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Emerson 3000 World Class, Instruction Manual, Reference Air, Semiautomatic Calibration

Models: 3000

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Instruction Manual

IB-106-300NH Rev. 4.3 May 2005

World Class 3000

Reference Air

Provides a known oxygen concentration to the reference side of the oxygen sensing cell.

Semiautomatic Calibration

Semiautomatic calibration is performed when the system does not include an MPS 3000 Multi- probe Calibration Gas Sequencer. The IFT 3000 provides prompts to direct the user to switch calibration gases when performing the calibration.

Thermocouple

An electrical device made of two dissimilar metals. A thermocouple develops a millivolt signal proportional to its temperature.

Vee Deflector

Protects the optional ceramic diffusor from the process gases. The vee deflector must be posi- tioned so it points toward the direction of the process gas flow. See Figure 2-2 for an illustration of the vee deflector.

P-4	Rosemount Analytical Inc. A Division of Emerson Process Management

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Emerson 3000 World Class, Instruction Manual, Reference Air, Semiautomatic Calibration, Thermocouple, Vee Deflector

Contents

Instruction Manual Oxygen Analyzerwith IFT 3000 Intelligent Field Transmitter World ClassREAD THIS PAGE BEFORE PROCEEDING ESSENTIAL INSTRUCTIONSPage HIGHLIGHTS OF CHANGESEffective May, 1999 Rev. SummaryPage HIGHLIGHTS OF CHANGES CONTINUEDEffective May, 2005 Rev. SummaryEffective May, 1996 Rev. APPENDIX AHIGHLIGHTS OF CHANGES PagePage HIGHLIGHTS OF CHANGES CONTINUEDEffective November, 2001 Rev. SummaryEffective February, 1992 Rev. APPENDIX BHIGHLIGHTS OF CHANGES PagePage Effective June, 1994 Rev. APPENDIX DHIGHLIGHTS OF CHANGES PagePage HIGHLIGHTS OF CHANGES CONTINUEDEffective July, 1998 Rev. SummaryEffective May, 1996 Rev. APPENDIX EHIGHLIGHTS OF CHANGES PageHIGHLIGHTS OF CHANGES CONTINUED Revised Electrical Noise specificationsfiguration. Revised replacement parts list Effective May, 2005 Rev.Effective April, 1995 Rev. APPENDIX JHIGHLIGHTS OF CHANGES PagePage SETUP TABLE OF CONTENTSWorld Class Instruction ManualWorld Class LIST OF ILLUSTRATIONSInstruction Manual World Class LIST OF TABLESInstruction Manual World Class Instruction ManualNOTE TO USERS PREFACEDEFINITIONS World ClassWorld Class SAFETY INSTRUCTIONSFOR THE WIRING AND INSTALLATION OF THIS APPARATUS Instruction ManualInstruction Manual GLOSSARY OF TERMSWorld Class Abrasive ShieldReference Air World ClassInstruction Manual Semiautomatic CalibrationWITH WORLD CLASS 3000 PROBE WHAT YOU NEED TO KNOWIFT 3000 INTELLIGENT FIELD TRANSMITTER World ClassInstruction Manual QUICK START GUIDEWorld Class Use this Quick Start Guide ifWorld Class QUICK START GUIDE FOR IFT 3000 SYSTEMSInstruction Manual 220 V.A.C. JM6, JM5, JM2 240 V.A.C. JM6, JM5, JM1 LINE VOLTAGE JUMPER SECTION INSTALL100 V.A.C. JM3, JM7, JM2 120 V.A.C. JM8, JM7, JM1 PROBE JUNCTION BOX WIRINGSetting up the Analog Output QUICK REFERENCE GUIDEIFT 3000 INTELLIGENT FIELD TRANSMITTER World ClassInstruction Manual HART COMMUNICATOR FAST KEY SEQUENCESWorld