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Instruction Manual

IB-106-3081 Rev. 1.5

September 2002

Rosemount Analytical Inc. A Division of Emerson Process Management

Replacement Parts 8-1

Model 3081FG

SECTION 8

REPLACEMENT PARTS

Table 8-1. Replacement Parts List

Figure and

Index No.

Part Number

Description

1-1, 2

1A99138G01

Model 3081 Transmitter CENELEC

1-1, 2

1A99138G02

Model 3081 Transmitter CSA

1-1, 2

1A99138G03

Model 3081 Transmitter FM

1-1, 3

5R10092G01

20” Replacement Oxygen Probe, with Alumina Outer Protection Tube

1-1, 3

5R10092G02

26” Replacement Oxygen Probe, with Alumina Outer Protection Tube

1-1, 3

5R10092G03

34.625” Replacement Oxygen Probe, with Alumina Outer Protection Tube

1-1, 3

5R10092G09

20” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube

1-1, 3

5R10092G010

26” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube

1-1, 3

5R10092G011

34.625” Replacement Oxygen Probe, with Inconel 600 Outer Protection Tube

5-1, 10

23574-04

PC Board Stack Assembly (CPU and Analog Boards)

5-1, 11

23601-00

Display Board

5-1, 6

23581-00

Terminal Block

5-1, 13

23593-01

Circuit End Cap (with Glass)

Summary of Contents for 3081FG

Page 1: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 http www processanalytic com Model 3081FG Two Wire In Situ Oxygen Analyzer 550 to 1600 C ...

Page 2: ... 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 applic...

Page 3: ...probe and Mullite probe references from specifications Page 2 1 through 2 6 Changed probe installation mounting and insertion procedures and requirements Page 5 1 Revised PC board stack replacement procedure Throughout Changed all references to power supply board to read analog board Reformatted document in accordance with the latest style guide Effective October 2000 Rev 1 2 Page Summary Througho...

Page 4: ......

Page 5: ...g Proper Calibration Check Gas Flow Rate 3 2 3 4 Operation 3 3 3 5 Program Menu 3 6 3 6 Diagnostics Menu 3 11 3 7 CALCHECK MENU 3 13 4 0 HART AMS 4 1 4 1 Overview 4 1 4 2 HART Communicator Signal Line Connections 4 1 4 3 HART Communicator PC Connections 4 3 4 4 Off Line and On Line Operations 4 3 4 5 Menu Tree for HART Communicator Two Wire In Situ Oxygen Analyzer Applications 4 3 4 6 HART Communi...

Page 6: ...nection 2 12 Figure 3 1 Normal Operation Display 3 1 Figure 3 2 Faulted Operation Display 3 1 Figure 3 3 Proper Calibration Check Gas Flow Rate 3 2 Figure 3 4 Normal Operation Display 3 3 Figure 3 5 Model 3081 Transmitter Menu Tree 3 4 Figure 3 6 Infrared Remote Control IRC 3 5 Figure 3 7 CODE 3 6 Figure 3 8 DISPLAY CODE 3 6 Figure 3 9 FAULT VAL 3 7 Figure 3 10 UPPER RANGE VAL 3 7 Figure 3 11 CELL...

Page 7: ...e 6 1 Figure 6 2 Speed of Response 6 2 Figure 6 3 Faulted Operation Display 6 2 Figure 6 4 Model 3081 Transmitter Terminal Block 6 3 Figure 6 5 Fault 1 Open Thermocouple 6 4 Figure 6 6 Fault 2 Reversed Thermocouple 6 4 Figure 6 7 Fault 3 Shorted Thermocouple 6 5 Figure 6 8 Fault 4 High Probe Temperature 6 5 Figure 6 9 Fault 5 O2 Cell Open 6 6 Figure 6 10 Fault 6 Cell Impedance Too High 6 6 Figure ...

Page 8: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 iv Rosemount Analytical Inc A Division of Emerson Process Management Model 3081FG ...

