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