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Emerson 3000 instruction manual Troubleshooting, World Class, Instruction Bulletin, J-8OVERVIEW

Models: 3000

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Instruction Bulletin

Appendix J Rev. 1.2 May 2005

World Class 3000

TROUBLESHOOTING

J-8 OVERVIEW	used. If the HART Communicator model num-
	ber is correct, and if it is properly assembled,
If the HART Communicator fails to function	the troubleshooting flowchart, Figure J-5, may
properly, verify that the unit's battery pack and	be useful to find and correct problems.
memory module are correctly assembled to the	J-9 TROUBLESHOOTING FLOWCHART.
communicator. Check the communicator's	J-9 TROUBLESHOOTING FLOWCHART.
model number. For IFT applications, HART
Communicator model number 275D9E must be	Refer to Figure J-5.

J-10 Appendices

Rosemount Analytical Inc. A Division of Emerson Process Management

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Emerson 3000 Troubleshooting, World Class, Instruction Bulletin, J-8OVERVIEW, J-9TROUBLESHOOTING FLOWCHART

Contents

Oxygen Analyzer with IFT 3000 Intelligent Field TransmitterInstruction Manual World ClassREAD THIS PAGE BEFORE PROCEEDING ESSENTIAL INSTRUCTIONSHIGHLIGHTS OF CHANGES Effective May, 1999 Rev.Page SummaryHIGHLIGHTS OF CHANGES CONTINUED Effective May, 2005 Rev.Page SummaryAPPENDIX A HIGHLIGHTS OF CHANGESEffective May, 1996 Rev. PageHIGHLIGHTS OF CHANGES CONTINUED Effective November, 2001 Rev.Page SummaryAPPENDIX B HIGHLIGHTS OF CHANGESEffective February, 1992 Rev. PagePage APPENDIX D HIGHLIGHTS OF CHANGESEffective June, 1994 Rev. PageHIGHLIGHTS OF CHANGES CONTINUED Effective July, 1998 Rev.Page SummaryAPPENDIX E HIGHLIGHTS OF CHANGESEffective May, 1996 Rev. PageRevised Electrical Noise specifications figuration. Revised replacement parts listHIGHLIGHTS OF CHANGES CONTINUED Effective May, 2005 Rev.APPENDIX J HIGHLIGHTS OF CHANGESEffective April, 1995 Rev. PagePage TABLE OF CONTENTS World ClassSETUP Instruction ManualInstruction Manual LIST OF ILLUSTRATIONSWorld Class Instruction Manual LIST OF TABLESWorld Class World Class Instruction ManualPREFACE DEFINITIONSNOTE TO USERS World ClassSAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUSWorld Class Instruction ManualGLOSSARY OF TERMS World ClassInstruction Manual Abrasive ShieldWorld Class Instruction ManualReference Air Semiautomatic CalibrationWHAT YOU NEED TO KNOW IFT 3000 INTELLIGENT FIELD TRANSMITTERWITH WORLD CLASS 3000 PROBE World ClassQUICK START GUIDE World ClassInstruction Manual Use this Quick Start Guide ifInstruction Manual QUICK START GUIDE FOR IFT 3000 SYSTEMSWorld Class LINE VOLTAGE JUMPER SECTION INSTALL 100 V.A.C. JM3, JM7, JM2 120 V.A.C. JM8, JM7, JM1220 V.A.C. JM6, JM5, JM2 240 V.A.C. JM6, JM5, JM1 PROBE JUNCTION BOX WIRINGQUICK REFERENCE GUIDE IFT 3000 INTELLIGENT FIELD TRANSMITTERSetting up the Analog Output World ClassHART COMMUNICATOR FAST KEY SEQUENCES World ClassInstruction Manual Technical Support HotlineSECTION DESCRIPTION AND SPECIFICATIONS 