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Instruction Manual

IB-106-3081 Rev. 1.4

January 2002

http://www.processanalytic.com

Model 3081FG

Two-Wire In Situ

Oxygen Analyzer

(550° to 1600°C)

Summary of content (78 pages)

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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG Two-Wire In Situ Oxygen Analyzer (550° to 1600°C) http://www.processanalytic.
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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.
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HIGHLIGHTS OF CHANGES Effective June, 1998 Rev. 1.0 Page Summary Page 2-10 Corrected part numbers in Figure 2-9 for Flowmeter and Ref Air Set. Page 3-4 Modified Figure 3-5 to reflect selection of additional faults. Page 3-11 Modified paragraph 3-6a to select additional fault screens. Page 4-4 Updated menus for O2 value, SV, TV, and 4V values. Page 8-1 Added in replacement part numbers for Model 3081 Transmitter. Effective April, 1999 Rev. 1.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG TABLE OF CONTENTS PREFACE........................................................................................................................ P-1 Definitions ........................................................................................................................ P-1 Safety Instructions ..........................................................................................................
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG LIST OF ILLUSTRATIONS Figure 1-1. Figure 1-2. Figure 1-3. Figure 1-4. Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 2-7. Figure 2-8. Figure 2-9. Figure 2-10. Figure 2-11. Figure 2-12. Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 3-6. Figure 3-7. Figure 3-8. Figure 3-9. Figure 3-10. Figure 3-11. Figure 3-12. Figure 3-13. Figure 3-14. Figure 3-15. Figure 3-16. Figure 3-17. Figure 3-18.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG Figure 4-3. Menu Tree for HART/AMS on the Two-Wire In Situ Oxygen Analyzer (Sheet 1 of 3)............................................................................. 4-4 Figure 5-1. Two-Wire In Situ Oxygen Analyzer Exploded View............................................... 5-2 Figure 5-2. Oxygen Probe Terminal Block ............................................................................... 5-4 Figure 6-1. Slope vs. Impedance .......
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 iv Model 3081FG Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG PREFACE The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Model 3081FG Two-Wire In Situ Oxygen Analyzer (550° to 1600°C). Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 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.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 1 DESCRIPTION AND SPECIFICATIONS 1-1 COMPONENT CHECKLIST OF TYPICAL SYSTEM (PACKAGE CONTENTS) page of this manual. Also, use the product matrix in Table 1-1 to compare your order number against your unit. The first part of the matrix defines the model. The last part defines the various options and features of the analyzer. Ensure the features and options specified by your order number are on or included with the unit.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG Table 1-1. Product Matrix 3081FG High Temperature Oxygen Flue Gas Analyzer High Temperature Analyzer - Instruction Book Code 1 2 3 Sensing Probe Length 20 in. (508 mm) probe, 1/4 in. tube fittings 26 in. (660 mm) probe, 1/4 in. tube fittings 34.625 in. (880 mm) probe, 1/4 in. tube fittings Code 1 2 Probe Outer Tube Material - Maximum Operating Temperature Alumina - 2912°F (1600°C) maximum - 1.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 1-2 SYSTEM OVERVIEW a. Scope This Instruction Bulletin is designed to supply details needed to install, start up, operate, and maintain the Rosemount Two-Wire In Situ Oxygen Analyzer. The analyzer consists of an oxygen probe and Model 3081 Transmitter. The signal conditioning electronics of the Model 3081 Transmitter outputs a 4-20 mA signal representing an O2 value.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 The Model 3081 Transmitter is a two-wire transmitter providing an isolated output, 420 mA, that is proportional to the measured oxygen concentration. A customer-supplied 24 VDC power source is required to simultaneously provide power to the electronics and a 4-20 mA signal loop. The transmitter accepts millivolt signals generated by the probe and produces the outputs to be used by other remotely connected devices.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG HART MODEL 275 HAND HELD INTERFACE TWO-WIRE IN SITU OXYGEN ANALYZER O2 mV SIGNAL 4-20 mA OUTPUT (TWISTED PAIR) MODEL 3081 TRANSMITTER + CALIBRATION CHECK GAS LINE REFERENCE TEMPERATURE AIR LINE mV SIGNAL TERMINATION IN CONTROL ROOM 24 VDC POWER SUPPLY INTRINSIC ASSET MANAGEMENT SAFETY SOLUTIONS BARRIER (OPTIONAL) 26020037 Figure 1-2. Two-Wire In Situ Oxygen Analyzer HART Connections and AMS Application e.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG GASES DUCT STACK OPTIONAL ADAPTER PLATE OXYGEN PROBE INSTRUMENT AIR SUPPLY (REFERENCE AIR) FLOWMETER PRESSURE REGULATOR MODEL 3081 TRANSMITTER 4-20 mA SIGNAL 26020038 Figure 1-3. Typical System Installation A source of instrument air is required at the oxygen probe for reference air use.
