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Emerson 3000 World Class, Instruction Bulletin, Group, Part No, Code, Description

Models: 3000

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World Class 3000

Instruction Bulletin

Appendix A Rev. 3.9 May 2005

Extended Temperature By-Pass Arrangements (2400°F; 1300°C)

	GROUP
PART NO.	CODE	DESCRIPTION

1U0571	G01	3’ By-pass Package with ANSI bolt pattern.

1U0571	G02	6’ By-pass Package with ANSI bolt pattern.

1U0571	G03	9’ By-pass Package with ANSI bolt pattern.

1U0571	G04	3’ By-pass Package with JIS bolt pattern.

1U0571	G05	6’ By-pass Package with JIS bolt pattern.

1U0571	G06	9’ By-pass Package with JIS bolt pattern.

1U0571	G07	3’ By-pass Package with DIN bolt pattern.

1U0571	G08	6’ By-pass Package with DIN bolt pattern.

1U0571	G09	9’ By-pass Package with DIN bolt pattern.

Figure A-15. Bypass Probe Option (Sheet 3 of 3)

Rosemount Analytical Inc. A Division of Emerson Process Management

Appendices A-11

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Emerson 3000 instruction manual World Class, Instruction Bulletin, Group, Part No, Code, Description

Contents

World Class Oxygen Analyzerwith IFT 3000 Intelligent Field Transmitter Instruction ManualESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDINGSummary HIGHLIGHTS OF CHANGESEffective May, 1999 Rev. PageSummary HIGHLIGHTS OF CHANGES CONTINUEDEffective May, 2005 Rev. PagePage APPENDIX AHIGHLIGHTS OF CHANGES Effective May, 1996 Rev.Summary HIGHLIGHTS OF CHANGES CONTINUEDEffective November, 2001 Rev. PagePage APPENDIX BHIGHLIGHTS OF CHANGES Effective February, 1992 Rev.Page Page APPENDIX DHIGHLIGHTS OF CHANGES Effective June, 1994 Rev.Summary HIGHLIGHTS OF CHANGES CONTINUEDEffective July, 1998 Rev. PagePage APPENDIX EHIGHLIGHTS OF CHANGES Effective May, 1996 Rev.Effective May, 2005 Rev. Revised Electrical Noise specificationsfiguration. Revised replacement parts list HIGHLIGHTS OF CHANGES CONTINUEDPage APPENDIX JHIGHLIGHTS OF CHANGES Effective April, 1995 Rev.Page Instruction Manual TABLE OF CONTENTSWorld Class SETUPLIST OF ILLUSTRATIONS World ClassInstruction Manual LIST OF TABLES World ClassInstruction Manual Instruction Manual World ClassWorld Class PREFACEDEFINITIONS NOTE TO USERSInstruction Manual SAFETY INSTRUCTIONSFOR THE WIRING AND INSTALLATION OF THIS APPARATUS World ClassAbrasive Shield GLOSSARY OF TERMSWorld Class Instruction ManualSemiautomatic Calibration World ClassInstruction Manual Reference AirWorld Class WHAT YOU NEED TO KNOWIFT 3000 INTELLIGENT FIELD TRANSMITTER WITH WORLD CLASS 3000 PROBEUse this Quick Start Guide if QUICK START GUIDEWorld Class Instruction ManualQUICK START GUIDE FOR IFT 3000 SYSTEMS World ClassInstruction Manual PROBE JUNCTION BOX WIRING LINE VOLTAGE JUMPER SECTION INSTALL100 V.A.C. JM3, JM7, JM2 120 V.A.C. JM8, JM7, JM1 220 V.A.C. JM6, JM5, JM2 240 V.A.C. JM6, JM5, JM1World Class QUICK REFERENCE GUIDEIFT 3000 INTELLIGENT FIELD TRANSMITTER Setting up the Analog OutputTechnical Support Hotline HART COMMUNICATOR FAST KEY SEQUENCESWorld Class Instruction ManualWorld Class SECTION DESCRIPTION AND SPECIFICATIONS1-1COMPONENT CHECKLIST OF TYPICAL SYSTEM PACKAGE CONTENTSb.System Description World ClassInstruction Manual 1-2SYSTEM OVERVIEW a.ScopeInstruction Manual c.System Configurationd.System Features World Classf.System Considerations World ClassInstruction Manual e. Handling the Oxygen AnalyzerSTANDARD Figure 1-2.Typical System InstallationWorld Class Instruction ManualTermination in 1-6Description and SpecificationsWorld Class Instruction ManualWorld Class Instruction ManualIB-106-300NHRev. 