Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 Oxygen Analyzer with HPS Heater Power Supply Field Module (for use with Existing Signal Conditioning Electronics) http://www.processanalytic.
ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications.
HIGHLIGHTS OF CHANGES Effective October, 1995 Rev. 3 Page Summary Page 1-1 Updated art to reflect new probe configuration. Page 1-3 Updated art to reflect new probe configuration. Page 1-4 Updated art to reflect new probe configuration. Page 2-1 Update installation procedure to include optional ceramic diffusor and vee deflector. Page 2-2 Updated art and dimensions to reflect new probe configurations. Page 2-3 Updated art and dimensions to reflect new probe configurations.
Effective May, 1997 Rev. 3.3 Page Summary Page P-2 Added safety sheets. Effective February, 1998 Rev. 3.4 Page Summary Page 2-2 Figure 2-1. Changed calibration gas tube dimensions.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 TABLE OF CONTENTS PREFACE......................................................................................................................... P1 Definitions ......................................................................................................................... P1 Safety Instructions ........................................................................................................... P2 1-0 1-1 1-2 DESCRIPTION .
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 LIST OF ILLUSTRATIONS Figure 1-1. Figure 1-2. Figure 1-3. Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 2-7. Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. ii Typical System Package ....................................................................................... 1-1 Typical System Installation ....................................................................................
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 ! CAUTION If the HPS 3000 and World Class 3000 probe are used with any of the following model electronics; 218, 225, 218A, and TC200, read appropriate set point adjustment in Instruction Bulletin (IB) 106-300NE to prevent damage to the World Class 3000 probe. PREFACE The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of this particular oxygen analyzer.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. NonEU states should also comply with the following unless superseded by local or National Standards. 1.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 SECTION 1 DESCRIPTION 1-1 COMPONENT CHECKLIST OF TYPICAL SYSTEM (PACKAGE CONTENTS) A typical Rosemount World Class 3000 Oxygen Analyzer with HPS 3000 Heater Power Supply package should contain the items shown in Figure 1-1. Record the Part Number, Serial Number, and Order Number for each component of your system in the table located on the first page of this manual.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 The equipment measures oxygen percentage by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output voltage of the cell is given by the following Nernst equation: EMF = KT log10(P1/P2) + C Where: 1.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 6. Suitable for use in temperatures up to 1300°F (700°C). A typical installation is illustrated in Figure 1-2 and Figure 1-3. 7. Heater power supply allows World Class 3000 probe to be interfaced with existing analog and 218A digital electronic packages. After selecting the probe mounting location, provision should be made for a platform where the probe can be easily serviced.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 EXISTING ELECTRONICS RELAY ANALOG HEATER STACK TEMP + + PROBE MV PROBE TC } } } } *TRIAC + BK WH YE WH AD590 } } } RD BK GN J9 + OR BL + + SHIELD RD YE OR BK WH BL J8 GN } } SHIELD YE PROBE TC PROBE MV SHIELD + + STACK TC } + GN SHIELD RD YE PROBE HEATER MAINS } BK WH R N H J2 L GN BK J1 WH SHIELD (SEE PARAGRAPH 2.2.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 SECTION 2 INSTALLATION 2 2-1 OXYGEN ANALYZER (PROBE) INSTALLATION Before starting to install this equipment, read the "Safety instructions for the wiring and installation of this apparatus" at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury or death. Install all protective equipment covers and safety ground leads after installation.
Installation 5.71 (145) 4.75 (121) (4) HOLES EQ SP ON BC Rosemount Analytical Inc. 81.3 (2065) 117.3 (2980) 34 (864) 70 (1778) 106 (2692) 142 (3607) 3 FT 6 FT 9 FT 12 FT DIM "B" 16 (406) 18 IN. 153.3 (3894) 45.3 (1151) 27.3 (694) DIM "A" PROBE 5.12 (130) 0.59 (15) 6.10 (155) ANSI DIN JIS CAL GAS 1/4 IN. TUBE 6 MM TUBE 6 MM TUBE REF GAS 24610001 2. THESE FLAT FACED FLANGES ARE MANUFACTURED TO ANSI, DIN, AND JIS BOLT PATTERNS AND ARE NOT PRESSURE RATED. NOTES: 1.
