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Emerson instruction manual Oxygen Analyzer, with IFT 3000 Intelligent Field Transmitter

Models: 3000

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Instruction Manual

IB-106-300NH Rev. 4.3

May 2005

World Class 3000

Oxygen Analyzer

with IFT 3000 Intelligent Field Transmitter

http://www.raihome.com

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Emerson instruction manual Oxygen Analyzer, with IFT 3000 Intelligent Field Transmitter, Instruction Manual

Contents

with IFT 3000 Intelligent Field Transmitter Oxygen AnalyzerInstruction Manual World ClassESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDINGEffective May, 1999 Rev. HIGHLIGHTS OF CHANGESPage SummaryEffective May, 2005 Rev. HIGHLIGHTS OF CHANGES CONTINUEDPage SummaryHIGHLIGHTS OF CHANGES APPENDIX AEffective May, 1996 Rev. PageEffective November, 2001 Rev. HIGHLIGHTS OF CHANGES CONTINUEDPage SummaryHIGHLIGHTS OF CHANGES APPENDIX BEffective February, 1992 Rev. PagePage HIGHLIGHTS OF CHANGES APPENDIX DEffective June, 1994 Rev. PageEffective July, 1998 Rev. HIGHLIGHTS OF CHANGES CONTINUEDPage SummaryHIGHLIGHTS OF CHANGES APPENDIX EEffective May, 1996 Rev. Pagefiguration. Revised replacement parts list Revised Electrical Noise specificationsHIGHLIGHTS OF CHANGES CONTINUED Effective May, 2005 Rev.HIGHLIGHTS OF CHANGES APPENDIX JEffective April, 1995 Rev. PagePage World Class TABLE OF CONTENTSSETUP Instruction ManualWorld Class LIST OF ILLUSTRATIONSInstruction Manual World Class LIST OF TABLESInstruction Manual Instruction Manual World ClassDEFINITIONS PREFACENOTE TO USERS World ClassFOR THE WIRING AND INSTALLATION OF THIS APPARATUS SAFETY INSTRUCTIONSWorld Class Instruction ManualWorld Class GLOSSARY OF TERMSInstruction Manual Abrasive ShieldInstruction Manual World ClassReference Air Semiautomatic CalibrationIFT 3000 INTELLIGENT FIELD TRANSMITTER WHAT YOU NEED TO KNOWWITH WORLD CLASS 3000 PROBE World ClassWorld Class QUICK START GUIDEInstruction Manual Use this Quick Start Guide ifWorld Class QUICK START GUIDE FOR IFT 3000 SYSTEMSInstruction Manual 100 V.A.C. JM3, JM7, JM2 120 V.A.C. JM8, JM7, JM1 LINE VOLTAGE JUMPER SECTION INSTALL220 V.A.C. JM6, JM5, JM2 240 V.A.C. JM6, JM5, JM1 PROBE JUNCTION BOX WIRINGIFT 3000 INTELLIGENT FIELD TRANSMITTER QUICK REFERENCE GUIDESetting up the Analog Output World ClassWorld Class HART COMMUNICATOR FAST KEY SEQUENCESInstruction Manual Technical Support Hotline1-1COMPONENT CHECKLIST OF TYPICAL SECTION DESCRIPTION AND SPECIFICATIONSSYSTEM PACKAGE CONTENTS World ClassInstruction Manual World Class1-2SYSTEM OVERVIEW a.Scope b.System Descriptiond.System Features c.System ConfigurationWorld Class Instruction ManualInstruction Manual World Classe. Handling the Oxygen Analyzer f.System ConsiderationsWorld Class Figure 1-2.Typical System InstallationInstruction Manual STANDARDWorld Class 1-6Description and SpecificationsInstruction Manual Termination inInstruction Manual World ClassIB-106-300NHRev. 