4.3 May 1-8Description and Specifications World ClassInstruction Manual World Class SECTION INSTALLATION2-1OXYGEN ANALYZER PROBE INSTALLATION b.Mechanical InstallationBOTTOM VIEW Figure 2-1.Probe Installation Sheet 1 ofWorld Class Instruction ManualFigure 2-1.Probe Installation Sheet 2 of World ClassInstruction Manual Instruction Manual Figure 2-1.Probe Installation Sheet 3 of2-4Installation World ClassFigure 2-1.Probe Installation Sheet 4 of INSTALLATION FOR METAL WALL STACK OR DUCTINSTALLATION FOR MASONRY WALL STACK CONSTRUCTION CONSTRUCTIONInstruction Manual Figure 2-1.Probe Installation Sheet 5 of2-6Installation World ClassFigure 2-2.Orienting the Optional Vee Deflector Probe InstallationWorld Class Instruction Manualc.Reference Air Package d.Service RequiredWorld Class Instruction ManualInstruction Manual 2-2INTELLIGENT FIELD TRANSMITTER IFT INSTALLATIONa.Mechanical Installation World ClassWorld Class Instruction ManualIB-106-300NHRev. 4.3 May Instruction Manual Figure 2-6.IFT Power Supply Board JumpersInstallation World ClassInstruction Manual 2-12InstallationBOX WIRING World ClassMechanical Installation Switch SW3Jumper Configuration 2-3HEATER POWER SUPPLY INSTALLATIONInstruction Manual SELECTOR SWITCH2-14Installation World ClassJUMPER World ClassInstruction Manual OUTPUTNEMA Figure 2-12.Outline of Heater Power SupplyWorld Class Instruction ManualWORLD CLASS PROBE J8 + - +World Class Instruction ManualINTELLIGENT FIELD TRANSMITTER IFT 2-18InstallationWorld Class Instruction ManualFRONT InstallationWorld Class Instruction ManualFigure 2-16.Jumpers on HPS Mother Board World ClassInstruction Manual Figure 2-15.Jumper Selection LabelInstruction Manual AnalyticalSEQUENCER INSTALLATION a.Mechanical Installation World ClassFigure 2-18.MPS Gas Connections World ClassInstruction Manual c.Electrical ConnectionsPROBE Figure 2-19.MPS Probe WiringWorld Class Instruction Manual2-24Installation World ClassInstruction Manual World Class SECTION SETUP3-2CONFIGURING THE ANALOG OUTPUT 3-3SETTING CALIBRATION PARAMETERSWorld Class 3-4SETTING THE O2 ALARM SETPOINTS3-5CONFIGURING EFFICIENCY CALCULATIONS 3-6CONFIGURING THE RELAY OUTPUTS4-1ANALOG OUTPUT CALIBRATION SECTION 4 CALIBRATIONWorld Class Instruction Manualc.Manual Semiautomatic Calibration World ClassInstruction Manual 2. Calibration MethodsWorld Class Instruction ManualIB-106-300NHRev. 