Page 9: ...d NOTES found throughout this publication Highlights an operation or maintenance procedure practice condition state ment etc If not strictly observed could result in injury death or long term health hazards of personnel Highlights an operation or maintenance procedure practice condition state ment etc If not strictly observed could result in damage to or destruction of equipment or loss of effecti...

Page 10: ...on of this equipment connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault 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 provided and clearly marked as such Circuit breakers or switche...

Page 11: ...is manual Also use the product ma trix in Table 1 1 to compare your order number against your unit The first part of the matrix de fines the model The last part defines the vari ous options and features of the analyzer Ensure the features and options specified by your order number are on or included with the unit o HART Communicator FISHER ROSEMOUNTTM MAN 4275A00 English October 1994 7 2 3 1 8 6 2...

Page 12: ...er Mounting Adapter below Code Mounting Adapter Probe Side 0 No adapter plate 1 ANSI 2 in 150 lb flange to 1 25 NPT adapter 6 in dia flange 4 75 in BC with 4 x 0 75 in dia holes 2 DIN to 1 25 NPT adapter 184 mm flange 145 mm BC with 4 x 18 mm dia holes 3 JIS to 1 25 NPT adapter 155 mm flange 130 mm BC with 4 x 13 mm dia holes 4 Model 450 to 1 25 NPT adapter 5 Competitor s mounting flange Code Elec...

Page 13: ... on one side of the cell 2 P1 is the partial pressure of the oxygen in the reference air on the opposite side of the cell 3 T is the absolute temperature 4 C is the cell constant 5 K is an arithmetic constant NOTE For best results use clean dry in strument air 20 95 oxygen as the reference air NOTE The probe uses a Type B thermocou ple to measure the cell temperature When the cell is at 550 C to 1...

Page 14: ...trol IRC allows interfacing without exposing the electronics 8 An operator can operate and diagnos tically troubleshoot the Two Wire In Situ Oxygen Analyzer in one of two ways a Infrared Remote Control The IRC allows access to fault indication menus on the Model 3081 Trans mitter LCD display Calibration can be performed from the IRC keypad b Optional HART Interface The Two Wire In Situ Oxygen Ana ...

Page 15: ...uit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to pre vent possible equipment damage The oxygen probe is designed for in dustrial applications Treat with care to avoid physical damage The probe contains components made from ce ramic which are susceptible to shock when mishandled THE WARRANTY DOES NOT COVER DAMAGE FROM MISHANDLING f System C...

Page 16: ...cting calibration check gas tanks to the oxygen probe during calibration If the calibration check gas bottles are to be permanently connected a check valve is required next to the calibration fittings on the integral electronics This check valve is to prevent breathing of calibration check gas line and subsequent flue gas condensation and corrosion The check valve is in addition to the stop valve ...

Page 17: ...2 F Operation to 1600 C 2912 F with reduced cell life Ambient 40 to 149 C 40 to 300 F Ambient Mounting and Mounting Position Vertical or Horizontal Materials of Construction Process Wetted Parts Inner Probe Zirconia Outer Protection Tube Alumina 1600 C 2912 F limit Inconel 600 1000 C 1832 F limit Probe Junction Box Cast aluminum Speed of Installation Withdrawal 1 in 25 4 mm per minute Hazardous Ar...

Page 18: ...igital HART signal Hazardous Area Certification Cenelec EEx ia IIC T4 or T5 2 NEC Class I Div I Group B C D Fisher Rosemount has satisfied all obliga tions coming from the European legislation to harmonize the product requirements in Europe Power Transient Protection IEC 801 4 Shipping Weight 10 lbs 4 5 kg INFRARED REMOTE CONTROL Power Requirements Three AAA batteries Hazardous Area Certification ...

Page 19: ...y due to stratification A point too near the wall of the duct or the in side radius of a bend may not provide a representative sample because of the very low flow conditions The sensing point should be selected so the process gas temperature falls within a range of 550 to 1600 C 1022 to 2912 F Figure 2 1 provides mechanical installation references 2 Check the flue or stack for holes and air leakag...