Class Technical Support HotlineSYSTEM PACKAGE CONTENTS SECTION DESCRIPTION AND SPECIFICATIONS1-1COMPONENT CHECKLIST OF TYPICAL World Class1-2SYSTEM OVERVIEW a.Scope World ClassInstruction Manual b.System DescriptionWorld Class c.System Configurationd.System Features Instruction Manuale. Handling the Oxygen Analyzer World ClassInstruction Manual f.System ConsiderationsInstruction Manual Figure 1-2.Typical System InstallationWorld Class STANDARDInstruction Manual 1-6Description and SpecificationsWorld Class Termination inInstruction Manual World ClassIB-106-300NHRev. 4.3 May World Class 1-8Description and SpecificationsInstruction Manual b.Mechanical Installation SECTION INSTALLATION2-1OXYGEN ANALYZER PROBE INSTALLATION World ClassInstruction Manual Figure 2-1.Probe Installation Sheet 1 ofWorld Class BOTTOM VIEWWorld Class Figure 2-1.Probe Installation Sheet 2 ofInstruction Manual World Class Figure 2-1.Probe Installation Sheet 3 of2-4Installation Instruction ManualCONSTRUCTION INSTALLATION FOR METAL WALL STACK OR DUCTINSTALLATION FOR MASONRY WALL STACK CONSTRUCTION Figure 2-1.Probe Installation Sheet 4 ofWorld Class Figure 2-1.Probe Installation Sheet 5 of2-6Installation Instruction ManualInstruction Manual Probe InstallationWorld Class Figure 2-2.Orienting the Optional Vee DeflectorInstruction Manual d.Service RequiredWorld Class c.Reference Air PackageWorld Class 2-2INTELLIGENT FIELD TRANSMITTER IFT INSTALLATIONa.Mechanical Installation Instruction ManualInstruction Manual World ClassIB-106-300NHRev. 4.3 May World Class Figure 2-6.IFT Power Supply Board JumpersInstallation Instruction ManualWorld Class 2-12InstallationBOX WIRING Instruction Manual2-3HEATER POWER SUPPLY INSTALLATION Switch SW3Jumper Configuration Mechanical InstallationWorld Class SELECTOR SWITCH2-14Installation Instruction ManualOUTPUT World ClassInstruction Manual JUMPERInstruction Manual Figure 2-12.Outline of Heater Power SupplyWorld Class NEMAInstruction Manual J8 + - +World Class WORLD CLASS PROBEInstruction Manual 2-18InstallationWorld Class INTELLIGENT FIELD TRANSMITTER IFTInstruction Manual InstallationWorld Class FRONTFigure 2-15.Jumper Selection Label World ClassInstruction Manual Figure 2-16.Jumpers on HPS Mother BoardWorld Class AnalyticalSEQUENCER INSTALLATION a.Mechanical Installation Instruction Manualc.Electrical Connections World ClassInstruction Manual Figure 2-18.MPS Gas ConnectionsInstruction Manual Figure 2-19.MPS Probe WiringWorld Class PROBEWorld Class 2-24InstallationInstruction Manual 3-3SETTING CALIBRATION PARAMETERS SECTION SETUP3-2CONFIGURING THE ANALOG OUTPUT World Class3-6CONFIGURING THE RELAY OUTPUTS 3-4SETTING THE O2 ALARM SETPOINTS3-5CONFIGURING EFFICIENCY CALCULATIONS World ClassInstruction Manual SECTION 4 CALIBRATIONWorld Class 4-1ANALOG OUTPUT CALIBRATION2. Calibration Methods World ClassInstruction Manual c.Manual Semiautomatic CalibrationInstruction Manual World ClassIB-106-300NHRev. 