C4

C3C8

C86

U11

C1

6 R6

C7

C8C9

R4

4

TX2

CR19 R5

6

C38

C36

C7

U1

9

IA

R1

P6

8R

59

R5

7R

58

CR

9R

81

08

U17

U16

U18

R1

8R

16

R1

7

R1

9C

R8

CR

5

CR

6C

R7

R1

6

R1

8

CR

4C

R3

R11

CR

21

CR

20

R1

4R

6

R2

3R

28

R7

C46

LK1

LK2

R4

CR

2C

R1

R5

CR

22

CR

23

R2

R1

3 C17

R2

4R

21

R1

CK

1

F1

F2

F4

F3

20

01

A

5A

5A

20

01

A

MO

V1

MO

V2

T8

3

C11

T8

2

ON

OF

F

T8

1

SW

1

FIL

1

BR

1

C1

0

D1

2

C1

3

R37

U4

C1

6

CR11

CR12

CR14

CR13

C12

C21

C4

6

C2

4

R1

2

C2

3

C2

2

D1

4D

13

U6

TP

2

CR24

R36

TX

1

R3

8 C30

CR

25

P3

6P

25

C29

C1

4D

1

R2

6

D2

AL

AR

MM

TR

-T/C

CE

LL

SK

GS

TK

-T/C

ML

-O/P

EE

LL

NN

HE

AT

ER

MA

ININ

PU

T

TR

1

MAIN PCBEPROM

P0022

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


February 2000


World Class 3000

1 2 3 4 5 6 7 8

}}}

ZA8COR

AV8CCONVERTER

CELL

THERMOCOUPLE

COLDJUNCTION

3+

4–

5+

6–

7+

8–

16

1732

GND SHIELD

PROBEHEATER

+ –

COLD JUNCTION

DEVICE

HEATER AND SIGNAL CABLE

WORLD CLASS 3000REPLACEMENT PROBE

WITH ADAPTER FLANGESTACK WALL

EXISTINGMOUNTING

ZA8COR

AV8CTERMINAL

GN OR YE RD BK BK GN

SHIELD

TEST GASIF AVAILABLE

SIGNALCABLE

REFERENCE AIRIF AVAILABLE

PROBETERMINAL

PROBE

ZA8C OR AV8C

NOTES: 1. HEATER TEMPERATURE SET TO 1380oF (750oC)

624023

THE GREATER MASS OF THE WORLD CLASS DIRECT REPLACEMENT PROBE REQUIRESLONGER TIME TO HEAT UP. UPON STARTUP, THE YOKOGAWA ELECTRONICS MAYINDICATE AN ERROR BECAUSE THE PROBE HAS NOT REACHED TEMPERATURE SETPOINTIN THE NORMAL TIME. REMOVE POWER FROM THE YOKOGAWA ELECTRONICS OR PROBEMODULE TO CLEAR THE ERROR, AND RESTORE POWER. THIS PROCEDURE MAY HAVE TOBE REPEATED A COUPLE OF TIMES BEFORE PROBE OPERATING TEMPERATURE IS REACHED.

2.

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



World Class 3000


February 2000

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

World Class 3000

SECTION 4MAINTENANCE AND SERVICE

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.

4-1 OVERVIEW

This section describes routine maintenance ofthe oxygen analyzer probe. Spare parts referredto are avail-able from Rosemount. Probe disas-sembly kit 3535B42G01 contains the requiredspanner and hex wrenches. Refer to Section 7for part numbers and 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.

4-2 PROBE CALIBRATION

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.

4-3 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 7-1.

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 preserveprecise surface finishes. Do not remove itemsfrom packaging until they are ready to be used.Spanner wrenches and hex wrenches neededfor this procedure are part of an available spe-cial tools kit, Table 7-1.

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.


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

World Class 3000

CELL EXTENSIONWIRE (ORANGE)

BOMB TAILCONNECTOR

INCONELCELL WIRE

(CLEARSLEEVING)

HEATERWIRES(BLACK

SLEEVING)THERMOCOUPLE -

(RED ALUMEL)

THERMOCOUPLE +(YELLOW CHROMEL)

CALIBRATIONGAS FITTING

REFERENCEGAS FITTING

PROBE JUNCTIONBOX COVER

CABLE 21220001

Figure 4-1. Cell Wiring Connection

a. Disconnect and lock out power to electron-ics. Shut off and disconnect reference gasand calibration gas supplies from junctionbox, Figure 4-1. Wearing heat resistantgloves and clothing, remove probe assem-bly from stack carefully and allow to cool toroom temperature. Do not attempt to workon unit until it has cooled to a comfortableworking temperature.