4.3 May Figure 4-1.Typical Calibration Setup World ClassInstruction Manual Oxygen Calibration Gas Kit World ClassInstruction Manual Figure 4-2.Portable Rosemount AnalyticalInstruction Manual Figure 4-3.Typical Portable Calibration Setupd.Manual Semiautomatic Calibration Procedure World ClassWorld Class Instruction ManualFigure 4-4.Typical Automatic Calibration System World Class Instruction ManualTable 4-1.Automatic Calibration Parameters Probe Serial Number Probe Tag Number Probe Location Date Placed Into ServiceCalibration Record For Rosemount Analytical In Situ O2 ProbeWorld Class Instruction Manual4-10Calibration 5-1OVERVIEW SECTION GENERAL USER INTERFACE GUI OPERATIONWorld Class Instruction ManualINTERNAL VIEW World ClassInstruction Manual 5-2DELUXE VERSION IFT DISPLAYS AND CONTROLS5-5QUICK REFERENCE CHART Press ENTER key to access DATA menuSETUP The SETUP menu is used to configure the IFT5-8CALIBRATE O2 SUB-MENU 5-9SETUP SUB-MENUWorld Class Instruction ManualFigure 5-2.Quick Reference Chart Sheet 1 of World ClassInstruction Manual 5-6General User Interface GUI Operation Figure 5-2.Quick Reference Chart Sheet 2 ofWorld Class Instruction ManualWorld Class Figure 5-2.Quick Reference Chart Sheet 3 ofCONTINUED FROM SHEET SETUP COUNTRY SOURCE AOUT TYPE RANGE SETUP USA GBR FRA ESP GER5-8General User Interface GUI Operation Figure 5-2.Quick Reference Chart Sheet 4 ofWorld Class Instruction ManualCONTINUED FROM SHEET Figure 5-2.Quick Reference Chart Sheet 5 ofWorld Class Instruction ManualTable 5-4.CALIBRATE O2 Sub-Menu SETUP SETTINGWorld Class Instruction ManualTable 5-4.CALIBRATE O2 Sub-Menucontinued SETUP SETTINGWorld Class Instruction ManualSUB-MENU Table 5-5.SETUP Sub-MenuWorld Class Instruction ManualInstruction Manual Table 5-5.SETUP Sub-Menucontinuedselected in the SETUP sub-menu World ClassInstruction Manual Table 5-5.SETUP Sub-MenucontinuedDual Range Setup World ClassWorld Class SECTION TROUBLESHOOTING6-2SPECIAL TROUBLESHOOTING NOTES a.Grounding 6-3SYSTEM TROUBLESHOOTINGWorld Class Instruction ManualTable 6-1.IFT Status Codes Instruction Manual 6-4HEATER PROBLEMTable 6-2.Heater Troubleshooting Problem World ClassInstruction Manual Table 6-2.Heater Troubleshooting continuedProblem World ClassInstruction Manual 6-5CELL PROBLEMTable 6-3.Cell Troubleshooting Problem World ClassStatus is ResHi or CalEr Table 6-3.Cell Troubleshooting continued ProblemWorld Class Instruction ManualWorld Class 6-6IFT PROBLEMTable 6-4.IFT Troubleshooting Problem Faulty GUI or LDP IFT LED is FlashingInstruction Manual 6-7MPS PROBLEMTable 6-5.MPS Troubleshooting Problem World ClassInstruction Manual Table 6-6.Performance Problem TroubleshootingProblem World Class6-10Troubleshooting World ClassInstruction Manual SECTION RETURN OF MATERIAL World ClassInstruction Manual World Class Instruction Manual7-2Return of Material SECTION APPENDICES World ClassInstruction Manual Figure A-1.Oxygen Analyzer Probe Exploded View Instruction BulletinWorld Class APPENDIX AWorld Class APPENDIX A, REV.WORLD CLASS 3000 OXYGEN ANALYZER PROBE DESCRIPTIONWorld Class Instruction BulletinAppendix A Rev. 3.9 May c.Snubber Diffusion Assembly A-2PROBE ASSEMBLY EXTERIORa.Cell and Flange Assembly b.Probe Tube AssemblyInstruction Bulletin A-3INNER PROBE ASSEMBLYFigure A-5.Inner Probe Assembly World ClassInstruction Bulletin A-5CABLE ASSEMBLYA-6PROBE OPTIONS a.Abrasive Shield Assembly World ClassFigure A-7.Abrasive Shield Assembly World ClassInstruction Bulletin c.Flame