1-1COMPONENT CHECKLIST OF TYPICALSYSTEM PACKAGE CONTENTS World ClassWorld Class Instruction Manual1-2SYSTEM OVERVIEW a.Scope b.System Descriptionc.System Configuration d.System FeaturesWorld Class Instruction ManualWorld Class Instruction Manuale. Handling the Oxygen Analyzer f.System ConsiderationsFigure 1-2.Typical System Installation World ClassInstruction Manual STANDARD1-6Description and Specifications World ClassInstruction Manual Termination inIB-106-300NHRev. 4.3 May World ClassInstruction Manual Instruction Manual 1-8Description and SpecificationsWorld Class SECTION INSTALLATION 2-1OXYGEN ANALYZER PROBE INSTALLATIONb.Mechanical Installation World ClassFigure 2-1.Probe Installation Sheet 1 of World ClassInstruction Manual BOTTOM VIEWInstruction Manual Figure 2-1.Probe Installation Sheet 2 ofWorld Class Figure 2-1.Probe Installation Sheet 3 of 2-4InstallationWorld Class Instruction ManualINSTALLATION FOR METAL WALL STACK OR DUCT INSTALLATION FOR MASONRY WALL STACK CONSTRUCTIONCONSTRUCTION Figure 2-1.Probe Installation Sheet 4 ofFigure 2-1.Probe Installation Sheet 5 of 2-6InstallationWorld Class Instruction ManualProbe Installation World ClassInstruction Manual Figure 2-2.Orienting the Optional Vee Deflectord.Service Required World ClassInstruction Manual c.Reference Air Package2-2INTELLIGENT FIELD TRANSMITTER IFT INSTALLATION a.Mechanical InstallationWorld Class Instruction ManualIB-106-300NHRev. 4.3 May World ClassInstruction Manual Figure 2-6.IFT Power Supply Board Jumpers InstallationWorld Class Instruction Manual2-12Installation BOX WIRINGWorld Class Instruction ManualSwitch SW3 Jumper Configuration2-3HEATER POWER SUPPLY INSTALLATION Mechanical InstallationSELECTOR SWITCH 2-14InstallationWorld Class Instruction ManualWorld Class Instruction ManualOUTPUT JUMPERFigure 2-12.Outline of Heater Power Supply World ClassInstruction Manual NEMAJ8 + - + World ClassInstruction Manual WORLD CLASS PROBE2-18Installation World ClassInstruction Manual INTELLIGENT FIELD TRANSMITTER IFTInstallation World ClassInstruction Manual FRONTWorld Class Instruction ManualFigure 2-15.Jumper Selection Label Figure 2-16.Jumpers on HPS Mother BoardAnalytical SEQUENCER INSTALLATION a.Mechanical InstallationWorld Class Instruction ManualWorld Class Instruction Manualc.Electrical Connections Figure 2-18.MPS Gas ConnectionsFigure 2-19.MPS Probe Wiring World ClassInstruction Manual PROBEInstruction Manual 2-24InstallationWorld Class SECTION SETUP 3-2CONFIGURING THE ANALOG OUTPUT3-3SETTING CALIBRATION PARAMETERS World Class3-4SETTING THE O2 ALARM SETPOINTS 3-5CONFIGURING EFFICIENCY CALCULATIONS3-6CONFIGURING THE RELAY OUTPUTS World ClassSECTION 4 CALIBRATION World ClassInstruction Manual 4-1ANALOG OUTPUT CALIBRATIONWorld Class Instruction Manual2. Calibration Methods c.Manual Semiautomatic CalibrationIB-106-300NHRev. 