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

c. If equipped with the optional ceramic diffu-sor assembly, remove and discardsetscrews, Figure 4-2, and remove vee de-flector. Use spanner wrenches from probedisassembly kit, Table 7-1, to turn hub freefrom retainer. Inspect diffusion element. Ifdamaged, replace 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 usedto 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 4-5).


February 2000


World Class 3000

OPTIONAL CERAMICDIFFUSION ELEMENT

VEEDEFLECTOR

HUB

PINWRENCH

SETSCREW

RETAINER

CEMENTPORT

CEMENTFILLET

21240026

Figure 4-2. Removal of Optional Ceramic Diffusorand Vee Deflector

e. If contact assembly is damaged, replacecontact and thermocouple according toparagraph 4-5, Replacement of Contact andThermocouple 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 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 35 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).

PROBE TUBE(NOT INCLUDED

IN KIT)

SOCKET HEADCAP SCREWS

CORRUGATEDSEAL

CELL ANDFLANGE

ASSEMBLY

CALIBRATION GASPASSAGE

21240009

Figure 4-3. Cell Replacement Kit

j. On systems equipped with an abrasiveshield, install dust seal gaskets, with joints180° 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 15° reducing cone.

l. Turn power on to electronics and monitorthermocouple output. It should stabilize at29.3 ±0.2 mV. Set reference air flow at 2scfh (56.6 L/hr). After probe stabilizes, cali-brate probe per Instruction Bulletin applica-ble to your electronics package. If newcomponents have been installed, repeatcalibration after 24 hours of operation.

4-4 OPTIONAL CERAMIC DIFFUSIONELEMENT REPLACEMENT

a. General

The optional ceramic diffusion elementprotects the cell from particles in processgases. It does not normally need to be re-placed because the vee deflector protects itfrom particulate erosion. In severe environ-ments the filter may be broken or subject toexcessive erosion. Examine the diffusionelement whenever removing the probe forany purpose. Replace if damaged.



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 followingprocedure are available as part of a specialtool kit, Table 7-1.

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). Thesehigh temperatures can cause severeburns.

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

Do not remove the cell unless it is cer-tain that replacement is necessary.Cell cannot be removed for inspectionwithout damaging it. Refer to para-graph 4-3, Cell Replacement.

b. Replacement Procedure.

1. Shut off power to electronics. Discon-nect cable conductors and remove ca-ble, Figure 4-1. Shut off and disconnectreference gas and calibration gas sup-plies from probe head. Wearing heatresistant gloves and clothing, carefullyremove probe assembly from stackand allow to cool to room temperature.Do not attempt to work on unit until ithas cooled to a comfortable workingtemperature.

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

with 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 specialtool kit, Table 7-1, to turn hub free fromretainer.

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 7-1. 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.


February 2000


World Class 3000

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

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

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.

4-5 REPLACEMENT OF CONTACT ANDTHERMOCOUPLE ASSEMBLY

Use heat resistant gloves and clothingwhen removing junction box and innerprobe assembly. Do not attempt towork on these components until theyhave cooled to room temperature.Probe components can be as hot as800°°°°F (427°°°°C), and can cause severeburns.


a. Disconnect and lock out power to electron-ics. Using heat resistant gloves and cloth-ing, remove junction box cover. Squeezingtabs on hose clamps, remove hoses fromjunction box, Figure 4-4. Remove fourscrews in corners of the junction box. Pulljunction 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 4-1.

c. Remove two screws, Figure 4-4, lockwash-ers, and flat washers that connect junctionbox to inner probe assembly. Pull heater,V-strut and backplate assembly away fromjunction box. Inspect all O-rings and insu-lating gasket; replace if worn or 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 4-4. Junction Box Mechanical Connections



World Class 3000

35900001

MOUNTING SCREW(REAR VIEW)

CONTACT ANDTHERMOCOUPLER

ASSEMBLY

V-STRUT

HEATER SCREWS(NOT SHOWN)

HEATERCERAMIC ROD

SPRINGCLIP

INSULATINGGASKET

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

d. Use a pencil to mark locations of spring clipon ceramic rod, Figure 4-5.

e. Pry or squeeze tabs on spring clips, andpull contact and thermocouple assembly outof probe 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.

