Emerson World Class 3000 Instruction Bulletin

Oxygen analyzer with hps heater power supply field module (for use with existing signal conditioning electronics)
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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.com

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Summary of Contents for Emerson World Class 3000

  • Page 1 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.com...
  • Page 2 The information contained in this document is subject to change without notice. Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St.
  • Page 3 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 4 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.
  • Page 5: Table Of Contents

    Model 218A Electronics Setup ..................3-2 Model TC200 VERITRIM Electronics Setup..............3-3 Model 132 Digital Electronics Setup................3-4 TROUBLESHOOTING ....................4-1 Overview.......................... 4-1 System Troubleshooting....................4-1 RETURN OF MATERIAL ....................5-1 APPENDICES ......................... 6-1 INDEX..........................7-1 Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 6 Temperature Controller Card Calibration Points ........... 3-1 Figure 3-2. Main PCB (Model 218A) EPROM Replacement ........... 3-2 Figure 3-3. Main PCB (Model TC200) EPROM Replacement ..........3-3 Figure 3-4. Main PCB (Model 132) EPROM Replacement............3-4 Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 7: Preface

    The number in the lower right corner of each illustration in this publication is a manual illus- tration number. It is not a part number, and is not related to the illustration in any technical manner. Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 8: Safety Instructions

    9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions. 10. All graphical symbols used in this product are from one or more of the follow- ing standards: EN61010-1, IEC417, and ISO3864. Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 9: Description

    3000 Heater Power Supply Field Module. Oxygen Analyzer (Probe) Heater Power Supply Instruction Bulletin Mounting Adaptor Plate with Mounting Hardware and Gasket 19260001 Figure 1-1. Typical System Package Rosemount Analytical Inc. A Division of Emerson Process Management Description...
  • Page 10 5. Analyzer constructed of rugged 316 paratus, which provides an analysis on a LSS for all wetted parts. "dry" gas basis, the "wet" analysis will, in general, indicate a lower percentage of Description Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 11: Figure 1-2. Typical System Installation

    ELECTRONICS PACKAGE placed in terms of available power supply, 19260002 ambient temperatures, environmental con- Figure 1-2. Typical System Installation siderations, convenience, and serviceability. Rosemount Analytical Inc. A Division of Emerson Process Management Description...
  • Page 12: Figure 1-3. Typical System Wiring

    PROBE TEST GAS INPUT AT 2-3 L/MIN (4-7 SCFH) PROBE HEAD CHECK WIRING REF. GAS SUPPLY VALVE INPUT AIR AT 1 L/MIN (2 SCFH) 19260003 Figure 1-3. Typical System Wiring Description Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 13: Installation

    The presence of this con- dition will substantially affect the accu- 3. Weld or bolt adapter plate (Figure 2-1) racy of the oxygen reading. Therefore, onto the duct. Rosemount Analytical Inc. A Division of Emerson Process Management Installation...
  • Page 14: Figure 2-1. Probe Installation

    Instruction Bulletin 106-300NE Rev. 3.4 World Class 3000 May 2000 Figure 2-1. Probe Installation (Sheet 1 of 5) Installation Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 15 Instruction Bulletin 106-300NE Rev. 3.4 World Class 3000 May 2000 Figure 2-1. Probe Installation (Sheet 2 of 5) Rosemount Analytical Inc. A Division of Emerson Process Management Installation...
  • Page 16 Instruction Bulletin 106-300NE Rev. 3.4 World Class 3000 May 2000 Figure 2-1. Probe Installation (Sheet 3 of 5) Installation Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 17 PLATE TO METAL WALL OF STACK OR DUCT. JOINT MUST BE AIRTIGHT. NOTE: DIMENSIONS IN INCHES WITH MILLIMETERS IN PARENTHESES. PROBE MOUNTING P0038 Figure 2-1. Probe Installation (Sheet 4 of 5) Rosemount Analytical Inc. A Division of Emerson Process Management Installation...
  • Page 18 In a vertical instal- inside the flue or stack. See Figure 2-1, lation, the system cable can be ori- sheet 5. ented in any direction. Installation Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 19: Figure 2-2. Orienting The Optional Vee Deflector

    (c) Bottled compressed gas mixture Figure 2-2. Orienting the Optional Vee Deflector (20.95% oxygen in nitrogen). (d) Other equivalent clean, dry, oil-free air supply. Figure 2-3. Outline of Heater Power Supply Rosemount Analytical Inc. A Division of Emerson Process Management Installation...
  • Page 20: Figure 2-4. Electrical Installation Of Heater Power Supply