Rosemount Analytical Inc. 103.1 (2619) 139.1 (3533) 81.3 (2065) 117.3 (2980) 153.3 (3894) 63 (1600) 99 (2515) 135 (3429) 6 FT 9 FT 12 FT A Division of Emerson Process Management 3.6 NOMINAL 0.945 0.75 0.75 (8) HOLES DIAMETER 7.48 7.48 7.50 BOLT CIRCLE INSULATE IF EXPOSED TO AMBIENT WEATHER CONDITIONS SEE TABLE IV FOR FLANGE SIZES 7.00 (178) CHECK VALVE FOR CAL GAS LINES ELECTRICAL CONNECTOR DIM "D" REMOVAL ENVELOPE 14.5 (369) 5.
2-4 Installation 5.708 (145) (M-16 x 2) 7.5 (191) DIN (P/N 4512C36G01) B C 45o A 7.50 (191) "D" DIA Rosemount Analytical Inc. 4 STUDS, LOCKWASHERS AND NUTS EQUALLY SPACED ON C DIA B.C. ADAPTOR PLATE FOR 3, 6, 9, AND 12 FT ABRASIVE SHIELD INSTALLATIONS. SEE SHEET 2. A B CROSSHATCHED AREA IN 4 CORNERS MAY BE USED TO PROVIDE ADDITIONAL HOLES FOR FIELD BOLTING OF PLATE TO OUTSIDE WALL SURFACE. A C 22.5o 16860021 ABRASIVE SHIELD FLANGE O.D. 8 THREADED HOLES EQUALLY SPACED ON D DIA B.C. 7.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 INSTALLATION FOR METAL WALL STACK OR DUCT CONSTRUCTION INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION 2 0.50 (13) 0.50 (13) BOLT ADAPTOR PLATE TO OUTSIDE WALL SURFACE MTG HOLES SHOWN oROTATED 22.5 OUT OF TRUE POSITION 3.75 (95) MIN DIA HOLE IN WALL STACK OR DUCT METAL WALL FIELD WELD PIPE TO ADAPTOR PLATE MTG HOLES SHOWN ROTATED o 22.5 OUT OF TRUE POSITION PIPE 4.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 BRACE BARS (NOT BY ROSEMOUNT) NOTE: DIMENSIONS IN INCHES WITH MILLIMETERS IN PARETHESES. 2.00 (51) o 60 MAX. } 1.00 (25) 30o MIN. VERTICAL BRACE CLAMP ASSY. BY ROSEMOUNT HORIZONTAL BRACE CLAMP ASSY. (BOTH BRACE CLAMP ASSEMBLIES ARE THE SAME. INSTALLATION AND LOCATION OF CLAMP ASSEMBLIES AND BRACE BARS TO BE DONE IN FIELD.) 2 HOLES - 0.625 (16) DIA. FOR 0.50 (12) DIA. BOLT 5.62 (143) ABRASIVE SHIELD 4.12 (105) 4.12 (105) 0.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 c. Service Required GAS FLOW DIRECTION APEX VEE DEFLECTOR FILTER 1. Power input: 100, 115 or 220 Vac single phase, 50 to 60 Hz, 3 amp minimum. (See label.) DIFFUSION ELEMENT SETSCREW VEE DEFLECTOR 2. Compressed air: 10 psig (68.95 kPag) minimum, 225 psig (1551.38 kPag) maximum at 2 scfh (56.6 L/hr) maximum; supplied by one of the following (less than 40 parts-per-million total hydrocarbons).