4.3 May World Class Figure 4-1.Typical Calibration SetupInstruction Manual Figure 4-2.Portable Rosemount Analytical World ClassInstruction Manual Oxygen Calibration Gas KitWorld Class Figure 4-3.Typical Portable Calibration Setupd.Manual Semiautomatic Calibration Procedure Instruction ManualInstruction Manual World ClassFigure 4-4.Typical Automatic Calibration System Instruction Manual World ClassTable 4-1.Automatic Calibration Parameters Rosemount Analytical In Situ O2 Probe Probe Location Date Placed Into ServiceCalibration Record For Probe Serial Number Probe Tag NumberInstruction Manual World Class4-10Calibration Instruction Manual SECTION GENERAL USER INTERFACE GUI OPERATIONWorld Class 5-1OVERVIEW5-2DELUXE VERSION IFT DISPLAYS AND CONTROLS World ClassInstruction Manual INTERNAL VIEWThe SETUP menu is used to configure the IFT Press ENTER key to access DATA menuSETUP 5-5QUICK REFERENCE CHARTInstruction Manual 5-9SETUP SUB-MENUWorld Class 5-8CALIBRATE O2 SUB-MENUWorld Class Figure 5-2.Quick Reference Chart Sheet 1 ofInstruction Manual Instruction Manual Figure 5-2.Quick Reference Chart Sheet 2 ofWorld Class 5-6General User Interface GUI OperationSOURCE AOUT TYPE RANGE SETUP USA GBR FRA ESP GER Figure 5-2.Quick Reference Chart Sheet 3 ofCONTINUED FROM SHEET SETUP COUNTRY World ClassInstruction Manual Figure 5-2.Quick Reference Chart Sheet 4 ofWorld Class 5-8General User Interface GUI OperationInstruction Manual Figure 5-2.Quick Reference Chart Sheet 5 ofWorld Class CONTINUED FROM SHEETInstruction Manual SETUP SETTINGWorld Class Table 5-4.CALIBRATE O2 Sub-MenuInstruction Manual SETUP SETTINGWorld Class Table 5-4.CALIBRATE O2 Sub-MenucontinuedInstruction Manual Table 5-5.SETUP Sub-MenuWorld Class SUB-MENUWorld Class Table 5-5.SETUP Sub-Menucontinuedselected in the SETUP sub-menu Instruction ManualWorld Class Table 5-5.SETUP Sub-MenucontinuedDual Range Setup Instruction Manual6-3SYSTEM TROUBLESHOOTING SECTION TROUBLESHOOTING6-2SPECIAL TROUBLESHOOTING NOTES a.Grounding World ClassInstruction Manual World ClassTable 6-1.IFT Status Codes World Class 6-4HEATER PROBLEMTable 6-2.Heater Troubleshooting Problem Instruction ManualWorld Class Table 6-2.Heater Troubleshooting continuedProblem Instruction ManualWorld Class 6-5CELL PROBLEMTable 6-3.Cell Troubleshooting Problem Instruction ManualInstruction Manual Table 6-3.Cell Troubleshooting continued ProblemWorld Class Status is ResHi or CalErFaulty GUI or LDP IFT LED is Flashing 6-6IFT PROBLEMTable 6-4.IFT Troubleshooting Problem World ClassWorld Class 6-7MPS PROBLEMTable 6-5.MPS Troubleshooting Problem Instruction ManualWorld Class Table 6-6.Performance Problem TroubleshootingProblem Instruction ManualWorld Class 6-10TroubleshootingInstruction Manual World Class SECTION RETURN OF MATERIALInstruction Manual Instruction Manual World Class7-2Return of Material World Class SECTION APPENDICESInstruction Manual APPENDIX A Instruction BulletinWorld Class Figure A-1.Oxygen Analyzer Probe Exploded ViewDESCRIPTION APPENDIX A, REV.WORLD CLASS 3000 OXYGEN ANALYZER PROBE World ClassInstruction Bulletin World ClassAppendix A Rev. 3.9 May b.Probe Tube Assembly A-2PROBE ASSEMBLY EXTERIORa.Cell and Flange Assembly c.Snubber Diffusion AssemblyWorld Class A-3INNER PROBE ASSEMBLYFigure A-5.Inner Probe Assembly Instruction BulletinWorld Class A-5CABLE ASSEMBLYA-6PROBE OPTIONS a.Abrasive Shield Assembly