    TEST GAS INPUT AT 2-3 L/MIN (4-7 SCFH) PROBE HEAD CHECK WIRING REF. GAS SUPPLY VALVE INPUT AIR AT 1 L/MIN (2 SCFH) 19260003 Figure 2-4. Electrical Installation of Heater Power Supply Installation Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 21: Heater Power Supply Installation

    150 feet (45 m) from the probe. The ways reinstall terminal covers after heater power supply must be located in a making connections. location free from significant ambient tem- Rosemount Analytical Inc. A Division of Emerson Process Management Installation...
  • Page 22: Figure 2-6. Jumper Selection Label

    When using the HPS installed, Figure 2-6. with 100 Vac transformer, install jumpers JM1 and JM4. 2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 23: Figure 2-7. Jumpers On Hps Mother Board

    During outages, and if possible, leave all probes running to prevent condensation and premature aging from thermal cycling. If the ducts will be washed down during outage, MAKE SURE to power down the probes and remove them from the wash area. Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11...
  • Page 24 Instruction Bulletin 106-300NE Rev. 3.4 World Class 3000 May 2000 2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 25: Setup

    World Class 3000 probe. The set point adjustment procedure required for Models 218, 225, and 132 analog Figure 3-1. Temperature Controller Card electronics is as follows: Calibration Points Rosemount Analytical Inc. A Division of Emerson Process Management Setup...
  • Page 26: Model 218A Electronics Setup

    PCB and check back of board to identify unit as G02 or G04. The replacement EPROM needed e. Close electronics enclosure and power up is as identified below: system. Figure 3-2. Main PCB (Model 218A) EPROM Replacement Setup Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 27: Model Tc200 Veritrim Electronics Setup

    2. Open electronics enclosure. "%O " "INC" "ACK" in sequence. 3. On the main PCB, Figure 3-3, locate 3. Depress "ACK" pushbutton to clear and remove old EPROMs U11 and display. U12. Rosemount Analytical Inc. A Division of Emerson Process Management Setup...
  • Page 28: Model 132 Digital Electronics Setup

    Class 3000 Probe and Heater Power Supply, an e. Close electronics enclosure and power up EPROM change is necessary. The replacement system. Figure 3-4. Main PCB (Model 132) EPROM Replacement Setup Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 29: Troubleshooting

    Troubleshooting information for the World Model 132 Digital Electronics Package Class 3000 Probe is contained in Appendix A, Probe Troubleshooting. Troubleshooting information for the Model 132 Electronics Package is contained in IB 106-106A. Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting...
  • Page 30 Instruction Bulletin 106-300NE Rev. 3.4 World Class 3000 May 2000 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 31: Return Of Material

    3. Site from which equipment was removed. 4. Whether warranty or nonwarranty service is requested. Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material...
  • Page 32 Instruction Bulletin 106-300NE Rev. 3.4 World Class 3000 May 2000 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 33: Appendices