Page 20: ... BOTTOM 3 4 NPT CONDUIT PORT DIM A 7 1 180 4 1 109 DIM B REMOVAL ENVELOPE 1 1 29 1 8 49 1 4 TUBE FITTING CALIBRATION CHECK GAS PORT 1 4 TUBE FITTING REFERENCE AIR PORT REFERENCE AIR VENT FRONT VIEW NOTE DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES TABLE 1 INSTALLATION REMOVAL PROBE 20 IN 26 IN 34 625 IN DIM A 20 508 26 660 34 625 880 DIM B 31 787 37 940 46 1170 3 0 77 29750001 Figure 2...

Page 21: ...MER WELD OR BOLT ADAPTER PLATE TO STACK OR DUCT JOINT MUST BE AIR TIGHT WELD PIPE TO ADAPTER PLATE JOINT MUST BE AIR TIGHT B C A A NOTE DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES 3 50 89 O D REF 2 50 63 5 MIN DIA Figure 2 2 Optional Adapter Plate TAP 1 25 NPT 0 50 12 7 C B A FLANGE DIMENSIONS DIMENSION ANSI 5R10158H01 DIN 5R10158H02 JIS 5R10158H03 MODEL 450 5R10158H04 C DIA 4 75 121 ...

Page 22: ...S REFERENCE AIR LINE CALIBRATION CHECK GAS LINE 2 0 IN 51 mm MIN DIA Figure 2 4 Horizontal Probe Installation 3 If the optional adapter plates are not used a 2 in NPT schedule 40 pipe nipple Figure 2 4 should be welded to the stack or duct wall When a 2 in NPT to 1 25 NPT adapter is threaded to the welded pipe nipple the adapter provides the pipe threads needed for the probe s process fitting 4 Wh...

Page 23: ...nc A Division of Emerson Process Management Installation 2 5 Model 3081FG 29750005 REFRACTORY STACK OR DUCT METAL WALL A 1 5 A 2 IN 1 25 NPT PIPE COUPLING DIMENSION A 1 5 8 2 1 2 3 OR 4 IN 1 25 NPT SCHEDULE 40 PIPE NIPPLE PROBE LENGTH Figure 2 5 Adjusting Probe Insertion Depth ...

Page 24: ... stallation See Figure 2 4 In vertical probe installations orient the probe so the system cable drops vertically from the probe Ensure the electrical conduit is routed below the level of the terminal block housing This drip loop minimizes the possibility that moisture will accu mulate in the housing 9 If insulation was removed to access the duct work for probe mounting make sure the insulation is ...

Page 25: ...of the transmitter housing Refer to Figure 2 6 for installation references b Pipe Mounting An optional pipe mounting bracket is available for this type of installation Refer to Figure 2 7 for installation references FLAT SURFACE MOUNTING PAD HOLE PATTERN TERMINAL BLOCK TB 26020003 TERMINAL END CAP OMITTED FOR CLARITY THIS VIEW 1 4 20 THREADS 4 PLACES SURFACE BY OTHERS NOTE DIMENSIONS ARE IN INCHES...

Page 26: ...KET OPTION U BOLT 2 PLACES C C L L BRACKET HOLE PATTERN FOR WALL MOUNTING 0 375 9 525 DIA 4 MOUNTING HOLES 3 25 82 55 6 5 165 1 4 00 101 6 6 9 175 3 6 35 161 3 9 63 244 6 6 32 160 5 7 5 190 5 3 87 98 3 1 405 35 687 2 81 71 374 mA mA 3 4 14 FNPT 2 PLACES 5 16 18 NUT 5 16 WASHER U BOLT 1 4 20 SCREW 26020042 SCREWS FURNISHED WITH MOUNTING KIT ONLY NOT FURNISHED WITH ANALYZER TRANSMITTER 1 4 20 THREAD...