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 4-6), spring (9), springclip (10) (held open by squeezing tabs), andtube supports (11, 13) until spring clipreaches pencil mark.

i. Reinstall insulating gasket on backplate, re-place two screws, O-rings, lockwashers andflat washers connecting junction box to in-ner probe assembly.

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

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

1 3 4

5

4

8

6

78

9101111213

12

21240011

1. Heater Ceramic Rod 2. Contact and Thermocouple

Assembly 3. Strut 4. Leaf Spring

5. Ring Lug 6. Butt Connector 7. Extension Wire 8. Backplate 9. Spring

10. Spring Clip Assembly 11. Common Tube Support 12. Heater 13. Short Tube Support

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


February 2000


World Class 3000

k. Connect color coded wires to proper termi-nals as shown in Figure 4-1. 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 in. (6.4mm) from end of ceramic rod. Dress wiresso they do not touch sides of junction box.

l. Slide assembled junction box and innerprobe assembly into probe tube. To aligncalibration gas tube with corresponding holein backplate (A, B, Figure 1-3), insert scriberthrough hole in backplate and into calibra-tion gas tube. Secure with screws. Reinstallhoses and probe cover.

m. Power up system. Monitor thermocoupleoutput. It should stabilize at setpoint mV±0.2 mV. Recalibrate probe per InstructionBulletin applicable to your electronics pack-age.

4-6 REPLACEMENT OF HEATER, V-STRUT AND BACKPLATE ASSEMBLY (InnerProbeAssembly; Includes Contact AndThermocouple Assembly).

Wear heat resistant gloves and cloth-ing when remove probe head and in-ner probe assembly. Do not attempt towork on these components until theyhave cooled to room temperature.Probe components can be as hot as800°°°°F (427°°°°C). This can cause severeburns.


There are two styles of the heater/strutinner probe assembly. P/Ns3D39441G06 through G10 identify the44 V heater design. P/Ns 3D39441G01through G05 and G11 through G15identify the 115 V heater design. Bothstyles look the same. When replacinga strut, be sure the replacement hasthe same part number as the original.A stainless steel tag is attached to theinner probe assembly to identify the115V design. Operating a probe on thewrong heater voltage can cause injuryor severe damage to equipment.

NOTEThis 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. Squeeze tabs onhose clamps and remove hoses from junc-tion box, Figure 4-4. Remove four screwsand lockwashers (7 and 10, Figure 4-7) thathold junction box and inner probe assemblyto probe tube. Pull junction box and innerprobe assembly free from probe tube. Seton bench and allow to cool to room tem-perature.

b. Disconnect cell extension wire (orange),thermocouple wire (red alumel), and ther-mocouple wire (yellow chromel) by cuttingbomb tail connections from the terminalstrip, Figure 4-1.

c. Remove two screws, lockwashers, and flatwashers that connect junction box to innerprobe assembly. Remove and discard innerprobe assembly (heater, V-strut, and back-plate assembly). Replace with new innerprobe assembly. Reinstall screws, lock-washers and flat washers.



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 0.63 (16 mm) 3. Cell and Flange assembly 4. Corrugated Seal 5. Probe Tube Assembly

6. Gasket4.0 in. (102 mm) x 4.0 in.x 0.12 in. (3 mm)

7. Fillister Hd Screw8-32 x 0.5 in. (12.7 mm)

8. Cover Head Assembly

9. Hose Clamp 10. Lockwasher, #8 Split 11. Heater Strut Assembly

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

d. Connect color coded wires to proper termi-nals as shown in Figure 4-1. 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 in. (6.4mm) from end of ceramic rod. Dress wiresso they do not touch sides of junction box.

e. Slide assembled junction box and innerprobe assembly into probe tube. To aligncalibration gas tube with corresponding holein backplate (A, B, Figure 1-3), insert align-ing tool (included in probe disassembly kit,P/N 3535B42G01) through hole in back-plate and into calibration gas tube, whilesliding the heater strut into the probe tube.Secure with screws. Reinstall hoses andprobe cover.

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


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World Class 3000

4-7 CALIBRATION AND REFERENCE GASLINES 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 junction box. The kit part number is4843B93G01.

a. Installation Procedure

Use heat resistant gloves and clothingwhen removing junction box and innerprobe assembly. Do not attempt towork on these components until theyhave cooled to room temperature.Probe components can be as hot as800°°°°F (427°°°°C). This can cause severeburns.


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 junction box(Figure 4-4).