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 EXISTING ELECTRONICS RELAY ANALOG HEATER STACK TEMP + + PROBE MV PROBE TC } } } } *TRIAC + BK WH YE WH AD590 } } } RD BK GN J9 + OR BL + + SHIELD RD YE OR BK WH BL J8 GN } } SHIELD YE PROBE TC PROBE MV SHIELD + + STACK TC } + GN SHIELD RD YE PROBE HEATER MAINS } BK WH R N H J2 L GN BK J1 WH SHIELD (SEE PARAGRAPH 2.2.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 2 Figure 2-5. Heater Power Supply Wiring Connections 2-2 HEATER POWER SUPPLY INSTALLATION Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death. a. Mechanical Installation The outline drawing of the heater power supply enclosure, Figure 2-3, shows mounting centers and clearances.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 JUMPER CONFIGURATIONS 1 LINE VOLTAGE SELECTION JUMPER (INSTALL) 100/120 V.A.C. ALWAYS DISCONNECT LINE VOLTAGE FROM HEATER POWER SUPPLY AND ANALOG ELECTRONICS (IF USED) BEFORE CHANGING JUMPERS. HEATER POWER JUMPER JM4, JM1 REMOTE REMOVE JM2 220/240 V.A.C.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 2 JM1 FUSES JM2 JM4 JM3 JM6 JM7 JM5 JM8 3D3 080G REV FUSE NOTE: ALL FUSES ARE 5A @ 250 VAC, ANTI-SURGE, CASE SIZE 5 X 20 MM, TYPE T TO IEC127, SCHURTER. 22540005 Figure 2-7. Jumpers on HPS Mother Board ! NOTE Upon completing installation, make sure that the probe is turned on and operating prior to firing up the combustion process. Damage can result from having a cold probe exposed to the process gases.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 2-12 Installation World Class 3000 Rosemount Analytical Inc.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 SECTION 3 SETUP 3-1 OVERVIEW a. Open electronics enclosure. This section covers the setup procedures for the World Class 3000 Oxygen Analyzer with HPS 3000 Heater Power Supply Field Module. Since this equipment may be used with a number of different electronics packages, this section has been divided into three parts: Models 218, 225, and 132 (Analog) Electronics, Model 218A, Electronics, and Model TC200 Electronics.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 NOTE The voltage given above is for an ambient (machinery space) temperature of 77°F (25°C). For each degree of ambient temperature above or below 77°F (25°C), add or subtract 0.242 mV from the nominal. Example; at 87°F (31°C), the nominal voltage of -322.3 should be increased (made less negative) by 10 x 0.242 or 2.42 mV, making the adjusted nominal -319.9. f. 3-3 Remove voltmeter leads.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 3 Figure 3-3. Main PCB (Model TC200) EPROM Replacement 3-4 MODEL TC200 VERITRIM ELECTRONICS SETUP Before beginning operation, it is important that the probe heater set point of the existing electronics be changed to support the World Class 3000 Probe. To convert the Model TC200 Electronics Package for use with the World Class 3000 Probe and Heater Power Supply, an EPROM change is necessary.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 4. Press "NUM" pushbutton. 5. Using "INC", "DEC" buttons, display parameter 125. 6. Press "VAL" button. 7. Using "INC", "DEC" buttons, change parameter 125 value to 15.4. 8. Press "ENT" to save new value. 3-5 MODEL 132 DIGITAL ELECTRONICS SETUP Before beginning operation, it is important that the probe heater set point of the existing electronics be changed to support the World Class 3000 Probe.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 SECTION 4 TROUBLESHOOTING 4-1 b. HPS 3000 Heater Power Supply OVERVIEW Troubleshooting information for the HPS 3000 Heater Power Supply is contained in Appendix B, HPS 3000 Troubleshooting. Troubleshooting for the oxygen analyzer system is broken down to the main component level. Faults within the probe or heater power supply may cause symptoms which overlap. c.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 4-2 Troubleshooting World Class 3000 Rosemount Analytical Inc.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 SECTION 5 RETURN OF MATERIAL 5-1 If factory repair of defective equipment is required, proceed as follows: 5. Complete shipping instructions for return of equipment. a. Secure a return authorization number from a Rosemount Analytical Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted. 6.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 5-2 Return of Material World Class 3000 Rosemount Analytical Inc.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 SECTION 6 APPENDICES APPENDIX A. WORLD CLASS 3000 OXYGEN ANALYZER (PROBE) APPENDIX B. HPS HEATER POWER SUPPLY FIELD MODULE 6 Rosemount Analytical Inc.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 APPENDIX A NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASE SEPARATELY. FOR LIST OF AVAILABLE PARTS, SEE TABLE A-3. 1 26 20 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 APPENDIX A, REV. 3.6 WORLD CLASS 3000 OXYGEN ANALYZER (PROBE) DESCRIPTION A-1 Read the “Safety instructions for the wiring and installation of this apparatus” at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury or death.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 1, 2 Table A-1. Specifications for Oxygen Analyzing Equipment. 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 process measurement area............................................................ 50° to 1300°F (10° to 704°C) Standard/current output ..........