Page 27: ...s For intrinsically safe applications re fer to drawing 1400184 page 10 2 of this Instruction Bulletin Disconnect and lock out power before connecting the unit to the power supply Install all protective equipment covers and safety ground leads after installa tion Failure to install covers and ground leads could result in serious injury or death To meet the Safety Requirements of IEC 1010 EC requir...

Page 28: ... side of the housing Moisture accumulation in the transmit ter housing can affect its performance and may void its warranty b Oxygen Probe Signal Connections 1 Two signals represent the O2 value and the cell temperature The probe pro vides these values to the Model 3081 Transmitter for processing and signal conditioning 2 Wiring connections for the probe are shown in Figure 2 9 c Model 3081 Transm...

Page 29: ...nections on the oxygen probe b Reference Air Package After the oxygen probe is installed connect the reference air set Install the reference air set according to Figure 2 12 c Instrument Air Reference Air Instrument air is required for reference Use 10 psig 68 95 kPa gage minimum 225 psig 1551 38 kPa gage at 0 2 scfh 100 ml min less than 40 parts per million total hydrocarbons Regulator outlet pre...

Page 30: ... IN PARENTHESES 1 2 3 4 81 122 17 FLOW SET POINT KNOB 0 125 27 NPT FEMALE OUTLET CONNECTION 1 19 30 22 10 0 254 REF DRAIN VALVE 3 12 79 25 MAX 8 50 215 90 MAX 2 0 50 80 2 MOUNTING HOLES 3 19 81 03 LG THROUGH BODY FOR 0 312 7 92 DIA BOLTS 1 50 38 10 2 250 57 15 OUTLET 0 25 18 NPT FEMALE INLET CONNECTION TO PROBE 26020034 REF AIR SET 263C152G05 INSTRUMENT AIR SUPPLY 10 225 PSIG MAX PRESSURE 1 4 TUBE...

Page 31: ...CD face of the Model 3081 Transmitter The O2 concentration cell temperature and 4 20 mA output current are displayed as shown in Figure 3 1 This and other infor mation may also be accessed using HART AMS b Startup Display When the probe is first inserted into the stack some time is required until minimum operating temperatures 550 C 1022 F are reached Some time is also required for the electronics...

Page 32: ... startup It is not necessary to perform this procedure for each cali bration check a Adjust the calibration check gas flow to 5 scfh 2 5 L min to ensure the cell is sur rounded by calibration check gas Due to the cooling effect of the gas the cell tem perature will decrease slightly causing the O2 concentration to drop Once the elec tronics compensates for this effect the O2 concentration will sta...

Page 33: ... here but is discussed in Section 4 HART AMS b Display The Model 3081 Transmitter LCD displays the O2 concentration cell temperature and 4 20 mA output current during normal op eration see Figure 3 4 The LCD will also display fault conditions when they occur To interact with the transmitter use the IRC and navigate through a series of menus displayed on the LCD c Menu Tree The screens that can be ...

Page 34: ...RESET OR EXIT NEXT NEXT NEXT NEXT NEXT NEXT NEXT NEXT NEXT NEXT NEXT NEXT NEXT SW BUILD DATE SW BUILD NUMBER UNIT SER SW VER MAX CELL T CELL IMPEDANCE SLOPE PREVIOUS SLOPE CONSTANT PREVIOUS CONSTANT O2 CELL mV ACCEPT LOW O2 T C mV ACCEPT HIGH O2 SHOW FAULT IN MANUAL FAULT IF PRESENT FAULT IF PRESENT PROCESS DISPLAY NORMAL OPERATION PROCESS DISPLAY FAULTED OPERATION DIAG CAL ON FROM ANY SCREEN WITH...

Page 35: ...creases the value of the currently selected digit on the display e CAL Accesses the CALCHECK MENU branch of the menu tree Only works from the PROCESS DISPLAY screen f PROG Accesses the PROGRAM MENU branch of the menu tree Only works from the PROCESS DISPLAY screen g DIAG Accesses the DIAGNOS TICS MENU branch of the menu tree Only works from the PROC ESS DISPLAY screen h ENTER Initiates the editing...