Instruction BulletinWorld Class Figure A-7.Abrasive Shield AssemblyInstruction Bulletin Figure A-10.Ceramic Diffusion Assembly Figure A-8.Ceramic Diffusion/Dust Seal Assemblyb.Ceramic Diffusion Assembly c.Flame Arrestor Diffusion Assemblye.Cup-TypeDiffusion Assembly d.Snubber Diffusion/Dust Seal AssemblyFigure A-12.Snubber Diffusion/Dust Seal Assembly Figure A-13. Cup-TypeDiffusion/Dust Seal AssemblyInstruction Bulletin World ClassFigure A-15.Bypass Probe Option Sheet 1 of Figure A-15.Bypass Probe Option Sheet 2 of World ClassInstruction Bulletin A-10AppendicesGROUP World ClassInstruction Bulletin PART NOTable A-2.Fault Finding PROBE TROUBLESHOOTINGA-8PROBE TROUBLESHOOTING a.Probe Faults SymptomFault Table A-2.Fault Finding ContinuedSymptom World ClassInstruction Bulletin World ClassA-14Appendices Instruction Bulletin World ClassAppendices A-15 World Class SERVICE AND NORMAL MAINTENANCEA-11CELL REPLACEMENT Instruction BulletinWorld Class Figure A-18.Cell Wiring ConnectionInstruction Bulletin World Class Figure A-20.Cell Replacement KitELEMENT REPLACEMENT a.General Instruction BulletinWorld Class b.Replacement ProcedureInstruction Bulletin World Class A-13REPLACEMENT OF CONTACT ANDTHERMOCOUPLE ASSEMBLY Instruction BulletinWorld Class Figure A-23.Heater, Strut, and Backplate AssemblyInner Probe Assembly Instruction BulletinInstruction Bulletin World ClassAppendix A Rev. 3.9 May Instruction Bulletin a. Installation ProcedureWorld Class A-15CALIBRATION GAS AND REFERENCE AIRInstruction Bulletin Figure A-25.High Temperature - CorrosiveWorld Class Environment KitWorld Class REPLACEMENT PARTSTable A-3.Replacement Parts for Probe Instruction BulletinInstruction Bulletin Table A-3.Replacement Parts for Probe ContinuedWorld Class Figure and Index NoDESCRIPTION APPENDIX B, REV. HPS 3000 HEATER POWER SUPPLYWorld Class Instruction BulletinInstruction Bulletin Figure B-2.Heater Power Supply, InteriorWorld Class FRONTWorld Class Table B-1.Specifications for Heater Power SupplyFigure B-3.Heater Power Supply Block Diagram Instruction BulletinWorld Class HPS 3000 TROUBLESHOOTINGB-4HPS 3000 TROUBLESHOOTING Instruction BulletinWorld Class SYMPTOMFigure B-4.HPS Troubleshooting Flowchart, #1 Instruction BulletinWorld Class SYMPTOMFigure B-5.HPS Troubleshooting Flowchart, #2 Instruction BulletinWorld Class SYMPTOMFigure B-6.HPS Troubleshooting Flowchart, #3 Instruction Bulletinmaintenance of the HPS 3000 Heater Power SERVICE AND NORMAL MAINTENANCEThis section describes service and routine Supply Field Module. Replacement partsWorld Class B-9DAUGHTER BOARD REPLACEMENTInstruction Bulletin Instruction Bulletin Figure B-7.Heater Power Supply, Exploded ViewWorld Class B-10AppendicesInstruction Bulletin REPLACEMENT PARTSWorld Class LEGEND FOR FIGURE B-7Instruction Bulletin World ClassB-12Appendices World Class APPENDIX D, REVMPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER DESCRIPTIONInstruction Bulletin World ClassAppendix D Rev. 2.5 May Figure D-3.Typical Automatic Calibration System World ClassInstruction Bulletin Appendices D-3BEBCO MODEL Z-PURGE World ClassInstruction Bulletin REAR VIEWTable D-2.Fault Finding MPS 3000 