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Instruction Manual Model 3081FG 1-3 IB-106-3081 Rev. 1.4 January 2002 SPECIFICATIONS Net O2 Range....................................................................... 0 to 25% O2 Fully Field Selectable via the HART Interface Lowest Limit................................................................. 0.05% O2 Highest Limit................................................................ 25.00% O2 Accuracy .............................................................................. ±1.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG ELECTRONICS Enclosure ....................................................................... IP65 (NEMA 4X), weatherproof, and corrosion-resistant Materials of Construction ............................................... Low copper aluminum Ambient Temperature Limits ......................................... -20° to 65°C (-4° to 149°F) Relative Humidity...........................................................
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 2 INSTALLATION 2 2-1 PRE-INSTALLATION a. Inspect Carefully inspect the shipping container for any evidence of damage. If the container is damaged, notify the carrier immediately. b. Packing List Confirm that all items shown on the packing list are present. Notify Rosemount Analytical immediately if items are missing.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 1/4 TUBE FITTING (REFERENCE AIR PORT) 1/4 TUBE FITTING (CALIBRATION CHECK GAS PORT) REFERENCE AIR VENT FRONT VIEW DIM “B” (REMOVAL ENVELOPE) O 7.1 (180) DIM “A” 1.1 (29) O 4.1 (109) 1.25 NPT PROCESS CONNECTION SIDE VIEW 1.8 (49) 3.0 (77) BOTTOM VIEW INSTALL WITH PORT AT THE BOTTOM TABLE 1. INSTALLATION (REMOVAL) PROBE 20 IN. 26 IN. 34.625 IN. DIM “A” DIM “B” 20 (508) 26 (660) 34.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG METAL WALL STACK OR DUCT MASONRY WALL STACK A WELD PIPE TO ADAPTER PLATE 2 B 2.50 (63.5) MIN. DIA. A 3.50 (89) O.D. REF C JOINT MUST BE AIR TIGHT NOTE: DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES. 3.00 SCHEDULE 40 PIPE SLEEVE SUPPLIED BY CUSTOMER WELD OR BOLT ADAPTER PLATE TO STACK OR DUCT. JOINT MUST BE AIR TIGHT. PLATE DIMENSIONS DIMENSION ANSI 4512C34G01 DIN 4512C36G01 JIS 4512C35G01 “A” 6.00 (153) 7.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG STACK OR DUCT METAL WALL WELD PIPE TO METAL WALL 1.25 NPT 2.0 IN. (51 mm) MIN. DIA. REFRACTORY CUSTOMER SUPPLIED ADAPTER 2 IN. NPT SCHEDULE 40 PIPE STACK OR DUCT METAL WALL INSULATE IF EXPOSED TO AMBIENT WEATHER CONDITIONS ADAPTER 2 IN. NPT SCHEDULE 40 PIPE CALIBRATION CHECK GAS LINE SYSTEM CABLE REFERENCE AIR LINE 29750004 Figure 2-4. Horizontal Probe Installation 3. If the optional adapter plates are not used, a 2 in.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG STACK OR DUCT METAL WALL 2 REFRACTORY PROBE LENGTH 1.5 + A A DIMENSION A -- 1-5/8, 2-1/2, 3, OR 4 IN. 1.25 NPT SCHEDULE 40 PIPE NIPPLE 2 IN., 1.25 NPT PIPE COUPLING 29750005 Figure 2-5. Adjusting Probe Insertion Depth Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 5. Use high temperature material (alumina wool) to seal around the probe during insertion. This prevents hot gases from escaping or cold air from entering the stack or duct. 6. Initially insert the probe to a depth of 3 in. (76.2 mm) or 1/2 the depth of the stack or duct refractory, whichever is greater. After initial insertion, do not insert the probe at a rate exceeding 1 in. per minute (25.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG d. Installing Model 3081 Transmitter surface using the threaded mounting holes located on the bottom of the transmitter housing. Refer to Figure 2-6 for installation references. 