Page 36: ...EXT a CODE Refer to Figure 3 7 After pressing the PROG key this screen will display if secu rity is enabled see paragraph 3 5m Use this screen to identify a specific analyzer in a process to prevent accessing an adjacent analyzer when using the IRC Press ENTER to begin editing At this point you can either specify the analyzer by its access code or view its code if it is un known 1 To gain further ...

Page 37: ... value of the upper range limit This value is the maximum limit of the O2 con centration measurement and is used to scale the 4 20 mA output Press ENTER to begin editing Use the arrow keys to select and change the value The upper range value can be between 0 and 25 Then press ENTER to accept the value Pressing NEXT displays the CELL T HI screen e CELL T HI Refer to Figure 3 11 Use this screen to s...

Page 38: ...of time it will take the O2 to reach 90 of the new reading Press EN TER to begin editing Use the arrow keys to select and change the screen value to the O2 filter value in seconds Enter a value between 0 and 300 seconds and press EN TER to accept the value Press NEXT to access the TRIM 4 mA screen h TRIM 4 mA Refer to Figure 3 14 Use this screen to trim the 4 mA value of the 4 20 mA output NOTE Be...

Page 39: ...ng EXIT returns to the initial TRIM 20 mA screen and pressing NEXT displays the SET HI BOTTLE O2 screen j SET HI BOTTLE O2 Refer to Figure 3 16 Use this screen to identify within the electronics the percent age of O2 used as the high calibration check gas Press ENTER to begin editing Use the arrow keys to select and change the screen value to the O2 percentage of the high cali bration check gas Pr...

Page 40: ...set the security code for the Model 3081 Transmitter Press ENTER to begin editing Use the arrow keys to select and change the value Select any value between 000 and 999 excluding 000 and 555 Code 000 indicates that no code is set Code 555 ac cesses the DISPLAY CODE screen Press ENTER to accept the value Pressing NEXT O CONCENTRATION 2 26020016 Figure 3 19 SET CODE returns to the FAULT VAL screen a...

Page 41: ... and screen descriptions a SHOW FAULT Refer to Figure 3 20 After pressing DIAG this screen displays Pressing ENTER ac cesses a screen displaying the current fault if any If more than one fault exists and you are in the FAULT screen press NEXT to go to the next fault Information on the fault screens can be found in Section 6 TROUBLESHOOTING Press EXIT to re turn from this fault sub menu and press N...

Page 42: ...ing temperature 550 C 1022 F this screen displays a fail indication e PREVIOUS SLOPE Refer to Figure 3 24 Use this screen to ex amine the slope calculated from the most recent calibration check The slope is the amount of cell voltage generated for a given O2 value For each calibration check record the slope over the life of the probe Tracking the slope will indicate if the probe is de grading Pres...

Page 43: ...he software build number for the Model 3081 Transmitter Pressing NEXT accesses the SW BUILD DATE screen k SW BUILD DATE Use this screen to see the software build date for the Model 3081 Transmitter Pressing NEXT returns to the beginning of the DIAGNOSTICS MENU branch the SHOW FAULT screen 3 7 CALCHECK MENU The CALCHECK MENU branch of the menu tree Figure 3 5 allows you to perform a cali bration ch...

Page 44: ... the selection and to display the ACCEPT HIGH O2 screen O CONCENTRATION 2 Y N FOR USER RESPONSE 26020054 Figure 3 27 IN MANUAL O CONCENTRATION 2 HIGH CALIBRATION CHECK GAS O VALUE 2 26020055 Figure 3 28 ACCEPT HIGH O2 b ACCEPT HIGH O2 Refer to Figure 3 28 After pressing ENTER to begin the calibration check the high cali bration check gas starts to flow After wait ing approximately three minutes fo...