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 junctionbox. Install the other end of the stain-less steel tube onto the tube going tothe probe (Figure 4-8).

NOTEIf 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.

Figure 4-8. High Temperature � CorrosiveEnvironment Kit

STAINLESSSTEEL

TUBING

TEFLONSLEEVES

21240028



World Class 3000


February 2000

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

World Class 3000

SECTION 5TROUBLESHOOTING

5-1 OVERVIEW

Troubleshooting for the oxygen analyzer systemis broken down to the main component level. Inaddition to the information in this section,instruction bulletins for individual models alsodiscuss troubleshooting.

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.

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

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

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

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

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

5-2 PROBE TROUBLESHOOTING

a. Probe Faults

Listed below are the five symptoms of probefailure.

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 test gas being applied duringcalibration.

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

5. The probe heater temperature isunstable.

b. Table 5-1 provides a guide to fault findingfor the above symptoms.


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

World Class 3000

Table 5-1. Fault Finding

SYMPTOM CHECK FAULT REMEDY

1. No response to oxygenconcentration changewhen:

Heater is cold andTC mV output is less than setpoint

Thermocouple continuity Thermocouple failure Replace thermocouple orreturn probe to Rosemount.

Heater cold resistanceshould be 67 ohm to77 ohm

Heater failure Replace heater or returnprobe to Rosemount.

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

Heater is hot andT/C mV output is at setpoint ±0.2 mV

Recorder chart Recorder failure See Recorder InstructionManual.

Cell mV input to electronicsand cell mV at probe head

No cell mV at probe whentest gas applied

Replace cell or return probeto Rosemount.

Probe cell mV OK but noinput to electronics

Check out cable connec-tion.

Cell mV satisfactory both atjunction box and input toelectronics - failure of elec-tronics

Check electronics package.

2. System responds to oxygen concentration changes but does not give correct indication

Good response, with incorrect indication

Recorder or remoteindicator

Calibration error Recalibrate recorder or in-dicator. Reference Re-corder Instruction Manual.

System calibration Calibration error Recalibrate system.

Probe mounting and condi-tion of duct

Air ingress into duct Stop air leaks or resiteprobe.

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

3. Probe does not giveaccurate indicationof applied test gas

Test gas input port Blocked port Clean port. If the flue gas iscondensing in the test gasline, insulate the back of theprobe. Make sure that thetest gas line is capped be-tween calibrations, or acheck valve is installed.

Ceramic diffusion elementBlocked port

Diffusion element cracked,broken, or missing

Replace diffusion element.


February 2000

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

World Class 3000

Table 5-1. Fault Finding (continued)

SYMPTOM CHECK FAULT REMEDY

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

Plugged diffusion element Plugged diffusion element Change diffusion element orsnubber diffusion element.

5. Probe heater temperature unstable

Proper voltage heater isinstalled

Wrong heater Change heater to propervoltage.


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

World Class 3000


February 2000

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

World Class 3000

SECTION 6RETURN OF MATERIAL

6-1 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 toinsure 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 RosemountReturn 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.


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

World Class 3000


February 2000

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

World Class 3000

SECTION 7REPLACEMENT PARTS

Table 7-1. Replacement Parts for Probe

FIGURE andINDEX No. PART NUMBER DESCRIPTION

4-5 3D39441G011 Heater, V-Strut, and Backplate Assembly (115 V), 18 in. (45.6 cm)4-5 3D39441G021 Heater, V-Strut, and Backplate Assembly (115 V), 3 ft (0.9 m)4-5 3D39441G031 Heater, V-Strut, and Backplate Assembly (115 V), 6 ft (1.8 m)4-5 3D39441G041 Heater, V-Strut, and Backplate Assembly (115 V), 9 ft (2.7 m)4-5 3D39441G051 Heater, V-Strut, and Backplate Assembly (115 V), 12 ft (3.6 m)4-5 3D39441G111 Heater, V-Strut, and Backplate Assembly, 18 in. (45.6 cm)

(For use with YEW electronics)4-5 3D39441G121 Heater, V-Strut, and Backplate Assembly, 3 ft (0.9 m)




