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Emerson Appendix A, Rev, WORLD CLASS 3000 OXYGEN ANALYZER PROBE, Description, World Class

Models: 3000

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World Class 3000

Instruction Bulletin

Appendix A Rev. 3.9 May 2005

APPENDIX A, REV. 3.9

WORLD CLASS 3000 OXYGEN ANALYZER (PROBE)

DESCRIPTION

Read the “Safety instructions for the wiring and installation of this appara- tus” at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury or death.

A-1 OXYGEN ANALYZER (PROBE) - GENERAL

The Oxygen Analyzer (Probe), Figure A-1, con- sists of three component groups: probe exterior, inner probe, and probe junction box, Figure A-2.

PROBE EXTERIOR

(SENSING CELL INSTALLED)

PROBE

INTERIOR

PROBE

JUNCTION

BOX

21240006

Figure A-2. Main Probe Components

Rosemount Analytical Inc. A Division of Emerson Process Management

Appendices A-1

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Emerson Appendix A, Rev, WORLD CLASS 3000 OXYGEN ANALYZER PROBE, Description, World Class, Instruction Bulletin

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 ManualInstruction Manual LIST OF ILLUSTRATIONSWorld Class Instruction Manual LIST OF TABLESWorld Class 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 ifInstruction Manual QUICK START GUIDE FOR IFT 3000 SYSTEMSWorld Class 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 inIB-106-300NHRev. 4.3 May World ClassInstruction Manual Instruction Manual 1-8Description and SpecificationsWorld Class 2-1OXYGEN ANALYZER PROBE INSTALLATION SECTION INSTALLATIONb.Mechanical Installation World ClassWorld Class Figure 2-1.Probe Installation Sheet 1 ofInstruction Manual BOTTOM VIEWInstruction Manual Figure 2-1.Probe Installation Sheet 2 ofWorld Class 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 ManualIB-106-300NHRev. 4.3 May World ClassInstruction Manual 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 PROBEInstruction Manual 2-24InstallationWorld Class 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 CalibrationIB-106-300NHRev. 4.3 May World ClassInstruction Manual Instruction Manual Figure 4-1.Typical Calibration SetupWorld Class 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 ManualFigure 4-4.Typical Automatic Calibration System World ClassInstruction Manual Table 4-1.Automatic Calibration Parameters World ClassInstruction Manual Calibration Record For Probe Location Date Placed Into ServiceRosemount Analytical In Situ O2 Probe Probe Serial Number Probe Tag Number4-10Calibration World ClassInstruction Manual 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-MENUInstruction Manual Figure 5-2.Quick Reference Chart Sheet 1 ofWorld Class 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 ClassTable 6-1.IFT Status Codes World ClassInstruction Manual 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 ManualInstruction Manual 6-10TroubleshootingWorld Class Instruction Manual SECTION RETURN OF MATERIALWorld Class 7-2Return of Material World ClassInstruction Manual Instruction Manual SECTION APPENDICESWorld Class World Class Instruction BulletinAPPENDIX A Figure A-1.Oxygen Analyzer Probe Exploded ViewWORLD CLASS 3000 OXYGEN ANALYZER PROBE APPENDIX A, REV.DESCRIPTION World ClassAppendix A Rev. 3.9 May World ClassInstruction Bulletin 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 BulletinInstruction Bulletin Figure A-7.Abrasive Shield AssemblyWorld Class 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 AssemblyFigure A-15.Bypass Probe Option Sheet 1 of World ClassInstruction Bulletin 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 ClassA-14Appendices World ClassInstruction Bulletin Appendices A-15 World ClassInstruction Bulletin A-11CELL REPLACEMENT SERVICE AND NORMAL MAINTENANCEWorld Class Instruction BulletinInstruction Bulletin Figure A-18.Cell Wiring ConnectionWorld Class ELEMENT REPLACEMENT a.General Figure A-20.Cell Replacement KitWorld Class Instruction BulletinInstruction Bulletin b.Replacement ProcedureWorld Class THERMOCOUPLE ASSEMBLY A-13REPLACEMENT OF CONTACT ANDWorld Class Instruction BulletinInner Probe Assembly Figure A-23.Heater, Strut, and Backplate AssemblyWorld Class Instruction BulletinAppendix A Rev. 3.9 May World ClassInstruction Bulletin 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 partsInstruction Bulletin B-9DAUGHTER BOARD REPLACEMENTWorld Class World Class Figure B-7.Heater Power Supply, Exploded ViewInstruction Bulletin B-10AppendicesWorld Class REPLACEMENT PARTSInstruction Bulletin LEGEND FOR FIGURE B-7B-12Appendices World ClassInstruction Bulletin MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER APPENDIX D, REVWorld Class DESCRIPTIONAppendix D Rev. 2.5 May World ClassInstruction Bulletin 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 REPLACEMENTD-8Appendices World ClassInstruction Bulletin 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 andD-12Appendices World ClassInstruction Bulletin 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 Bulletin1.Captive Screw 2.Enclosure Cover World ClassInstruction Bulletin 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 BOARDFigure E-8.Electronics Chassis – Exploded View World ClassInstruction Bulletin 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 CONNECTIONSAppendices J-5 World ClassInstruction Bulletin World Class OPERATIONInstruction Bulletin J-6 OFF-LINEAND ON-LINEOPERATIONSAppendices J-7 World ClassInstruction Bulletin J-8Appendices World ClassInstruction Bulletin Appendices J-9 World ClassInstruction Bulletin J-9TROUBLESHOOTING FLOWCHART TROUBLESHOOTINGWorld Class Instruction BulletinAppendices J-11 World ClassInstruction Bulletin J-12Appendices World ClassInstruction Bulletin Instruction Bulletin RETURNING EQUIPMENT TO THE FACTORYWorld Class J-14Appendices World ClassInstruction Bulletin World Class SECTION INDEXInstruction Manual World Class3656 3784/5-05 ROSEMOUNT ANALYTICAL WARRANTYWorld Class 3000 Probe World ClassInstruction Manual