Page 45: ...the life of the probe Tracking the slope will indicate if the probe is de grading Press NEXT to access the CON STANT screen O CONCENTRATION 2 CALCHECK CELL SLOPE VALUE 26020057 Figure 3 30 SLOPE e CONSTANT Refer to Figure 3 31 Use this screen to ex amine the cell zero constant calculated from the current calibration check The constant represents the voltage generated by the cell when no difference...

Page 46: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 3 16 Startup and Operation Rosemount Analytical Inc A Division of Emerson Process Management Model 3081FG ...

Page 47: ...requency shift keying FSK tech nique With the use of FSK high frequency digital communication signals are superimposed on the 4 20 mA transmitter current loop The communicator does not disturb the 4 20 mA signal since no net energy is added to the loop The HART Communicator may be interfaced with a personal computer PC providing special software has been installed To connect the HART Communicator ...

Page 48: ...s can result in death or seri ous injury Do not make connections to the HART Communicator s serial port 4 20 mV signal line or NiCad re charger jack in an explosive atmosphere Using the supplied lead set connect the HART Communicator in parallel to the Two Wire In Situ Oxygen Analyzer Use any wir ing termination points in the analog output 4 20 mA signal line b Method 2 For Load Resistance 250 Ohm...

Page 49: ...in regard to the PC interface option 4 4 OFF LINE AND ON LINE OPERATIONS The HART Communicator can be operated both off line and on line a Off line operations are those in which the communicator is not connected to the Two Wire In Situ Oxygen Analyzer Off line op erations can include interfacing the HART Communicator with a PC Refer to applica ble HART documentation regarding HART PC applications ...

Page 50: ...tart Calcheck method Refer to para 4 6 for the complete Start Calcheck method using the HART Communicator Max Temp RESET MAX TEMP VIEW TV VIEW 4V VIEW PV AOUT VIEW OUTPUT VARS TV is O2 cell mv TV value 4V is Cell Imp 4V value LOOP TEST Device Status O2 CALCHECK D A TRIM MAX CELL TEMP START CALCHECK OPtrakTG HighTG LowTG Slope Constant 26020044 CONTINUED ON SHEET 2 DEVICE SETUP O2 value O2 output L...

Page 51: ...iptor Message Ver Bld Bld Date O2 value Snsr unit USL LSL Min span Cell Temp Snsr unit USL LSL Min span Cell mV Snsr unit USL LSL Min span S W VERSION INFO DEVICE INFORMATION SENSORS DEVICE SETUP O2 value O2 output LRV URV Device SN Alarm Value 26020045 CONTINUED ON SHEET 3 CONTINUED ON SHEET 3 O2 CELL TEMP O2 CELL IMP CONTINUED SHEET FROM 1 CONTINUED SHEET FROM 1 Figure 4 3 Menu Tree for HART AMS...

Page 52: ...ev URV Filter Poll addr Num req preams DEVICE INFORMATION REVIEW DETAILED SETUP OUTPUTS CONFIG 26020046 CONTINUED SHEET FROM 2 CONTINUED SHEET FROM 2 OUTPUT CONDITION Filter O2 output AO Alrm typ D A TRIM LOOP TEST ANALOG OUTPUT HART OUTPUT Poll addr Num req preams D A trim method Loop test method URV LRV rnge SIGNAL CONDITION DEVICE SETUP O2 value O2 output LRV URV Device SN Alarm Value Figure 4 ...

Page 53: ...ation check procedure Failure to remove the analyzer from automatic control loops prior to per forming this procedure may result in a dangerous operating condition e In the first screen a Loop should be re moved from automatic control warning ap pears Remove the analyzer from any automatic control loops to avoid undesirable equipment performance and press OK f The next screen prompts you to apply ...

Page 54: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 4 8 HART AMS Rosemount Analytical Inc A Division of Emerson Process Management Model 3081FG ...