1. Ensure all components are available to install the Model 3081 Transmitter. 2. Choose a method or location to mount the transmitter. (b) Pipe Mounting. An optional pipe mounting bracket is available for this type of installation.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 6.35 (161.3) 9.63 (244.6) 6.9 (175.3) TERMINAL BLOCK (TB) TERMINAL END CAP OMITTED FOR CLARITY IN THIS VIEW. TERMINAL END CIRCUIT END 6.32 (160.5) COVER LOCK 3/4 -14 NPT 2 PLACES 1.32 (33.5) 2 IN. PIPE/WALL MOUNTING BRACKET (OPTION) 1.00 (25.4) U-BOLT (2 PLACES) 3.87 (98.3) 4.00 (101.6) 7.5 (190.5) 0.375 (9.525) DIA. (4 MOUNTING HOLES) 3.25 (82.55) 1.405 (35.687) 2.81 (71.374) 6.5 (165.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 3. For correct viewing orientation, the display may be changed 90 degrees, using the following procedure: (a) Refer to Figure 2-8. Loosen the cover lock screw until the cover lock is disengaged from the knurled surface on the threaded circuit end cap. (b) Remove the circuit end cap. (c) Remove the three screws retaining the display board in place.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG pairs are recommended. Ground the transmitter housing to an earth ground to prevent unwanted electromagnetic interference (EMI) or radio frequency interference (RFI). NOTE For optimum EMI/RFI immunity, shield the 4-20 mA current loop cable and enclose in an earth grounded metal conduit. NOTE Never run signal or sensor wiring in the same conduit, or open tray, with power cables. Keep signal or sensor wiring at least 12 in. (0.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 THERMOCOUPLE + (GY) 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) 10 12 5 3 13 15 14 4 16 GROUND 1 2 PROBE CABLE SHIELD b.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 0.125-27 NPT FEMALE OUTLET CONNECTION 1 2 3.12 (79.25) MAX OUTLET 3 2.250 (57.15) 4.81 (122.17) FLOW SET POINT KNOB NOTE: DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES. 0.25-18 NPT FEMALE INLET CONNECTION 1.19 (30.22) 2.0 (50.80) DRAIN VALVE 1.50 (38.10) 8.50 (215.90) MAX 2 MOUNTING HOLES 3.19 (81.03) LG THROUGH BODY FOR 0.312 (7.92) DIA BOLTS 10.0 (254) REF 1 2 3 FLOWMETER 2" PRESSURE GAGE COMBINATION FILTER-REG.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 3 STARTUP AND OPERATION c. Operating Display Install all protective equipment covers and safety ground leads before equipment startup. Failure to install covers and ground leads could result in serious injury or death. 3-1 After the probe has reached operating temperatures, the Model 3081 Transmitter display should look similar to Figure 3-1.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 3-3 Model 3081FG REESTABLISHING PROPER CALIBRATION CHECK GAS FLOW RATE a. Adjust the calibration check gas flow to 5 scfh (2.5 L/min.) to ensure the cell is surrounded by calibration check gas. Due to the cooling effect of the gas, the cell temperature will decrease slightly, causing the O2 concentration to drop. Once the electronics compensates for this effect, the O2 concentration will stabilize.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 3-4 OPERATION a. Overview This section explains the operator controls and displays of the Two-Wire In Situ Oxygen Analyzer. The use of the Infrared Remote Control (IRC) and the Model 3081 Transmitter Liquid Crystal Display (LCD) are described in detail. HART/AMS operation is not covered here but is discussed in Section 4, HART/AMS. 4-20 mA output current during normal operation (see Figure 3-4).
