World Class
Essential Instructions
Effective May, 1999 Rev
Highlights of Changes
Summary
Effective November, 2001 Rev
Effective May, 2005 Rev
Appendix a
Effective July, 2002 Rev
Appendix B
Effective February, 1992 Rev
Effective January, 1995 Rev
Page
Effective June, 1994 Rev
Appendix D
Revised view of check valve in Figure D-3
Effective June, 1999 Rev
Appendix E
Figuration. Revised replacement parts list
Appendix J
Effective April, 1995 Rev
Effective June, 1995 Rev
Page
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Table of Contents
List of Illustrations
Calibrate O2 Sub-Menu
List of Tables
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Definitions
Preface
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Glossary of Terms
Semiautomatic Calibration
Reference Air
Thermocouple
Vee Deflector
Complete World Class 3000 System
What YOU Need to Know
Use this Quick Start Guide if
Quick Start Guide
Quick Start Guide for IFT 3000 Systems
Line Voltage Jumper Section Install
Performing a Manual Semiautomatic Calibration
Setting up the Analog Output
Technical Support Hotline
Hart Communicator Fast KEY Sequences
Component Checklist of Typical System Package Contents
Section Description and Specifications
System Overview
Scope
System Description
System Features
System Configuration
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Standard
HPS
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Section Installation
Oxygen Analyzer Probe Installation
Selecting Location
Probe Installation Sheet 1
Probe Installation Sheet 2
Probe Installation Sheet 3
Probe Installation Sheet 4
Probe Installation Sheet 5
Orienting the Optional Vee Deflector
Reference Air Package
Service Required
Electrical Connections
Intelligent Field Transmitter IFT Installation
Power Supply Board Jumper Configuration
IFT Power Supply Board Jumpers
Wiring Layout for IFT Systems without HPS
Jumper Configuration
Condition during Microcontroller failure Switch SW3
Heater Power Supply Installation
Output Jumper
IFT Microprocessor Board
10. Interconnect Board Jumper Configuration
Refer to -16 for fuse locations and specifications
12. Outline of Heater Power Supply Electrical Connections
J8 + +
Conductor
14. Heater Power Supply Wiring Connections
16. Jumpers on HPS Mother Board
Gas Connections
Multiprobe Calibration GAS Sequencer Installation
18. MPS Gas Connections
Refer to -19 for fuse locations and specifications
19. MPS Probe Wiring
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Configuring the Analog Output
Section Setup
Setting Calibration Parameters
Overview
Setting the O2 Alarm Setpoints
Configuring Efficiency Calculations
Configuring the Relay Outputs
Analog Output Calibration
Calibration
System Calibration
Overview
Liquid Carbonic GAS Corp Specialty GAS Laboratories
Calibration Methods
Scott Environmental TECHNOLOGY, INC. Scott Specialty Gases
% O
Portable Rosemount Analytical Oxygen Calibration Gas Kit
Fully Automatic Calibration
Typical Automatic Calibration System
Figure analog output
Automatic Calibration Parameters
Calibration Record For Rosemount Analytical In Situ O2 Probe
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Hart Communicator Interface Devices
Section General User Interface GUI Operation
Index No Control/LED Description
Deluxe Version IFT Displays and Controls
MENU, SUB-MENU, Help Or Parameter Name Message Probe Data
Quick Reference Chart
Calibrate O2
Help KEY
Calibrate O2 SUB-MENU Setup SUB-MENU
Probe Data Sub-Menu
SUB-MENU Selection Parameter Description
Quick Reference Chart Sheet 1
Quick Reference Chart Sheet 2
Quick Reference Chart Sheet 3
Quick Reference Chart Sheet 4
Quick Reference Chart Sheet 5
Calibrate O2 Sub-Menu
XD XH
SUB-MENU Selection Parameters Description
Setup Sub-Menu
Selected in the Setup sub-menu
Xfer Fnct
Range Values
Normal Range Values
Dual Range Setup
Efficiency Constants
Constant United States Europe GAS OIL
Section Troubleshooting
Special Troubleshooting Notes
System Troubleshooting
IFT Status Codes
Heater Troubleshooting Problem
Heater Problem
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Cell Troubleshooting Problem
Cell Problem
Status is LowO2 Cell mV = -127 mV
Status is ResHi or CalEr Cell mV = -20 to 120 mV normal
Status is Res Hi Cell mV = -120 to 20 mV
IFT Problem
IFT Troubleshooting Problem
Faulty GUI or LDP IFT LED is Flashing
MPS Troubleshooting Problem
MPS Problem
Status is NoGas Cell mV is between -20 to 120 mV
Status is ResHi or CalEr Cell mV is between -20 to 120 mV
Performance Problem Troubleshooting
Performance Problem Process Response is Suspect