Page 55: ... cable connector between the display board and the CPU board of PC board stack 10 Ensure the cable connector is fully seated 6 Reposition display board 11 on the standoffs Rotate the display board 90 degrees either way as desired 7 Install and tighten all three screws 12 8 Install circuit end cap 13 9 Tighten cover lock screw 14 until cover lock 15 engages knurled sur face of circuit end cap 13 b ...

Page 56: ... 11 10 STANDOFF STANDOFF ANALOG BOARD CPU BOARD RIBBON CABLE 29750006 15 14 9 1 2 3 6 8 7 5 4 1 Housing 2 O ring 3 Lockwasher 4 Screw 5 Terminal End Cap 6 Terminal Block 7 Ground Screw 8 Washer 9 O ring 10 PC Board Stack CPU and Analog Boards 11 Display Board 12 Screw 13 Circuit End Cap 14 Screw 15 Cover Lock Figure 5 1 Two Wire In Situ Oxygen Analyzer Exploded View ...

Page 57: ... indication HI indicates a probe that is beyond its useful life Conduct a calibration check Follow the prompts provided by the electronics through the process of flowing two calibration check gases of known values Record the generated slope and constant values Probe replacement may be conducted online as long as the process in which the probe is mounted is operating at a negative or slightly posit...

Page 58: ...ires from the terminal block c Disconnect the reference air and the cali bration check gas lines d Unscrew the probe from the stack and remove e Using a replacement probe refer to para graph 2 2c for mechanical installation in structions f Refer to paragraph 2 3b for electrical in stallation instructions g Refer to paragraph 2 4 for reference air and calibration check gas installation instruc tion...

Page 59: ...tinued operation at elevated tempera tures above 1300 C 2372 F Operation in processes that contain high levels of sulfur SO2 or other acidic com pounds Operating conditions with simultaneously high levels of SO2 and low levels of O2 are particu larly damaging The health and accuracy of a given cell is closely related to the resistance or impedance of the cell Figure 6 1 illustrates that the amount...

Page 60: ...e process tem perature at which the calibration check gases are flowed so no adjustments to the electronics are made as a result of a calibration check Note that cells exposed to temperatures above 1300 C 2372 F may lose the ability to meas ure accurately and respond quickly when re turned to the lowest end of the operating temperature range 550 C 1022 F 6 3 FAULT INDICATIONS The fault conditions ...

Page 61: ...actions Refer to Figure 6 4 as needed for test points and wir ing information NOTE Allow adequate time for the oxygen probe to reach its operating tempera ture approximately 500 C 932 F be fore investigating a fault The SHOW FAULTS screen of the DIAGNOSTICS menu will indicate a fault until the unit reaches operating temperature NOTE The probe uses a Type B thermocou ple to measure the cell tempera...

Page 62: ...values indicate the thermocou ple is open 3 If the thermocouple is open replace the oxygen probe per paragraph 5 2 26020025 Figure 6 6 Fault 2 Reversed Thermocouple b Fault 2 Reversed Thermocouple Active The thermocouple connections are re versed The fault displays as shown in Fig ure 6 6 1 Allow adequate time for the oxygen probe to reach operating temperatures Probe temperatures below approxi ma...

Page 63: ...If the multimeter reading in voltage mode is between 0 5 and 0 5 mV the thermocouple is shorted 4 If the thermocouple is shorted replace the oxygen probe per paragraph 5 2 5 If the thermocouple is not shorted then replace the PC board stack assembly per paragraph 5 1 26020027 Figure 6 8 Fault 4 High Probe Temperature d Fault 4 High Probe Temperature The probe s temperature has exceeded the maximum...

Page 64: ...cell output voltage at the probe terminals not at the electronics 3 Apply low calibration check gas 0 4 O2 Measure the cell output from the O2 cell wires at the probe terminal block The cell output should be 100 20 mV If no voltage can be meas ured the cell is open 4 If the O2 cell is open replace the oxy gen probe per paragraph 5 2 26020029 Figure 6 10 Fault 6 Cell Impedance Too High f Fault 6 Ce...