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Instruction Manual IB-106-3081 Rev. 1.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG d. Navigation The IRC in Figure 3-6 is used to interact with the Model 3081 Transmitter and navigate through the screens on the LCD. 1. Hold the IRC within 6 ft (1.8 m) of the Model 3081 Transmitter and within 15 degrees from the centerline of the transmitter LCD. The amount of ambient light may also affect IRC performance. NOTE The LCD may react slowly to IRC commands.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 3-5 Model 3081FG O2 CONCENTRATION PROGRAM MENU The PROGRAM MENU branch of the menu tree allows you to program and edit some process parameters, faults, outputs, and security codes. To access this branch of the menu tree, press the PROG key on the IRC when in the PROCESS DISPLAY screen (Normal or Faulted). If security is enabled, you must enter the analyzer code to gain further access to the screens in this branch.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG O2 CONCENTRATION % lowed cell temperature before a fault condition is indicated. Press ENTER to begin editing. Use the arrow keys to select and change the value. The value must be between 550° and 1600°C. Press ENTER to accept the value. Pressing NEXT displays the RESET MAX CELL T screen. O2 CONCENTRATION 3 mA % INDICATOR FAULT VALUE 26020010 Figure 3-9. FAULT VAL % c. FAULT VAL Refer to Figure 3-9.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 f. Model 3081FG RESET MAX CELL T g. SET O2 FILTER TIME Refer to Figure 3-12. The transmitter tracks the maximum cell temperature obtained. Use this screen to reset the maximum cell temperature attained value to the current cell temperature. Press ENTER to begin editing. Use the arrow keys to select and change the value (Y/N). Then, press ENTER to accept the value. Pressing NEXT displays the SET O2 FILTER TIME screen.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG O2 CONCENTRATION O2 CONCENTRATION % % 3 HIGH CALIBRATION CHECK GAS O2 PERCENTAGE 26020015 Figure 3-15. TRIM 20 mA? i. TRIM 20 mA? Refer to Figure 3-15. Use this screen to trim the 20 mA value of the 4-20 mA output. NOTE Before trimming the 20 mA value, you must break the loop to add the ammeter.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG O2 CONCENTRATION O2 CONCENTRATION % % TRACK O2 DURING CALCHECK 26020051 26020016 Figure 3-18. SET O2 TRACKING l. SET O2 TRACKING Refer to Figure 3-18. Use this screen to permit the 4-20 mA line to track the O2 value during a calibration check. Press ENTER to begin editing. Use the arrow keys to select Y or N. Entering Y (yes) will allow the 4-20 mA line to track the O2 value during the calibration check.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG % % 3 THERMOCOUPLE mV 26020017 26020018 Figure 3-20. SHOW FAULT 3-6 DIAGNOSTICS MENU The DIAGNOSTICS MENU branch of the menu tree allows you to examine outputs, current faults, and unit information. None of the items in the DIAGNOSTICS MENU are editable. This branch of the menu tree may be accessed by pressing DIAG on the IRC when in the PROCESS DISPLAY screen (Normal or Faulted).
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG O2 CONCENTRATION O2 CONCENTRATION % % CALCHECK CELL SLOPE VALUE 26020052 O2 CELL IMPEDANCE STATUS Figure 3-24. PREVIOUS SLOPE 26020020 Figure 3-23. CELL IMPEDANCE d. CELL IMPEDANCE Refer to Figure 3-23. Use this screen to examine the O2 cell impedance status. GOOD indicates the cell is operating normally. WARN indicates the cell has degraded but is still operational.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG j. SW BUILD NUMBER Use this screen to see the 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). CELL TEMPERATURE MAXIMUM 26020021 Figure 3-26. MAX CELL T g. MAX CELL T Refer to Figure 3-26.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG O2 CONCENTRATION a. IN MANUAL? Refer to Figure 3-27. % Failure to remove the analyzer from automatic control loops prior to performing this procedure may result in a dangerous operating condition. % If the O2 output value is used in any automatic process control loops, the loop must be placed in manual before beginning a calibration check. Once the analyzer is removed from any automatic control loops, press ENTER to edit the screen.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG O2 CONCENTRATION e. CONSTANT Refer to Figure 3-31. Use this screen to examine the cell zero constant calculated from the current calibration check. The constant represents the voltage generated by the cell when no difference exists between the amount of O2 on the reference and process sides of the cell. Note this value for comparison against future calibration checks. Press RESET or EXIT to return to the PROCESS DISPLAY screen.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 3-16 Startup and Operation Model 3081FG Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 4 HART/AMS 4-1 OVERVIEW The HART Communicator is a handheld communications interface device. It provides a common communications link to all microprocessor-based instruments that are HART compatible. The handheld communicator contains an 8 x 21 character liquid crystal display (LCD) and 25 keys. A pocket-sized manual, included with the HART Communicator, details the specific functions of all the keys.