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Section Return of Material
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Section Appendices
Appendix a
Figure A-2. Main Probe Components
Oxygen Analyzer Probe General
Table A-1. Specifications for Oxygen Analyzing Equipment.1
Probe Assembly Exterior
Cell and Flange Assembly
Probe Tube Assembly
Cell General
Inner Probe Assembly
Abrasive Shield Assembly
Cable Assembly
Probe Junction BOX
Probe Options
View a
Ceramic Diffusion Assembly
Figure A-8. Ceramic Diffusion/Dust Seal Assembly
Probe Mounting Jacket Options
Snubber Diffusion/Dust Seal Assembly
Figure A-15. Bypass Probe Option Sheet 1
Figure A-15. Bypass Probe Option Sheet 2
Group Code Description
Extended Temperature By-Pass Arrangements 2400F 1300C
Probe Troubleshooting
Probe Troubleshooting
Probe Faults
Table A-2. Fault Finding Symptom Check Remedy
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Figure A-16. Flowchart of Probe Related Problems, #1
Figure A-17. Flowchart of Probe Related Problems, #2
Service and Normal Maintenance
Cell Replacement
Probe Recalibration
Figure A-18. Cell Wiring Connection
General
Optional Ceramic Diffusion Element Replacement
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Figure A-21. Probe Junction Box Mechanical Connections
Replacement of Contact Thermocouple Assembly
Contact Heater Screws Not Shown Thermocoupler
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Figure A-24. Oxygen Analyzer Probe, Cross-Sectional View
Figure A-25. High Temperature Corrosive Environment Kit
Index No
Replacement Parts
Figure A-9
Figure B-1. HPS 3000 Heater Power Supply Field Module
Appendix B, REV HPS 3000 Heater Power Supply Description
Front
Theory of Operation
Table B-1. Specifications for Heater Power Supply
Overview HPS 3000 Troubleshooting
HPS 3000 Troubleshooting
Symptom
Figure B-5. HPS Troubleshooting Flowchart, #2
Figure B-6. HPS Troubleshooting Flowchart, #3
Fuse Replacement
Transformer Replacement
Mother Board Replacement
Daughter Board Replacement
Figure B-7. Heater Power Supply, Exploded View
Part Number Description
Table B-2. Replacement Parts for Heater Power Supply
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Figure D-1. MPS 3000 Multiprobe Calibration Gas Sequencer
20 to 160F -30 to 71C
Figure D-3. Typical Automatic Calibration System
Bebco Model Z-PURGE Rear View
Troubleshooting
MPS 3000 Troubleshooting
Table D-2. Fault Finding
Symptom Check Fault Remedy
Figure D-5. MPS Troubleshooting Flowchart
Power Supply Replacement
Solenoid Valve Replacement
4543
Pressure Regulator Maintenance
Pressure Adjustments
Condensation Drain
Adding Probes to the MPS
Flowmeter Adjustments
Figure D-6 1A97909H01 Power Supply
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Interconnect Board
Power Supply Board
GUI/LED Display Board
Heater optional
Purge optional
Table E-1. Specifications for Intelligent Field Transmitter
Heater Power Supply Optional IFT
IFT Troubleshooting
IFT 3000 Troubleshooting
Microprocessor Status LED
Equipment Status LCD Displays
Figure E-3. IFT Troubleshooting Flowchart, #1
Symptom Microprocessor Board LED is Steady on
Symptom Component Failure
Table E-2. GUI Equipped IFT Fault Finding
Figure E-6. Intelligent Field Transmitter, Exploded View
Remove Power and Open Cover
Replace Fuse
Remove Electronics Chassis from Enclosure
Figure E-7. Microprocessor Assembly Exploded View
Replace Microprocessor Board
Replace Power Supply Board
Replace Interconnect Board
Replace FAN
Figure E-8. Electronics Chassis Exploded View
Install Electronics Chassis
Replace Heater and Thermoswitch
Replace Transformer
Figure E-9. Electronics Chassis Installation
Replace GUI Assembly or
Close Cover and Restore Power
Ribbon Cable
Figure E-8 1N04946G01 Transformer
Figure J-1. Typical Hart Communicator Package, Model 275D9E
Specifications
Method 1, For Load Resistance 250 Ohms
Hart Communicator Signal Line Connections
Hart Communicator PC Connections
Load Resistor See Note Hart Communicator
OFF-LINE and ON-LINE Operations
Operation
Menu Tree for Hart Communicator
World Class 3000 IFT Applications
Figure J-4. Menu Tree for IFT 3000 Applications Sheet 1
Figure J-4. Menu Tree for IFT 3000 Applications Sheet 2
Figure J-4. Menu Tree for IFT 3000 Applications Sheet 3
Troubleshooting Flowchart
Figure J-5. Model 275D9E, Troubleshooting Flowchart Sheet 1
Figure J-5. Model 275D9E, Troubleshooting Flowchart Sheet 2
Returning Equipment to the Factory
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Section Index
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Rosemount Analytical Warranty
World Class 3000 Probe HPS Serial No Order No IFT MPS