4.3 May World ClassInstruction Manual Instruction Manual Figure 4-1.Typical Calibration SetupWorld Class World Class Instruction ManualFigure 4-2.Portable Rosemount Analytical Oxygen Calibration Gas KitFigure 4-3.Typical Portable Calibration Setup d.Manual Semiautomatic Calibration ProcedureWorld Class Instruction ManualFigure 4-4.Typical Automatic Calibration System World ClassInstruction Manual Table 4-1.Automatic Calibration Parameters World ClassInstruction Manual Probe Location Date Placed Into Service Calibration Record ForRosemount Analytical In Situ O2 Probe Probe Serial Number Probe Tag Number4-10Calibration World ClassInstruction Manual SECTION GENERAL USER INTERFACE GUI OPERATION World ClassInstruction Manual 5-1OVERVIEWWorld Class Instruction Manual5-2DELUXE VERSION IFT DISPLAYS AND CONTROLS INTERNAL VIEWPress ENTER key to access DATA menu SETUPThe SETUP menu is used to configure the IFT 5-5QUICK REFERENCE CHART5-9SETUP SUB-MENU World ClassInstruction Manual 5-8CALIBRATE O2 SUB-MENUInstruction Manual Figure 5-2.Quick Reference Chart Sheet 1 ofWorld Class Figure 5-2.Quick Reference Chart Sheet 2 of World ClassInstruction Manual 5-6General User Interface GUI OperationFigure 5-2.Quick Reference Chart Sheet 3 of CONTINUED FROM SHEET SETUP COUNTRYSOURCE AOUT TYPE RANGE SETUP USA GBR FRA ESP GER World ClassFigure 5-2.Quick Reference Chart Sheet 4 of World ClassInstruction Manual 5-8General User Interface GUI OperationFigure 5-2.Quick Reference Chart Sheet 5 of World ClassInstruction Manual CONTINUED FROM SHEETSETUP SETTING World ClassInstruction Manual Table 5-4.CALIBRATE O2 Sub-MenuSETUP SETTING World ClassInstruction Manual Table 5-4.CALIBRATE O2 Sub-MenucontinuedTable 5-5.SETUP Sub-Menu World ClassInstruction Manual SUB-MENUTable 5-5.SETUP Sub-Menucontinued selected in the SETUP sub-menuWorld Class Instruction ManualTable 5-5.SETUP Sub-Menucontinued Dual Range SetupWorld Class Instruction ManualSECTION TROUBLESHOOTING 6-2SPECIAL TROUBLESHOOTING NOTES a.Grounding6-3SYSTEM TROUBLESHOOTING World ClassTable 6-1.IFT Status Codes World ClassInstruction Manual 6-4HEATER PROBLEM Table 6-2.Heater Troubleshooting ProblemWorld Class Instruction ManualTable 6-2.Heater Troubleshooting continued ProblemWorld Class Instruction Manual6-5CELL PROBLEM Table 6-3.Cell Troubleshooting ProblemWorld Class Instruction ManualTable 6-3.Cell Troubleshooting continued Problem World ClassInstruction Manual Status is ResHi or CalEr6-6IFT PROBLEM Table 6-4.IFT Troubleshooting ProblemFaulty GUI or LDP IFT LED is Flashing World Class6-7MPS PROBLEM Table 6-5.MPS Troubleshooting ProblemWorld Class Instruction ManualTable 6-6.Performance Problem Troubleshooting ProblemWorld 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 Instruction Bulletin World ClassAPPENDIX A Figure A-1.Oxygen Analyzer Probe Exploded ViewAPPENDIX A, REV. WORLD CLASS 3000 OXYGEN ANALYZER PROBEDESCRIPTION World ClassAppendix A Rev. 3.9 May World ClassInstruction Bulletin A-2PROBE ASSEMBLY EXTERIOR a.Cell and Flange Assemblyb.Probe Tube Assembly c.Snubber Diffusion AssemblyA-3INNER PROBE ASSEMBLY Figure A-5.Inner Probe AssemblyWorld Class Instruction BulletinA-5CABLE ASSEMBLY A-6PROBE OPTIONS a.Abrasive Shield AssemblyWorld Class Instruction BulletinInstruction Bulletin Figure A-7.Abrasive Shield AssemblyWorld Class Figure A-8.Ceramic Diffusion/Dust Seal Assembly b.Ceramic Diffusion AssemblyFigure A-10.Ceramic Diffusion Assembly c.Flame Arrestor Diffusion Assemblyd.Snubber Diffusion/Dust Seal Assembly Figure A-12.