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Instruction Manual 4 3 1 2 4-20 mA + 16 15 14 13 12 10 11 8 9 Model 3081FG 5 6 7 IB-106-3081 Rev. 1.4 January 2002 RL 250 4-20 mA SIGNAL LINE ANALOG OUTPUT DEVICE MODEL 3081 TRANSMITTER TERMINAL BLOCK LOOP CONNECTORS SERIAL PORT & BATTERY CHARGER MUST NOT BE USED IN LOOP CONNECTORS USE INTERFACE 00275 0013 ONLY SERIAL PORT HAZARDOUS AREAS HART COMMUNICATOR LEAD SET HART COMMUNICATOR REAR PANEL 26020040 Figure 4-1. Signal Line Connections, > 250 Ohms Lead Resistance a.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 12 10 11 8 9 4-20 mA + 16 15 14 13 1 2 3 4 5 6 7 Model 3081FG RL < 250Ω 4-20 mA SIGNAL LINE ANALOG OUTPUT DEVICE MODEL 3081 TRANSMITTER TERMINAL BLOCK 4 LOOP CONNECTORS SERIAL PORT & BATTERY LOOP CONNECTORS CHARGER MUST NOT BE USED IN 250 OHM LOAD RESISTOR (SEE NOTE) USE INTERFACE 00275 0013 ONLY SERIAL PORT HAZARDOUS AREAS HART COMMUNICATOR NOTE: THE SIGNAL LOOP MUST BE BROKEN TO INSERT THE OPTIONAL 250 OHM LOAD RESISTOR.
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Instruction Manual IB-106-3081 Rev. 1.
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Instruction Manual IB-106-3081 Rev. 1.
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Instruction Manual IB-106-3081 Rev. 1.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 4-6 HART COMMUNICATOR START CALCHECK METHOD To perform a calibration check on the Two-Wire In Situ Oxygen Analyzer with the HART Communicator, use the following procedure. If necessary, use the menu tree in Figure 4-3 (sheet 1 of 3) for reference. NOTE To select a menu item, either use the up and down arrow keys to scroll to the menu item and press the right arrow key or use the number keypad to select the menu item number.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 4-8 HART/AMS Model 3081FG Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 5 MAINTENANCE AND SERVICE Install all protective equipment covers and safety ground leads after equipment repair or service. Failure to install covers and ground leads could result in serious injury or death. 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.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 1. 2. 3. 4. 5. 6. 7. 8. Model 3081FG Housing O-ring Lockwasher Screw Terminal End Cap Terminal Block Ground Screw Washer 9. 10. O-ring PC Board Stack (CPU and Analog Boards) Display Board 4 Screw 3 Circuit End Cap Screw Cover Lock 11. 12. 13. 14. 15. 2 5 1 6 7 8 9 10 15 14 STANDOFF 11 12 STANDOFF 13 ANALOG BOARD CPU BOARD RIBBON CABLE 29750006 Figure 5-1.
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Instruction Manual Model 3081FG 9. Connect the ribbon cable connector between display board (11) and the CPU board of PC board stack (10). Ensure the cable connector is fully seated. 10. Reposition display board (11) on the standoffs. Rotate the display board 90 degrees either way as desired. 11. Install and tighten all three screws (12) and circuit end cap (13). 12. Tighten cover lock screw (14) until cover lock (15) engages knurled surface of circuit end cap (13).