TROUBLESHOOTINGD-4TROUBLESHOOTING SYMPTOMWorld Class SYMPTOMFigure D-5.MPS Troubleshooting Flowchart Instruction BulletinSOLENOID VALVE REPLACEMENT SERVICE AND NORMAL MAINTENANCED-6FUSE REPLACEMENT D-7POWER SUPPLY REPLACEMENTInstruction Bulletin World ClassD-8Appendices World Class D-9PRESSURE REGULATOR MAINTENANCEPressure Adjustments Instruction BulletinInstruction Bulletin D-10FLOWMETER ADJUSTMENTSWorld Class D-11ADDING PROBES TO THE MPSInstruction Bulletin REPLACEMENT PARTSWorld Class FIGURE andInstruction Bulletin World ClassD-12Appendices World Class APPENDIX E, REV.c.Power Supply Board IFT 3000 INTELLIGENT FIELD TRANSMITTERf.Z-Purgeoptional World ClassInstruction Bulletin E-2THEORY OF OPERATIONWorld Class HEATER POWER SUPPLY OPTIONAL IFTFigure E-2.System Block Diagram Instruction BulletinWorld Class IFT 3000 TROUBLESHOOTINGE-4IFT TROUBLESHOOTING Instruction BulletinInstruction Bulletin Figure E-3.IFT Troubleshooting Flowchart, #1World Class Appendices E-5SYMPTOM - GENERAL USER INTERFACE OR SYMPTOM - MICROPROCESSOR BOARD LED IS STEADY ONFigure E-4.IFT Troubleshooting Flowchart, #2 Figure E-5.IFT Troubleshooting Flowchart, #3World Class Table E-2.GUI Equipped IFT Fault FindingSYMPTOM Instruction BulletinInstruction Bulletin World Class1.Captive Screw 2.Enclosure Cover World Class SERVICE AND NORMAL MAINTENANCEE-6REMOVE POWER AND OPEN COVER Instruction BulletinInstruction Bulletin Figure E-7.Microprocessor Assembly –World Class Exploded ViewInstruction Bulletin E-12REPLACE POWER SUPPLY BOARDWorld Class E-9REPLACE MICROPROCESSOR BOARDInstruction Bulletin World ClassFigure E-8.Electronics Chassis – Exploded View World Class E-15INSTALL ELECTRONICS CHASSISE-14REPLACE HEATER AND THERMOSWITCH Instruction Bulletin27.Captive Screw 28.Power Supply Board Figure E-9.Electronics Chassis Installation25.Microprocessor Assembly 26.Protective Cover World ClassFigure E-10.Replacing the GUI Assembly E-16REPLACE GUI ASSEMBLY ORE-17CLOSE COVER AND RESTORE POWER World ClassInstruction Bulletin REPLACEMENT PARTSWorld Class FIGURE and INDEX NoJ-1COMPONENT CHECKLIST OF TYPICAL APPENDIX J, REV HART COMMUNICATOR MODEL 275/375IFT 3000 APPLICATIONS World ClassPhysical Specifications J-3SPECIFICATIONSTable J-1.HART Communicator Specifications Functional SpecificationsWorld Class INSTALLATIONJ-4HART COMMUNICATOR SIGNAL LINE CONNECTIONS Instruction Bulletinb.Method 2, For Load Resistance < 250 Ohms World ClassInstruction Bulletin HART COMMUNICATOR PC CONNECTIONSInstruction Bulletin World ClassAppendices J-5 Instruction Bulletin OPERATIONWorld Class J-6 OFF-LINEAND ON-LINEOPERATIONSInstruction Bulletin World ClassAppendices J-7 Instruction Bulletin World ClassJ-8Appendices Instruction Bulletin World ClassAppendices J-9 World Class TROUBLESHOOTINGJ-9TROUBLESHOOTING FLOWCHART Instruction BulletinInstruction Bulletin World ClassAppendices J-11 Instruction Bulletin World ClassJ-12Appendices World Class RETURNING EQUIPMENT TO THE FACTORYInstruction Bulletin Instruction Bulletin World ClassJ-14Appendices SECTION INDEX World ClassWorld Class Instruction ManualROSEMOUNT ANALYTICAL WARRANTY 3656 3784/5-05Instruction Manual World ClassWorld Class 3000 Probe