    Instruction Bulletin 106-300NE Rev. 3.4 World Class 3000 May 2000 SECTION 6 APPENDICES APPENDIX A. WORLD CLASS 3000 OXYGEN ANALYZER (PROBE) APPENDIX B. HPS HEATER POWER SUPPLY FIELD MODULE Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 34 Probe Junction Box Ground Wires Insulating Gasket NOTE: ITEM , CALIBRATION GAS TUBE, Washer FITS INTO HOLES WHEN PROBE IS Screw ASSEMBLED. 21240005 Figure A-1. Oxygen Analyzer (Probe) Exploded View Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 35 Figure A-2. Bulletin. Failure to follow the safety instructions could result in serious injury or death. PROBE EXTERIOR (SENSING CELL INSTALLED) PROBE INTERIOR PROBE JUNCTION 21240006 Figure A-2. Main Probe Components Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 36 Equipment ordered utilizing this document as reference will be supplied to the USA standard design. Custom- ers requiring the EEC standard design should request the EEC documentation and utilize its ordering data. Temperatures over 1000°F (537°C) may affect the ease of field cell replaceability. Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 37 DIFFUSION ELEMENT PROBE TUBE CORRUGATED SEAL CELL AND FLANGE ASSEMBLY WRENCH DEFLECTOR 21240024 21240007 Figure A-4. Optional Ceramic Diffusor and Vee Deflector Assembly Figure A-3. Cell and Tube Assemblies Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 38 Ceramic support rod with four holes running 27270015 through the length. The holes serve as Figure A-5. Inner Probe Assembly insulated paths for the cell signal wire and thermocouple wires. Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 39 Though ambient air can be used for this a modified diffusor and vee deflector purpose, accuracy can only be assured if a assembly, fitted with dual dust seal packing. reference air set is used. Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 40 Figure A-7. Abrasive Shield Assembly NOTE In highly abrasive applications, rotate the shield 90 degrees at normal service intervals to present a new wear surface to the abrasive flow stream. Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 41 This keeps 1500°F (816°C) cell tem- face area for the probe. peratures from igniting unburned fuel in the stack. P0012 P0011 Figure A-11. Flame Arrestor Diffusion Assembly Figure A-9. Flame Arrestor Diffusion/Dust Seal Assembly Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 42 2000°F (1095°C). A separate the maximum allowable temperature of instruction bulletin is available for this 1300°F (704°C) a bypass sensor package option. can be employed. The bypass system uses Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 43 Instruction Manual Appendix A Rev. 3.6 World Class 3000 July 1998 Figure A-13. Bypass Probe Option (Sheet 1 of 3) Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 44 Instruction Manual Appendix A Rev. 3.6 World Class 3000 July 1998 Figure A-13. Bypass Probe Option (Sheet 2 of 3) A-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 45 3’ By-pass Package with DIN bolt pattern. 1U0571 6’ By-pass Package with DIN bolt pattern. 1U0571 9’ By-pass Package with DIN bolt pattern. Figure A-13. Bypass Probe Option (Sheet 3 of 3) Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-11...
  • Page 46 Probe cell mV OK but no Check out cable input to electronics connection. Cell mV satisfactory both Check electronics at probe junction box and package. input to electronics - fail- ure of electronics A-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 47 4. System takes a long Diffusion element Plugged diffusion element Change diffusion element time to return to flue or snubber diffusion gas value after calibra- element. tion gas is turned off Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-13...
  • Page 48 Instruction Manual Appendix A Rev. 3.6 World Class 3000 July 1998 Figure A-14. Flowchart of Probe Related Problems, #1 A-14 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 49 Instruction Manual Appendix A Rev. 3.6 World Class 3000 July 1998 Figure A-15. Flowchart of Probe Related Problems, #2 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-15...
  • Page 50 Items are carefully packaged to preserve A-16 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 51 (see paragraph A-13). the assembly and the corrugated seal. The cell flange has a notch which may be used Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-17...
  • Page 52 Remove burrs and raised surfaces with amine the diffusion element whenever re- block of wood and crocus cloth. Clean moving the probe for any purpose. Replace threads on retainer and hub. if damaged. A-18 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 53 10. Allow filter to dry at room temperature Inspect setscrews. If damaged, replace overnight or 1 to 2 hours at 200°F with M-6 x 6 stainless setscrews (93°C). coated with anti-seize compound. Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-19...
  • Page 54 21240027 a. Disconnect and lock out power to electron- Figure A-19. Probe Junction Box Mechanical ics. Using heat resistant gloves and cloth- Connections ing, remove probe junction box cover. A-20 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 55 Contact and Thermocouple Assembly Butt Connector Spring Clip Assembly Strut Extension Common Tube Support Leaf Spring Backplate Heater Short Tube Support Figure A-21. Heater, Strut, and Backplate Assembly (Inner Probe Assembly) Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-21...