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG a. Remove the end cap of the probe to expose the terminal block. b. Refer to Figure 5-2. Disconnect the four wires (two oxygen signal wires and two thermocouple wires) from the terminal block. TERMINAL BLOCK c. Disconnect the reference air and the calibration check gas lines. d. Unscrew the probe from the stack and remove. e. Using a replacement probe, refer to paragraph 2-2c for mechanical installation instructions.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 6 TROUBLESHOOTING Life of the probe is negatively impacted by: 6-1 Install all protective equipment covers and safety ground leads after troubleshooting. Failure to install covers and ground leads could result in serious injury or death. • GENERAL Operating conditions with simultaneously high levels of SO2 and low levels of O2 are particularly damaging.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG 500 SPEED OF RESPONSE (t90), sec 400 300 AIR TO 0.4% O2 0.4% O2 TO AIR 200 100 0 IMPEDANCE, Ω 26020060 Figure 6-2. Speed of Response Frequently conduct calibration checks to look for the following conditions: • • Continued degradation of cell slope. Sluggish response. (Note how long it takes the cell to respond to the application of calibration check gases.) See Figure 6-2.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG GROUND CELL AND THERMOCOUPLE 10 12 16 PROBE CABLE SHIELD 13 15 14 4 5 6 7 TERMINAL BLOCK (TB1) 3 Allow adequate time for the oxygen probe to reach its operating temperature [approximately 500°°C (932°°F)] before investigating a fault. The SHOW FAULTS screen of the DIAGNOSTICS menu will indicate a fault until the unit reaches operating temperature.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG % % 26020025 26020024 Figure 6-5. Fault 1, Open Thermocouple a. Fault 1, Open Thermocouple The thermocouple connection is open. The fault displays as shown in Figure 6-5. 1. Refer to Figure 6-4 and check the thermocouple wiring connections at terminals 8 and 10. Ensure the wires are properly connected. 2. Remove power. Disconnect the thermocouple wires (gray and red) from terminals 10 and 8.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG % % 26020026 Figure 6-7. Fault 3, Shorted Thermocouple c. Fault 3, Shorted Thermocouple The thermocouple connections are shorted. The fault displays as shown in Figure 6-7. 1. Allow adequate time for the oxygen probe to reach operating temperatures. Probe temperatures below approximately 500°C (932°F) may result in this fault. 2. Refer to Figure 6-4. Using a multimeter, measure between terminals 8(-) and 10(+). 3.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG % % 26020028 Figure 6-9. Fault 5, O2 Cell Open e. Fault 5, O2 Cell Open The O2 cell connection is open. The fault displays as shown in Figure 6-9. 1. Allow adequate time for the oxygen probe to reach operating temperatures. Probe temperatures below approximately 500°C (932°F) may result in this fault. 2. Refer to Figure 6-4 and check the O2 cell wiring connections at terminals 7 and 8. Ensure the wires are properly connected.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG g. Fault 7, Reversed O2 Cell The O2 cell connections are reversed. The fault displays as shown in Figure 6-11. 1. Refer to Figure 6-4. Check the black (to 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 output reading is negative, the O2 cell wiring is reversed.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 6-8 Troubleshooting Model 3081FG Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 7 RETURN OF MATERIAL 7-1 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.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 7-2 Return of Material Model 3081FG Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 8 REPLACEMENT PARTS Table 8-1. Replacement Parts List Figure and Index No.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 8-2 Replacement Parts Model 3081FG Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 9 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.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG U Z UNIT SER # Screen, 3-13 UPPER RANGE VAL Screen, 3-7 Zirconia Disc, 1-3 Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG SECTION 10 DRAWINGS AND SCHEMATICS 10 Rosemount Analytical Inc.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 10-2 Drawings and Schematics Model 3081FG Rosemount Analytical Inc.
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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.
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Instruction Manual IB-106-3081 Rev. 1.4 January 2002 Model 3081FG Two-Wire In Situ Oxygen Analyzer 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.