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 World Class Instruction BulletinFigure A-15.Bypass Probe Option Sheet 2 of A-10AppendicesWorld Class Instruction BulletinGROUP PART NOPROBE TROUBLESHOOTING A-8PROBE TROUBLESHOOTING a.Probe FaultsTable A-2.Fault Finding SymptomTable A-2.Fault Finding Continued SymptomFault World ClassA-14Appendices World ClassInstruction Bulletin Appendices A-15 World ClassInstruction Bulletin SERVICE AND NORMAL MAINTENANCE A-11CELL REPLACEMENTWorld Class Instruction BulletinInstruction Bulletin Figure A-18.Cell Wiring ConnectionWorld Class Figure A-20.Cell Replacement Kit ELEMENT REPLACEMENT a.GeneralWorld Class Instruction BulletinInstruction Bulletin b.Replacement ProcedureWorld Class A-13REPLACEMENT OF CONTACT AND THERMOCOUPLE ASSEMBLYWorld Class Instruction BulletinFigure A-23.Heater, Strut, and Backplate Assembly Inner Probe AssemblyWorld Class Instruction BulletinAppendix A Rev. 3.9 May World ClassInstruction Bulletin a. Installation Procedure World ClassInstruction Bulletin A-15CALIBRATION GAS AND REFERENCE AIRFigure A-25.High Temperature - Corrosive World ClassInstruction Bulletin Environment KitREPLACEMENT PARTS Table A-3.Replacement Parts for ProbeWorld Class Instruction BulletinTable A-3.Replacement Parts for Probe Continued World ClassInstruction Bulletin Figure and Index NoAPPENDIX B, REV. HPS 3000 HEATER POWER SUPPLY World ClassDESCRIPTION Instruction BulletinFigure B-2.Heater Power Supply, Interior World ClassInstruction Bulletin FRONTTable B-1.Specifications for Heater Power Supply Figure B-3.Heater Power Supply Block DiagramWorld Class Instruction BulletinHPS 3000 TROUBLESHOOTING B-4HPS 3000 TROUBLESHOOTINGWorld Class Instruction BulletinSYMPTOM Figure B-4.HPS Troubleshooting Flowchart, #1World Class Instruction BulletinSYMPTOM Figure B-5.HPS Troubleshooting Flowchart, #2World Class Instruction BulletinSYMPTOM Figure B-6.HPS Troubleshooting Flowchart, #3World Class Instruction BulletinSERVICE AND NORMAL MAINTENANCE This section describes service and routinemaintenance of the HPS 3000 Heater Power Supply Field Module. Replacement partsInstruction Bulletin B-9DAUGHTER BOARD REPLACEMENTWorld Class Figure B-7.Heater Power Supply, Exploded View World ClassInstruction Bulletin B-10AppendicesREPLACEMENT PARTS World ClassInstruction Bulletin LEGEND FOR FIGURE B-7B-12Appendices World ClassInstruction Bulletin APPENDIX D, REV MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCERWorld Class DESCRIPTIONAppendix D Rev. 2.5 May World ClassInstruction Bulletin World Class Instruction BulletinFigure D-3.Typical Automatic Calibration System Appendices D-3World Class Instruction BulletinBEBCO MODEL Z-PURGE REAR VIEWMPS 3000 TROUBLESHOOTING D-4TROUBLESHOOTINGTable