4.3 May World Class 1-8Description and SpecificationsInstruction Manual 2-1OXYGEN ANALYZER PROBE INSTALLATION SECTION INSTALLATIONb.Mechanical Installation World ClassWorld Class Figure 2-1.Probe Installation Sheet 1 ofInstruction Manual BOTTOM VIEWWorld Class Figure 2-1.Probe Installation Sheet 2 ofInstruction Manual 2-4Installation Figure 2-1.Probe Installation Sheet 3 ofWorld Class Instruction ManualINSTALLATION FOR MASONRY WALL STACK CONSTRUCTION INSTALLATION FOR METAL WALL STACK OR DUCTCONSTRUCTION Figure 2-1.Probe Installation Sheet 4 of2-6Installation Figure 2-1.Probe Installation Sheet 5 ofWorld Class Instruction ManualWorld Class Probe InstallationInstruction Manual Figure 2-2.Orienting the Optional Vee DeflectorWorld Class d.Service RequiredInstruction Manual c.Reference Air Packagea.Mechanical Installation 2-2INTELLIGENT FIELD TRANSMITTER IFT INSTALLATIONWorld Class Instruction ManualInstruction Manual World ClassIB-106-300NHRev. 4.3 May Installation Figure 2-6.IFT Power Supply Board JumpersWorld Class Instruction ManualBOX WIRING 2-12InstallationWorld Class Instruction ManualJumper Configuration Switch SW32-3HEATER POWER SUPPLY INSTALLATION Mechanical Installation2-14Installation SELECTOR SWITCHWorld Class Instruction ManualInstruction Manual World ClassOUTPUT JUMPERWorld Class Figure 2-12.Outline of Heater Power SupplyInstruction Manual NEMAWorld Class J8 + - +Instruction Manual WORLD CLASS PROBEWorld Class 2-18InstallationInstruction Manual INTELLIGENT FIELD TRANSMITTER IFTWorld Class InstallationInstruction Manual FRONTInstruction Manual World ClassFigure 2-15.Jumper Selection Label Figure 2-16.Jumpers on HPS Mother BoardSEQUENCER INSTALLATION a.Mechanical Installation AnalyticalWorld Class Instruction ManualInstruction Manual World Classc.Electrical Connections Figure 2-18.MPS Gas ConnectionsWorld Class Figure 2-19.MPS Probe WiringInstruction Manual PROBEWorld Class 2-24InstallationInstruction Manual 3-2CONFIGURING THE ANALOG OUTPUT SECTION SETUP3-3SETTING CALIBRATION PARAMETERS World Class3-5CONFIGURING EFFICIENCY CALCULATIONS 3-4SETTING THE O2 ALARM SETPOINTS3-6CONFIGURING THE RELAY OUTPUTS World ClassWorld Class SECTION 4 CALIBRATIONInstruction Manual 4-1ANALOG OUTPUT CALIBRATIONInstruction Manual World Class2. Calibration Methods c.Manual Semiautomatic CalibrationInstruction Manual World ClassIB-106-300NHRev. 4.3 May World Class Figure 4-1.Typical Calibration SetupInstruction Manual Instruction Manual World ClassFigure 4-2.Portable Rosemount Analytical Oxygen Calibration Gas Kitd.Manual Semiautomatic Calibration Procedure Figure 4-3.Typical Portable Calibration SetupWorld Class Instruction ManualInstruction Manual World ClassFigure 4-4.Typical Automatic Calibration System Instruction Manual World ClassTable 4-1.Automatic Calibration Parameters Calibration Record For Probe Location Date Placed Into ServiceRosemount Analytical In Situ O2 Probe Probe Serial Number Probe Tag NumberInstruction Manual World Class4-10Calibration World Class SECTION GENERAL USER