  • Page 56 There is voltage up to 115 Vac. wires so they do not touch sides of probe junction box. NOTE This replacement may be done without removing the probe from the duct. A-22 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 57 Squeezing tabs on hose clamps, stainless steel tubing and teflon fittings for in- remove hoses from probe junction box side the probe junction box. The kit part number (Figure A-19). is 4843B93G01. Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-23...
  • Page 58 90° every time the probe is powered down for service. 21240028 Figure A-23. High Temperature - Corrosive Environment Kit A-24 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 59 Cell Replacement Kit, DIN 12 ft (3.6 m) Figure A-18 3535B42G01 Probe Disassembly Kit Figure A-10 3534B18G01 Diffuser Assembly Figure A-8 3535B60G01 Diffuser Dust Seal Hub Assembly (For use with Abrasive Shield) Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-25...
  • Page 60 Heater, V-strut, and backplate assembly includes contact and thermocouple assembly. Contact and thermocouple assembly includes platinum pad and inconel wire. Abrasive shield assembly includes accessories necessary for its use and a mounting plate and gasket. A-26 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 61 Replacement for installation procedure; refer to probes with a number of different electronics packages. Table B-2, for transformer part numbers. 35730001 Figure B-1. HPS 3000 Heater Power Supply Field Module Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 62 Appendix B Rev. 2.2 World Class 3000 January 1997 TRANSFORMER TERMINAL COVERS FRONT TERMINAL STRIP (FROM ELECTRONICS) TRANSFORMER TERMINAL STRIP (FROM PROBE) SIDE 35730002 Figure B-2. Heater Power Supply, Interior Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 63 This allows for the LINE TO HEATER RELAY TRIAC AD590 FROM PROBE PROBE TC PROBE TC STACK TC STACK TC CELL MV CELL 686015 Figure B-3. Heater Power Supply Block Diagram Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 64 Figure B-5, and Figure B-6 provide trouble- shooting information. Install all protective equipment covers and safety ground leads after trouble- shooting. Failure to replace covers and ground leads could result in seri- ous injury or death. Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 65 INSIDE OF HPS COVER. *SIMPSON MODEL 260 OR EQUIVALENT MULTIMETER. RESISTANCE MEASURED SHOULD BE NOMINALLY REPLACE BLOWN FUSES. 12 OHMS. HEATER IS OPEN. REPLACE HEATER. 35730004 Figure B-4. HPS Troubleshooting Flowchart, #1 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 66 HAS BEEN CHANGED ACCORDING TO APPLICABLE ELECTRONICS PACKAGE IB. CHECK IF PROBE HEATER VOLTAGE SELECTION JUMPER JM7 INSTALLED (REMOVE JM8). 35730003 *SIMPSON MODEL 260 OR EQUIVALENT MULTIMETER. Figure B-5. HPS Troubleshooting Flowchart, #2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 67 THEN LOOSES TEMPERATURE. (MODEL TC200 ONLY) CHECK PARAMETER 35 ON TC200. IF THE NUMBER IS NEGATIVE THEN SOMEWHERE THE THERMOCOUPLE WIRES ARE REVERSED. 35730005 Figure B-6. HPS Troubleshooting Flowchart, #3 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 68 Remove daughter board transformer assembly. Remove retaining (7). plate (24) and gasket (22). h. Unscrew four stand offs that supported the d. Disconnect transformer harness plug from daughter board. mother board. Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 69 When turning power off at the HPS, also turn off the respective probe at associated electronics. When service on the HPS is completed, restore power at the HPS and the associated electronics. Rosemount Analytical Inc. A Division of Emerson Process Management Appendices...
  • Page 70 World Class 3000 January 1997 NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASE SEPARATELY. FOR LIST OF AVAILABLE PARTS SEE TABLE B-2. 35730006 Figure B-7. Heater Power Supply, Exploded View B-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 71: Replacement Parts

    Schurter Figure B-7, 12 3D39080G02 Mother Board Figure B-7, 7 3D39078G01 Daughter Board Figure B-7, 23 1M02961G01 Transformer (120, 220, 240 Vac) Figure B-7, 23 1M02961G02 Transformer (100 Vac) Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-11...
  • Page 72 Instruction Manual Appendix B Rev. 2.2 World Class 3000 January 1997 B-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 73: Index

    Hub Grooves, 2-6 Vee Deflector, 2-6 In Situ, 1-2 Instrument Air, 1-3 Water Vapor, 1-2 Model 132 Digital Electronics Package, 3-4 Zirconia Disc, 1-2 Model 218A Digital Electronics Package, 3-2 Rosemount Analytical Inc. A Division of Emerson Process Management Index...
  • Page 74 Instruction Bulletin 106-300NE Rev. 3.4 World Class 3000 May 2000 Index Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 75 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.
  • Page 76 HPS 3000 Part No. ________________ Part No. ________________ Serial No. ________________ Serial No. ________________ Order No. ________________ Order No. ________________ Emerson Process Management Rosemount Analytical Inc. Fisher-Rosemount GmbH & Co. Process Analytic Division Industriestrasse 1 1201 N. Main St. 63594 Hasselroth...

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