Arrestor Diffusion Assembly Figure A-8.Ceramic Diffusion/Dust Seal Assemblyb.Ceramic Diffusion Assembly Figure A-10.Ceramic Diffusion AssemblyFigure A-13. Cup-TypeDiffusion/Dust Seal Assembly d.Snubber Diffusion/Dust Seal AssemblyFigure A-12.Snubber Diffusion/Dust Seal Assembly e.Cup-TypeDiffusion AssemblyWorld Class Instruction BulletinFigure A-15.Bypass Probe Option Sheet 1 of A-10Appendices World ClassInstruction Bulletin Figure A-15.Bypass Probe Option Sheet 2 ofPART NO World ClassInstruction Bulletin GROUPSymptom PROBE TROUBLESHOOTINGA-8PROBE TROUBLESHOOTING a.Probe Faults Table A-2.Fault FindingWorld Class Table A-2.Fault Finding ContinuedSymptom FaultWorld Class Instruction BulletinA-14Appendices World Class Instruction BulletinAppendices A-15 Instruction Bulletin SERVICE AND NORMAL MAINTENANCEA-11CELL REPLACEMENT World ClassFigure A-18.Cell Wiring Connection World ClassInstruction Bulletin Instruction Bulletin Figure A-20.Cell Replacement KitELEMENT REPLACEMENT a.General World Classb.Replacement Procedure World ClassInstruction Bulletin Instruction Bulletin A-13REPLACEMENT OF CONTACT ANDTHERMOCOUPLE ASSEMBLY World ClassInstruction Bulletin Figure A-23.Heater, Strut, and Backplate AssemblyInner Probe Assembly World ClassWorld Class Instruction BulletinAppendix A Rev. 3.9 May A-15CALIBRATION GAS AND REFERENCE AIR a. Installation ProcedureWorld Class Instruction BulletinEnvironment Kit Figure A-25.High Temperature - CorrosiveWorld Class Instruction BulletinInstruction Bulletin REPLACEMENT PARTSTable A-3.Replacement Parts for Probe World ClassFigure and Index No Table A-3.Replacement Parts for Probe ContinuedWorld Class Instruction BulletinInstruction Bulletin APPENDIX B, REV. HPS 3000 HEATER POWER SUPPLYWorld Class DESCRIPTIONFRONT Figure B-2.Heater Power Supply, InteriorWorld Class Instruction BulletinInstruction Bulletin Table B-1.Specifications for Heater Power SupplyFigure B-3.Heater Power Supply Block Diagram World ClassInstruction Bulletin HPS 3000 TROUBLESHOOTINGB-4HPS 3000 TROUBLESHOOTING World ClassInstruction Bulletin SYMPTOMFigure B-4.HPS Troubleshooting Flowchart, #1 World ClassInstruction Bulletin SYMPTOMFigure B-5.HPS Troubleshooting Flowchart, #2 World ClassInstruction Bulletin SYMPTOMFigure B-6.HPS Troubleshooting Flowchart, #3 World ClassSupply Field Module. Replacement parts SERVICE AND NORMAL MAINTENANCEThis section describes service and routine maintenance of the HPS 3000 Heater PowerB-9DAUGHTER BOARD REPLACEMENT World ClassInstruction Bulletin B-10Appendices Figure B-7.Heater Power Supply, Exploded ViewWorld Class Instruction BulletinLEGEND FOR FIGURE B-7 REPLACEMENT PARTSWorld Class Instruction BulletinWorld Class Instruction BulletinB-12Appendices DESCRIPTION APPENDIX D, REVMPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER World ClassWorld Class Instruction BulletinAppendix D Rev. 2.5 May Appendices D-3 World ClassInstruction Bulletin Figure D-3.Typical Automatic Calibration SystemREAR VIEW World ClassInstruction Bulletin BEBCO MODEL Z-PURGESYMPTOM MPS 3000 TROUBLESHOOTINGD-4TROUBLESHOOTING Table D-2.Fault FindingInstruction Bulletin SYMPTOMFigure D-5.MPS