INTERFACE GUI OPERATIONInstruction Manual 5-1OVERVIEWInstruction Manual World Class5-2DELUXE VERSION IFT DISPLAYS AND CONTROLS INTERNAL VIEWSETUP Press ENTER key to access DATA menuThe SETUP menu is used to configure the IFT 5-5QUICK REFERENCE CHARTWorld Class 5-9SETUP SUB-MENUInstruction Manual 5-8CALIBRATE O2 SUB-MENUWorld Class Figure 5-2.Quick Reference Chart Sheet 1 ofInstruction Manual World Class Figure 5-2.Quick Reference Chart Sheet 2 ofInstruction Manual 5-6General User Interface GUI OperationCONTINUED FROM SHEET SETUP COUNTRY Figure 5-2.Quick Reference Chart Sheet 3 ofSOURCE AOUT TYPE RANGE SETUP USA GBR FRA ESP GER World ClassWorld Class Figure 5-2.Quick Reference Chart Sheet 4 ofInstruction Manual 5-8General User Interface GUI OperationWorld Class Figure 5-2.Quick Reference Chart Sheet 5 ofInstruction Manual CONTINUED FROM SHEETWorld Class SETUP SETTINGInstruction Manual Table 5-4.CALIBRATE O2 Sub-MenuWorld Class SETUP SETTINGInstruction Manual Table 5-4.CALIBRATE O2 Sub-MenucontinuedWorld Class Table 5-5.SETUP Sub-MenuInstruction Manual SUB-MENUselected in the SETUP sub-menu Table 5-5.SETUP Sub-MenucontinuedWorld Class Instruction ManualDual Range Setup Table 5-5.SETUP Sub-MenucontinuedWorld Class Instruction Manual6-2SPECIAL TROUBLESHOOTING NOTES a.Grounding SECTION TROUBLESHOOTING6-3SYSTEM TROUBLESHOOTING World ClassInstruction Manual World ClassTable 6-1.IFT Status Codes Table 6-2.Heater Troubleshooting Problem 6-4HEATER PROBLEMWorld Class Instruction ManualProblem Table 6-2.Heater Troubleshooting continuedWorld Class Instruction ManualTable 6-3.Cell Troubleshooting Problem 6-5CELL PROBLEMWorld Class Instruction ManualWorld Class Table 6-3.Cell Troubleshooting continued ProblemInstruction Manual Status is ResHi or CalErTable 6-4.IFT Troubleshooting Problem 6-6IFT PROBLEMFaulty GUI or LDP IFT LED is Flashing World ClassTable 6-5.MPS Troubleshooting Problem 6-7MPS PROBLEMWorld Class Instruction ManualProblem Table 6-6.Performance Problem TroubleshootingWorld Class Instruction ManualWorld Class 6-10TroubleshootingInstruction Manual World Class SECTION RETURN OF MATERIALInstruction Manual Instruction Manual World Class7-2Return of Material World Class SECTION APPENDICESInstruction Manual World Class Instruction BulletinAPPENDIX A Figure A-1.Oxygen Analyzer Probe Exploded ViewWORLD CLASS 3000 OXYGEN ANALYZER PROBE APPENDIX A, REV.DESCRIPTION World ClassInstruction Bulletin World ClassAppendix A Rev. 3.9 May a.Cell and Flange Assembly A-2PROBE ASSEMBLY EXTERIORb.Probe Tube Assembly c.Snubber Diffusion AssemblyFigure A-5.Inner Probe Assembly A-3INNER PROBE ASSEMBLYWorld Class Instruction BulletinA-6PROBE OPTIONS a.Abrasive Shield Assembly A-5CABLE ASSEMBLYWorld Class Instruction BulletinWorld Class Figure A-7.Abrasive Shield AssemblyInstruction Bulletin b.Ceramic Diffusion Assembly Figure A-8.Ceramic Diffusion/Dust Seal AssemblyFigure A-10.Ceramic Diffusion Assembly c.Flame Arrestor Diffusion AssemblyFigure A-12.Snubber Diffusion/Dust Seal Assembly d.Snubber