(For use with YEW electronics)4-6, 2 3534B56G042 Contact and Thermocouple Assembly, 18 in. (45.6 cm)4-6, 2 3534B56G052 Contact and Thermocouple Assembly, 3 ft (0.9 m)4-6, 2 3534B56G062 Contact and Thermocouple Assembly, 6 ft (1.8 m)4-6, 2 3534B56G072 Contact and Thermocouple Assembly, 9 ft (2.7 m)4-6, 2 3534B56G082 Contact and Thermocouple Assembly, 12 ft (3.6 m)4-6, 2 4513C61G012 Contact and Thermocouple Assembly, 18 in. (45.6 cm)

(For use with YEW electronics)4-6, 2 4513C61G022 Contact and Thermocouple Assembly, 3 ft (0.9 m)




(For use with YEW electronics)4-6, 2 3D39003G013 Abrasive Shield Assembly, 3 ft (0.9 m)4-6, 2 3D39003G023 Abrasive Shield Assembly, 6 ft (1.8 m)1-9 3D39003G073 Abrasive Shield Assembly, 9 ft (2.7 m)1-9 3D39003G083 Abrasive Shield Assembly, 12 ft (3.6 m)1-9 4847B61G01 Cell Replacement Kit, ANSI w/No lead wire1-9 4847B61G02 Cell Replacement Kit, ANSI 18 in. (45.6 cm)4-3 4847B61G03 Cell Replacement Kit, ANSI 3 ft (0.9 m)4-3 4847B61G04 Cell Replacement Kit, ANSI 6 ft (1.8 m)4-3 4847B61G05 Cell Replacement Kit, ANSI 9 ft (2.7 m)4-3 4847B61G06 Cell Replacement Kit, ANSI 12 ft (3.6 m)


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

World Class 3000

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

FIGURE andINDEX No. PART NUMBER DESCRIPTION

4-3 4847B61G07 Cell Replacement Kit, JIS, w/No lead wire4-3 4847B61G08 Cell Replacement Kit, JIS 18 in. (45.6 cm)4-3 4847B61G09 Cell Replacement Kit, JIS 3 ft (0.9 m)4-3 4847B61G10 Cell Replacement Kit, JIS 6 ft (1.8 m)4-3 4847B61G11 Cell Replacement Kit, JIS 9 ft (2.7 m)4-3 4847B61G12 Cell Replacement Kit, JIS 12 ft (3.6 m)4-3 4847B61G13 Cell Replacement Kit, DIN w/No lead wire4-3 4847B61G14 Cell Replacement Kit, DIN 18 in. (45.6 cm)4-3 4847B61G15 Cell Replacement Kit, DIN 3 ft (0.9 m)4-3 4847B61G16 Cell Replacement Kit, DIN 6 ft (1.8 m)4-3 4847B61G17 Cell Replacement Kit, DIN 9 ft (2.7 m)4-3 4847B61G18 Cell Replacement Kit, DIN 12 ft (3.6 m)4-3 3535B42G01 Probe Disassembly Kit1-13 3535B18G01 Ceramic Diffusor Assembly1-11 3535B60G01 Ceramic Diffusor Dust Seal Hub Assembly

(For use with Abrasive Shield)1-13 4841B03G02 Stainless Steel Diffusor Assembly1-12 3535B63G01 Flame Arrestor Diffusor Dust Seal1-14 3535B62G01 Flame Arrestor Diffusor4-2 3535B48G01 Vee Deflector Assembly

(For use with standard ceramic or dust seal type diffusors)4-2 6292A74G02 Diffusion Element Replacement Kit2-1 1537B70G03 Horizontal and Vertical Brace Clamp Assembly, 9 and 12 foot

(2.7 and 3.6 m) probe4-8 4843B93G01 High Temperature - Corrosive Environment Kit

4843B37G01 Snubber Diffusion Assembly1-10 4843B38G01 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.


February 2000

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

World Class 3000

SECTION 8INDEX

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.

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

BBypass Probe Option, 1-12

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

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

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

FFlame Arrestor, 1-11

GGas Stratification, 2-1

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

IIn Situ, 1-1, 1-2Instrument Air, 1-2, 2-1

JJunction Box, 1-3, 1-8

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

NNernst Equation, 1-2

OOrsat Apparatus, 1-2Oxygen Analyzer, 1-1

PProbe Heater Setpoint, 3-3

RReference Gas, 1-3

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

TThermocouple, 4-2, 4-5

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


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

World Class 3000

WWater Vapor, 1-2

ZZirconia Disc, 1-2

24613267/2-00

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.


© Rosemount Analytical Inc. 2001

World Class 3000

Emerson Process ManagementRosemount 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 65-777-0947http://www.processanalytic.com

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._______________

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