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 A-2 c. Snubber Diffusion Assembly PROBE ASSEMBLY EXTERIOR Primary probe exterior components include a flange-mounted zirconium oxide cell, mounted on a tube assembly and protected by a snubber diffusion assembly. The snubber diffusion assembly protects the cell from heavy particles and isolates the cell from changes in temperature. The snubber diffusion assembly threads onto the cell and flange assembly.
Instruction Manual Appendix A Rev. 3.6 July 1998 d. Cell - General The components which make up the cell are machined to close tolerances and assembled with care to provide accurate oxygen measurements. Any replacement requires attention to detail and care in assembly to provide good results. Failure to follow the instructions in this manual could cause danger to personnel and equipment. Read and follow instructions in this manual carefully.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 PROBE JUNCTION BOX COVER TERMINAL STRIP During calibration, two gases of different known oxygen concentrations are injected one at a time through the calibration gas fitting. Stainless steel tubing delivers this gas to the process side of the cell. In a healthy cell, the difference in oxygen pressure from the process side to the reference side of the cell will cause a millivolt output proportional to the difference in oxygen levels.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 2 .187 1 .187 B A 15 o 3.584 3.554 90o ON INSIDE BREAK FOR SMOOTH ROUNDED EDGE ON BOTH ENDS OF CHAMFER A .45 MIN .187 B 125 6.00 SKIN CUT FACE FOR 90 o VIEW A VIEW B 22.5 o 0.75 THRU 4 PLS, EQ SP ON 4.75 B.C. NOTES: 1 WELD ON BOTH SIDES WITH EXPANDING CHILL BLOCK. 2 BEFORE WELDING, BUTT ITEM 2 OR 4 WITH ITEM 1 AS SHOWN. .745 DIA ON A 7.50 DIA B.C. (REF) .755 16860033 Figure A-7.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 19280010 P0010 Figure A-8. Ceramic Diffusion/Dust Seal Assembly These modified diffusion and vee deflector assemblies are available in standard, Figure A-8, and flame arrestor version, Figure A-9. b. Ceramic Diffusion Assembly The ceramic diffusion assembly, Figure A-10, is the traditional design for the probe. Used for over 25 years, the ceramic diffusion assembly provides a greater filter surface area for the probe. P0011 Figure A-9.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 an 18 inch (457 mm) or 3 foot (0.92 m) probe mounted externally on the stack or duct. The process or exhaust gases are directed out to the probe through a passive sampling system using inconel tubes. Flue gas flow induces the movement of gases into, through, and out of the bypass unit. The bypass arrangement does not require the use of aspiration air and the gas which flows past the probe is returned to the stack or duct.
Rosemount Analytical Inc. A Division of Emerson Process Management 4 DRAIN 05 OPTIONAL MOUNTING ARRANGEMENT, 4 IN. 150# FLANGE SUPPLIED BY CUSTOMER 06 GASKET AND HARDWARE 6.50 (165.1) REF 6.0 (152.4) REF 02 03 04 VIEW 2 CAL GAS 1 REF AIR ELECT CABLE 109.00 (2768.6) REF (4507C26G03) 37.00 (939.8) REF (4507C26G01) 73.00 (1854.2) REF (4507C26G02) 30.62 (777.75) REF (4507C26G01) 27270017 DIRECTION OF FLOW A-A C 9 FT (2743.2) GAS TUBE PICK-UP 62.50 (1587.5) REF (4507C26G03) 26.50 (673.