Diffusion/Dust Seal Assemblye.Cup-TypeDiffusion Assembly Figure A-13. Cup-TypeDiffusion/Dust Seal AssemblyInstruction Bulletin World ClassFigure A-15.Bypass Probe Option Sheet 1 of Instruction Bulletin World ClassFigure A-15.Bypass Probe Option Sheet 2 of A-10AppendicesInstruction Bulletin World ClassGROUP PART NOA-8PROBE TROUBLESHOOTING a.Probe Faults PROBE TROUBLESHOOTINGTable A-2.Fault Finding SymptomSymptom Table A-2.Fault Finding ContinuedFault World ClassInstruction Bulletin World ClassA-14Appendices Instruction Bulletin World ClassAppendices A-15 A-11CELL REPLACEMENT SERVICE AND NORMAL MAINTENANCEWorld Class Instruction BulletinWorld Class Figure A-18.Cell Wiring ConnectionInstruction Bulletin ELEMENT REPLACEMENT a.General Figure A-20.Cell Replacement KitWorld Class Instruction BulletinWorld Class b.Replacement ProcedureInstruction Bulletin THERMOCOUPLE ASSEMBLY A-13REPLACEMENT OF CONTACT ANDWorld Class Instruction BulletinInner Probe Assembly Figure A-23.Heater, Strut, and Backplate AssemblyWorld Class Instruction BulletinInstruction Bulletin World ClassAppendix A Rev. 3.9 May World Class a. Installation ProcedureInstruction Bulletin A-15CALIBRATION GAS AND REFERENCE AIRWorld Class Figure A-25.High Temperature - CorrosiveInstruction Bulletin Environment KitTable A-3.Replacement Parts for Probe REPLACEMENT PARTSWorld Class Instruction BulletinWorld Class Table A-3.Replacement Parts for Probe ContinuedInstruction Bulletin Figure and Index NoWorld Class APPENDIX B, REV. HPS 3000 HEATER POWER SUPPLYDESCRIPTION Instruction BulletinWorld Class Figure B-2.Heater Power Supply, InteriorInstruction Bulletin FRONTFigure B-3.Heater Power Supply Block Diagram Table B-1.Specifications for Heater Power SupplyWorld Class Instruction BulletinB-4HPS 3000 TROUBLESHOOTING HPS 3000 TROUBLESHOOTINGWorld Class Instruction BulletinFigure B-4.HPS Troubleshooting Flowchart, #1 SYMPTOMWorld Class Instruction BulletinFigure B-5.HPS Troubleshooting Flowchart, #2 SYMPTOMWorld Class Instruction BulletinFigure B-6.HPS Troubleshooting Flowchart, #3 SYMPTOMWorld Class Instruction BulletinThis section describes service and routine SERVICE AND NORMAL MAINTENANCEmaintenance of the HPS 3000 Heater Power Supply Field Module. Replacement partsWorld Class B-9DAUGHTER BOARD REPLACEMENTInstruction Bulletin World Class Figure B-7.Heater Power Supply, Exploded ViewInstruction Bulletin B-10AppendicesWorld Class REPLACEMENT PARTSInstruction Bulletin LEGEND FOR FIGURE B-7Instruction Bulletin World ClassB-12Appendices MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER APPENDIX D, REVWorld Class DESCRIPTIONInstruction Bulletin World ClassAppendix D Rev. 2.5 May Instruction Bulletin World ClassFigure D-3.Typical Automatic Calibration System Appendices D-3Instruction Bulletin World ClassBEBCO MODEL Z-PURGE REAR VIEWD-4TROUBLESHOOTING MPS 3000 TROUBLESHOOTINGTable D-2.Fault Finding SYMPTOMFigure D-5.MPS Troubleshooting Flowchart SYMPTOMWorld Class Instruction BulletinD-6FUSE REPLACEMENT SERVICE AND NORMAL