D-2.Fault Finding SYMPTOMSYMPTOM Figure D-5.MPS Troubleshooting FlowchartWorld Class Instruction BulletinSERVICE AND NORMAL MAINTENANCE D-6FUSE REPLACEMENTSOLENOID VALVE REPLACEMENT D-7POWER SUPPLY REPLACEMENTD-8Appendices World ClassInstruction Bulletin D-9PRESSURE REGULATOR MAINTENANCE Pressure AdjustmentsWorld Class Instruction BulletinD-10FLOWMETER ADJUSTMENTS World ClassInstruction Bulletin D-11ADDING PROBES TO THE MPSREPLACEMENT PARTS World ClassInstruction Bulletin FIGURE andD-12Appendices World ClassInstruction Bulletin APPENDIX E, REV. c.Power Supply BoardWorld Class IFT 3000 INTELLIGENT FIELD TRANSMITTERWorld Class Instruction Bulletinf.Z-Purgeoptional E-2THEORY OF OPERATIONHEATER POWER SUPPLY OPTIONAL IFT Figure E-2.System Block DiagramWorld Class Instruction BulletinIFT 3000 TROUBLESHOOTING E-4IFT TROUBLESHOOTINGWorld Class Instruction BulletinFigure E-3.IFT Troubleshooting Flowchart, #1 World ClassInstruction Bulletin Appendices E-5SYMPTOM - MICROPROCESSOR BOARD LED IS STEADY ON Figure E-4.IFT Troubleshooting Flowchart, #2SYMPTOM - GENERAL USER INTERFACE OR Figure E-5.IFT Troubleshooting Flowchart, #3Table E-2.GUI Equipped IFT Fault Finding SYMPTOMWorld Class Instruction Bulletin1.Captive Screw 2.Enclosure Cover World ClassInstruction Bulletin SERVICE AND NORMAL MAINTENANCE E-6REMOVE POWER AND OPEN COVERWorld Class Instruction BulletinFigure E-7.Microprocessor Assembly – World ClassInstruction Bulletin Exploded ViewE-12REPLACE POWER SUPPLY BOARD World ClassInstruction Bulletin E-9REPLACE MICROPROCESSOR BOARDFigure E-8.Electronics Chassis – Exploded View World ClassInstruction Bulletin E-15INSTALL ELECTRONICS CHASSIS E-14REPLACE HEATER AND THERMOSWITCHWorld Class Instruction BulletinFigure E-9.Electronics Chassis Installation 25.Microprocessor Assembly 26.Protective Cover27.Captive Screw 28.Power Supply Board World ClassE-16REPLACE GUI ASSEMBLY OR E-17CLOSE COVER AND RESTORE POWERFigure E-10.Replacing the GUI Assembly World ClassREPLACEMENT PARTS World ClassInstruction Bulletin FIGURE and INDEX NoAPPENDIX J, REV HART COMMUNICATOR MODEL 275/375 IFT 3000 APPLICATIONSJ-1COMPONENT CHECKLIST OF TYPICAL World ClassJ-3SPECIFICATIONS Table J-1.HART Communicator SpecificationsPhysical Specifications Functional SpecificationsINSTALLATION J-4HART COMMUNICATOR SIGNAL LINE CONNECTIONSWorld Class Instruction BulletinWorld Class Instruction Bulletinb.Method 2, For Load Resistance < 250 Ohms HART COMMUNICATOR PC CONNECTIONSAppendices J-5 World ClassInstruction Bulletin OPERATION World ClassInstruction Bulletin J-6 OFF-LINEAND ON-LINEOPERATIONSAppendices J-7 World ClassInstruction Bulletin J-8Appendices World ClassInstruction Bulletin Appendices J-9 World ClassInstruction Bulletin TROUBLESHOOTING J-9TROUBLESHOOTING FLOWCHARTWorld 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 SECTION INDEX World ClassWorld Class Instruction ManualROSEMOUNT ANALYTICAL WARRANTY 3656 3784/5-05World Class 3000 Probe World ClassInstruction Manual

TROUBLESHOOTING

J-8 OVERVIEW

J-9 TROUBLESHOOTING FLOWCHART.