A-10 Appendices 6 3 4 Rosemount Analytical Inc. PLATE WELDED TO STACK 4.026 (102.26) I.D. 02 03 04 11 12 13 14 15 16 C 9 FT (2743.2) GAS TUBE PICK-UP B 6 FT (1828.8) GAS TUBE PICK-UP GAS TUBE PICK-UP GROUP NOTE A 3 FT (914.4) ELECT CABLE 73.0 (1854.2) ON 6 FT (1828.8) PICKUP (3D390004G08) 37.0 (939.8) ON 3 FT (914.4) PICKUP (3D390004G07) 109.0 (2768.6) ON 9 FT (2743.2) PICKUP (3D390004G09) 62.5 (1587.5) ON 9 FT (2743.2) PICKUP (3D390004G09) 26.5 (673.1) ON 3 FT (914.4) OR 6 FT (1828.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 Extended Temperature By-Pass Arrangements (2400°°F; 1300°°C) PART NO. GROUP CODE DESCRIPTION 1U0571 G01 3’ By-pass Package with ANSI bolt pattern. 1U0571 G02 6’ By-pass Package with ANSI bolt pattern. 1U0571 G03 9’ By-pass Package with ANSI bolt pattern. 1U0571 G04 3’ By-pass Package with JIS bolt pattern. 1U0571 G05 6’ By-pass Package with JIS bolt pattern. 1U0571 G06 9’ By-pass Package with JIS bolt pattern.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 PROBE TROUBLESHOOTING A-7 OVERVIEW 1. The system does not respond to changes in the oxygen concentration. The probe troubleshooting section describes how to identify and isolate faults which may develop in the probe assembly. 2. The system responds to oxygen changes but does not give the correct indication. 3. The system does not give an acceptable indication of the value of the oxygen calibration gas being applied during calibration.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 Table A-2. Fault Finding (Continued) Symptom Check Fault Remedy 2. System responds to oxygen concentration changes but does not give correct indication Good response, with incorrect indication 3. System does not give accurate indication of applied calibration gas 4. System takes a long time to return to flue gas value after calibration gas is turned off Rosemount Analytical Inc.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 Figure A-14. Flowchart of Probe Related Problems, #1 A-14 Appendices Rosemount Analytical Inc.
Instruction Manual World Class 3000 Appendix A Rev. 3.6 July 1998 Figure A-15. Flowchart of Probe Related Problems, #2 Rosemount Analytical Inc.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 SERVICE AND NORMAL MAINTENANCE ! NOTE UPON COMPLETING INSTALLATION, MAKE SURE THAT THE PROBE IS TURNED ON AND OPERATING PRIOR TO FIRING UP THE COMBUSTION PROCESS. DAMAGE CAN RESULT FROM HAVING A COLD PROBE EXPOSED TO THE PROCESS GASES. During outages, and if possible, leave all probes running to prevent condensation and premature aging from thermal cycling.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 INCONEL CELL WIRE (CLEAR SLEEVING) HEATER WIRES (BLACK SLEEVING) THERMOCOUPLE (RED ALUMEL) BOMB TAIL CONNECTOR CELL EXTENSION WIRE (ORANGE) THERMOCOUPLE + (YELLOW CHROMEL) CALIBRATION GAS FITTING REFERENCE AIR FITTING CABLE PROBE JUNCTION BOX COVER 27270019 Figure A-16. Cell Wiring Connection b. If the probe uses the standard diffusion element, use a spanner wrench to remove the diffusion element. c.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 RETAINER PIN WRENCH g. Rub a small amount of anti-seize on both sides of new corrugated seal. OPTIONAL CERAMIC DIFFUSION ELEMENT h. Assemble cell and flange assembly, corrugated seal, and probe tube. Make sure the calibration tube lines up with the calibration gas passage in each component. Apply a small amount of anti-seize compound to screw threads and use screws to secure assembly. Torque to 55 in-lbs (4 N•m).