MAINTENANCESOLENOID VALVE REPLACEMENT D-7POWER SUPPLY REPLACEMENTInstruction Bulletin World ClassD-8Appendices Pressure Adjustments D-9PRESSURE REGULATOR MAINTENANCEWorld Class Instruction BulletinWorld Class D-10FLOWMETER ADJUSTMENTSInstruction Bulletin D-11ADDING PROBES TO THE MPSWorld Class REPLACEMENT PARTSInstruction Bulletin FIGURE andInstruction Bulletin World ClassD-12Appendices c.Power Supply Board APPENDIX E, REV.World Class IFT 3000 INTELLIGENT FIELD TRANSMITTERInstruction Bulletin World Classf.Z-Purgeoptional E-2THEORY OF OPERATIONFigure E-2.System Block Diagram HEATER POWER SUPPLY OPTIONAL IFTWorld Class Instruction BulletinE-4IFT TROUBLESHOOTING IFT 3000 TROUBLESHOOTINGWorld Class Instruction BulletinWorld Class Figure E-3.IFT Troubleshooting Flowchart, #1Instruction Bulletin Appendices E-5Figure E-4.IFT Troubleshooting Flowchart, #2 SYMPTOM - MICROPROCESSOR BOARD LED IS STEADY ONSYMPTOM - GENERAL USER INTERFACE OR Figure E-5.IFT Troubleshooting Flowchart, #3SYMPTOM Table E-2.GUI Equipped IFT Fault FindingWorld Class Instruction BulletinInstruction Bulletin World Class1.Captive Screw 2.Enclosure Cover E-6REMOVE POWER AND OPEN COVER SERVICE AND NORMAL MAINTENANCEWorld Class Instruction BulletinWorld Class Figure E-7.Microprocessor Assembly –Instruction Bulletin Exploded ViewWorld Class E-12REPLACE POWER SUPPLY BOARDInstruction Bulletin E-9REPLACE MICROPROCESSOR BOARDInstruction Bulletin World ClassFigure E-8.Electronics Chassis – Exploded View E-14REPLACE HEATER AND THERMOSWITCH E-15INSTALL ELECTRONICS CHASSISWorld Class Instruction Bulletin25.Microprocessor Assembly 26.Protective Cover Figure E-9.Electronics Chassis Installation27.Captive Screw 28.Power Supply Board World ClassE-17CLOSE COVER AND RESTORE POWER E-16REPLACE GUI ASSEMBLY ORFigure E-10.Replacing the GUI Assembly World ClassWorld Class REPLACEMENT PARTSInstruction Bulletin FIGURE and INDEX NoIFT 3000 APPLICATIONS APPENDIX J, REV HART COMMUNICATOR MODEL 275/375J-1COMPONENT CHECKLIST OF TYPICAL World ClassTable J-1.HART Communicator Specifications J-3SPECIFICATIONSPhysical Specifications Functional SpecificationsJ-4HART COMMUNICATOR SIGNAL LINE CONNECTIONS INSTALLATIONWorld Class Instruction BulletinInstruction Bulletin World Classb.Method 2, For Load Resistance < 250 Ohms HART COMMUNICATOR PC CONNECTIONSInstruction Bulletin World ClassAppendices J-5 World Class OPERATIONInstruction Bulletin J-6 OFF-LINEAND ON-LINEOPERATIONSInstruction Bulletin World ClassAppendices J-7 Instruction Bulletin World ClassJ-8Appendices Instruction Bulletin World ClassAppendices J-9 J-9TROUBLESHOOTING FLOWCHART TROUBLESHOOTINGWorld Class Instruction BulletinInstruction Bulletin World ClassAppendices J-11 Instruction Bulletin World ClassJ-12Appendices World Class RETURNING EQUIPMENT TO THE FACTORYInstruction Bulletin Instruction Bulletin World ClassJ-14Appendices World Class SECTION INDEXInstruction Manual World Class3656 3784/5-05 ROSEMOUNT ANALYTICAL WARRANTYInstruction Manual World ClassWorld Class 3000 Probe