Page 65: ...terminal 7 and white to terminal 8 wires for the proper placement Rewire if necessary 2 Apply the low calibration check gas 0 4 O2 3 Using a multimeter measure between terminals 7 and 8 If the cell out put reading is negative the O2 cell wiring is reversed 4 If the wiring is correct check if the mul timeter reading is the same as the reading shown on the O2 CELL mV di agnostics screen see Section ...

Page 66: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 6 8 Troubleshooting Rosemount Analytical Inc A Division of Emerson Process Management Model 3081FG ...

Page 67: ...ment is faulty 2 The environment in which the equip ment has been operating housing weather vibration dust etc 3 Site from which equipment was removed 4 Whether warranty or nonwarranty service is requested 5 Complete shipping instructions for re turn of equipment 6 Reference the return authorization number d Enclose a cover letter and purchase order and ship the defective equipment according to in...

Page 68: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 7 2 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Model 3081FG ...

Page 69: ...gen Probe with Alumina Outer Protection Tube 1 1 3 5R10092G02 26 Replacement Oxygen Probe with Alumina Outer Protection Tube 1 1 3 5R10092G03 34 625 Replacement Oxygen Probe with Alumina Outer Protection Tube 1 1 3 5R10092G09 20 Replacement Oxygen Probe with Inconel 600 Outer Protection Tube 1 1 3 5R10092G010 26 Replacement Oxygen Probe with Inconel 600 Outer Protection Tube 1 1 3 5R10092G011 34 6...

Page 70: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 8 2 Replacement Parts Rosemount Analytical Inc A Division of Emerson Process Management Model 3081FG ...

Page 71: ...igh Fault 6 6 Check Valve 1 6 Component Checklist 1 1 CONSTANT Screen 3 15 D DIAG Key 3 5 Diagnostics Menu 3 4 3 11 Display Board 2 9 Display Board Positioning 2 9 Display Board Replacement 5 1 DISPLAY Code 3 6 Drip Loop 2 6 E Earth Ground 2 10 Electrical Installation 2 9 Electromagnetic Interference EMI 2 10 ENTER Key 3 5 EXIT Key 3 5 F Fault Indications 6 2 FAULT VAL Screen 3 7 Faulted Operation...

Page 72: ... 8 PREVIOUS CONSTANT screen 3 12 PREVIOUS SLOPE Screen 3 12 Probe Insertion Depth 2 5 Probe Insertion Rate 2 6 Probe Installation Details 2 2 Probe Lengths 1 7 Probe Life 6 1 Probe Mounting 1 7 Probe Mounting Flange 2 3 Product Matrix 1 2 PROG Key 3 5 Program Menu 3 6 Program Menu 3 4 Protective Cover 2 1 R Radio Frequency Interference RFI 2 10 Reference Air 1 3 1 7 2 11 Reference Air Set 1 1 Rela...

Page 73: ...uction Manual IB 106 3081 Rev 1 5 September 2002 Rosemount Analytical Inc A Division of Emerson Process Management Index 9 3 Model 3081FG U UNIT SER Screen 3 13 UPPER RANGE VAL Screen 3 7 Z Zirconia Disc 1 3 ...

Page 74: ......

Page 75: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 Rosemount Analytical Inc A Division of Emerson Process Management Drawings and Schematics 10 1 Model 3081FG SECTION 10 DRAWINGS AND SCHEMATICS ...

Page 76: ...Instruction Manual IB 106 3081 Rev 1 5 September 2002 10 2 Drawings and Schematics Rosemount Analytical Inc A Division of Emerson Process Management Model 3081FG ...

Page 77: ...ssed 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 IMPLIED WARRANTIES 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...

Page 78: ...ore 128461 Republic of Singapore T 65 777 8211 F 65 777 0947 http www processanalytic com Fisher Rosemount GmbH Co Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884209 EUROPE MIDDLE EAST AFRICA Fisher Rosemount Ltd Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 LATIN AMERICA Fisher Rosemount Av das Americas 3333 sala 1004 Rio de Jane...

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