Instruction Manual World Class 3000 Damage to the diffusion element may become apparent during calibration. Compare probe response with previous response. A broken diffusion element will cause a slower response to calibration gas. Hex wrenches needed to remove setscrews and socket head screws in the following procedure are available as part of a special tool kit, Table A-3. Wear heat resistant gloves and clothing to remove probe from stack.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 Squeezing tabs on hose clamps, remove hoses from probe junction box, Figure A-19. Remove four screws in corners of probe junction box. Pull probe junction box and inner probe assembly free from probe tube. Set on bench and allow to cool to room temperature. 11. Wipe a heavy layer of anti-seize compound onto the threads and mating surfaces of the diffusion hub and retainer. 12.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 d. Use a pencil to mark locations of spring clip on ceramic rod, Figure A-20. g. Note wire lengths of old assembly as an aid for trimming new lengths in step (j). Trimming of wires will not always be necessary. Throw away old contact and thermocouple assembly. e. Pry or squeeze tabs on spring clips, and pull contact and thermocouple assembly out of probe assembly. Retain spring clips and spring; replace if damaged. h.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 terminal strip could act as additional thermocouple junctions. This could produce a voltage that would affect the thermocouple output signal. Do not bend wires closer than 1/4 inch (6.4 mm) from end of ceramic rod. Dress wires so they do not touch sides of probe junction box. l. Slide assembled probe junction box and inner probe assembly into probe tube.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 6 1 2 4 7 8 9 5 11 10 3 21240012 1. 2. 3. 4. 5. Snubber Diffusion Element Socket Hd Cap Screw [0.25 in.-28 x 0.063 (16 mm)] Cell and Flange Assembly Corrugated Seal Probe Tube Assembly 6. 7. 8. 9. 10. 11. Gasket [4.0 in. (102 mm) x 4.0 in. x 0.12 in. (3 mm)] Fillister Hd Screw [8-32 x 0.5 in. (12.7 mm)] Cover Head Assembly Hose Clamp Lockwasher (#8 Split) Heater Strut Assembly Figure A-22.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 TEFLON SLEEVES Do not use sealant when installing the stainless steel tubes. Gas samples may become contaminated. 2. First install the stainless steel tubing on the fitting at the bottom of the probe junction box. Install the other end of the stainless steel tube onto the tube going to the probe (Figure A-23). NOTE STAINLESS STEEL TUBING If abrasive conditions of high ash content and high velocity exist, an abrasive shield is recommended.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 REPLACEMENT PARTS Table A-3. Replacement Parts for Probe Figure and Index No.
Instruction Manual Appendix A Rev. 3.6 July 1998 World Class 3000 Table A-3. Replacement Parts for Probe (Continued) Figure and Index No.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 APPENDIX B, REV. 2.2 HPS 3000 HEATER POWER SUPPLY B DESCRIPTION Read the “Safety instructions for the wiring and installation of this apparatus” at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury or death. B-1 DESCRIPTION The Rosemount HPS 3000 Heater Power Supply Field Module acts as an interface between probe and electronics, and supplies power to the probe heater.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 TRANSFORMER TERMINAL COVERS FRONT TERMINAL STRIP (FROM ELECTRONICS) TRANSFORMER TERMINAL STRIP (FROM PROBE) SIDE 35730002 Figure B-2. Heater Power Supply, Interior B-2 Appendices Rosemount Analytical Inc.
Instruction Manual Appendix B Rev. 2.2 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 II Humidity Range .....................................................................95% Relative Humidity Ambient Temperature Range ......................