Troubleshooting Flowchart World ClassD-7POWER SUPPLY REPLACEMENT SERVICE AND NORMAL MAINTENANCED-6FUSE REPLACEMENT SOLENOID VALVE REPLACEMENTWorld Class Instruction BulletinD-8Appendices Instruction Bulletin D-9PRESSURE REGULATOR MAINTENANCEPressure Adjustments World ClassD-11ADDING PROBES TO THE MPS D-10FLOWMETER ADJUSTMENTSWorld Class Instruction BulletinFIGURE and REPLACEMENT PARTSWorld Class Instruction BulletinWorld Class Instruction BulletinD-12Appendices IFT 3000 INTELLIGENT FIELD TRANSMITTER APPENDIX E, REV.c.Power Supply Board World ClassE-2THEORY OF OPERATION World ClassInstruction Bulletin f.Z-PurgeoptionalInstruction Bulletin HEATER POWER SUPPLY OPTIONAL IFTFigure E-2.System Block Diagram World ClassInstruction Bulletin IFT 3000 TROUBLESHOOTINGE-4IFT TROUBLESHOOTING World ClassAppendices E-5 Figure E-3.IFT Troubleshooting Flowchart, #1World Class Instruction BulletinFigure E-5.IFT Troubleshooting Flowchart, #3 SYMPTOM - MICROPROCESSOR BOARD LED IS STEADY ONFigure E-4.IFT Troubleshooting Flowchart, #2 SYMPTOM - GENERAL USER INTERFACE ORInstruction Bulletin Table E-2.GUI Equipped IFT Fault FindingSYMPTOM World ClassWorld Class Instruction Bulletin1.Captive Screw 2.Enclosure Cover Instruction Bulletin SERVICE AND NORMAL MAINTENANCEE-6REMOVE POWER AND OPEN COVER World ClassExploded View Figure E-7.Microprocessor Assembly –World Class Instruction BulletinE-9REPLACE MICROPROCESSOR BOARD E-12REPLACE POWER SUPPLY BOARDWorld Class Instruction BulletinWorld Class Instruction BulletinFigure E-8.Electronics Chassis – Exploded View Instruction Bulletin E-15INSTALL ELECTRONICS CHASSISE-14REPLACE HEATER AND THERMOSWITCH World ClassWorld Class Figure E-9.Electronics Chassis Installation25.Microprocessor Assembly 26.Protective Cover 27.Captive Screw 28.Power Supply BoardWorld Class E-16REPLACE GUI ASSEMBLY ORE-17CLOSE COVER AND RESTORE POWER Figure E-10.Replacing the GUI AssemblyFIGURE and INDEX No REPLACEMENT PARTSWorld Class Instruction BulletinWorld Class APPENDIX J, REV HART COMMUNICATOR MODEL 275/375IFT 3000 APPLICATIONS J-1COMPONENT CHECKLIST OF TYPICALFunctional Specifications J-3SPECIFICATIONSTable J-1.HART Communicator Specifications Physical SpecificationsInstruction Bulletin INSTALLATIONJ-4HART COMMUNICATOR SIGNAL LINE CONNECTIONS World ClassHART COMMUNICATOR PC CONNECTIONS World ClassInstruction Bulletin b.Method 2, For Load Resistance < 250 OhmsWorld Class Instruction BulletinAppendices J-5 J-6 OFF-LINEAND ON-LINEOPERATIONS OPERATIONWorld Class Instruction BulletinWorld Class Instruction BulletinAppendices J-7 World Class Instruction BulletinJ-8Appendices World Class Instruction BulletinAppendices J-9 Instruction Bulletin TROUBLESHOOTINGJ-9TROUBLESHOOTING FLOWCHART World ClassWorld Class Instruction BulletinAppendices J-11 World Class Instruction BulletinJ-12Appendices RETURNING EQUIPMENT TO THE FACTORY World ClassInstruction Bulletin World Class Instruction BulletinJ-14Appendices World Class SECTION INDEXInstruction Manual World Class3656 3784/5-05 ROSEMOUNT ANALYTICAL WARRANTYWorld Class Instruction ManualWorld Class 3000 Probe

GROUP

PART NO.

CODE

Figure A-15. Bypass Probe Option (Sheet 3 of 3)