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 NOTE In operation, when connected to the CRE 3000 Control Room Electronics, line voltage passes through the relay (when on) and is converted into 44 volts by the transformer. If the probe thermocouple indicates that the probe has dropped below operating temperature, a signal from the CRE triggers the triac. The triac then supplies voltage to the probe heater, warming the cell.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 SYMPTOM HEATER DOES NOT HEAT UP (DOES NOT INCREASE IN OUTPUT). SET METER TO 250 VAC. PLACE METER PROBES ON J2, “FROM ELECTRONICS”, ANALOG HEATER. SET METER* FOR 50 VAC. PLACE PROBES ON TERMINAL BLOCK J2, “FROM PROBE”, PROBE HEATER. METER SHOULD REGISTER A PULSATING NOMINAL 115 VAC. B NO CHECK FUSES IN PROBE ELECTRONICS. YES METER INDICATES PULSATING NOMINAL 44 VAC. NO DISCONNECT POWER TO HPS AND PROBE ELECTRONICS.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 SYMPTOM HEATER OVERHEATS. NOTE: ON INITIAL STARTUP THE TEMPERATURE OF THE PROBE MAY OVERHEAT TO A NOMINAL TEMP OF 800°C. CHECK IF THE YELLOW WIRE IS CONNECTED TO POSITIVE AND THE RED TO NEGATIVE ON BOTH “FROM ELECTRONICS” AND “FROM PROBE” TERMINAL BLOCKS. (MODELS 218 AND 225 ONLY) NO CONNECT THE WIRING ACCORDING TO THE DECALS ON THE TERMINAL COVERS. SET METER* ON 250 VAC SCALE.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 SYMPTOM PROBE HEATER START TO HEAT UP AND THEN LOOSES TEMPERATURE. (MODEL TC200 ONLY) B CHECK PARAMETER 35 ON TC200. IF THE NUMBER IS NEGATIVE THEN SOMEWHERE THE THERMOCOUPLE WIRES ARE REVERSED. 35730005 Figure B-6. HPS Troubleshooting Flowchart, #3 Rosemount Analytical Inc.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 SERVICE AND NORMAL MAINTENANCE B-5 OVERVIEW e. Remove old transformer. Place new transformer in position and reconnect harness plug as noted in step d. This section describes service and routine maintenance of the HPS 3000 Heater Power Supply Field Module. Replacement parts referred to are available from Rosemount. Refer to Table B-2 of this manual for part numbers and ordering information. f.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 i. j. Making a note of the location and color of each wire, disconnect wires from terminal strip on mother board. Remove four screws (9) holding mother board to stand offs (10) on subplate (14). k. Remove mother board (12). l. Position new mother board on stand offs and reinstall screws removed in step j. m. Reconnect wires to terminal strip in positions noted in step i. n. Reinstall four stand offs removed in step h.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASE SEPARATELY. FOR LIST OF AVAILABLE PARTS SEE TABLE B-2. 35730006 Figure B-7. Heater Power Supply, Exploded View B-10 Appendices Rosemount Analytical Inc.
Instruction Manual Appendix B Rev. 2.2 January 1997 World Class 3000 LEGEND FOR FIGURE B-7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Enclosure Cover Screw Lockwasher Terminal Cover Stand Off Lockwasher Daughter Board Terminal Cover Screw Stand Off Hex Nut Mother Board Fuse 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Subplate Enclosure Box Lockwasher Stand Off Screw Lockwasher Mounting Plate Screw Gasket Transformer Retaining Plate Hex Nut B REPLACEMENT PARTS Table B-2.
Instruction Manual Appendix B Rev. 2.2 January 1997 B-12 Appendices World Class 3000 Rosemount Analytical Inc.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 World Class 3000 SECTION 7 INDEX This index is an alphabetized listing of parts, terms, and procedures having to do with the Hazardous Area Oxygen/Combustibles Transmitter. Every item listed in this index refers to a location in the manual by one or more page numbers.
Instruction Bulletin 106-300NE Rev. 3.4 May 2000 7-2 Index World Class 3000 Rosemount Analytical Inc.
WARRANTY Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects 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, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller.
Instruction Manual 106-300NE Rev. 3.4 May 2000 World Class 3000 World Class 3000 Probe Part No. ________________ Serial No. ________________ Order No. ________________ HPS 3000 Part No. ________________ Serial No. ________________ Order No. ________________ Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com Fisher-Rosemount GmbH & Co.
