Oxygen Analyzer
with IFT 3000 Intelligent Field Transmitter
Instruction Manual
World Class
READ THIS PAGE BEFORE PROCEEDING
ESSENTIAL INSTRUCTIONS
HIGHLIGHTS OF CHANGES
Effective May, 1999 Rev.
Page
Summary
HIGHLIGHTS OF CHANGES CONTINUED
Effective May, 2005 Rev.
Page
Summary
APPENDIX A
HIGHLIGHTS OF CHANGES
Effective May, 1996 Rev.
Page
HIGHLIGHTS OF CHANGES CONTINUED
Effective November, 2001 Rev.
Page
Summary
APPENDIX B
HIGHLIGHTS OF CHANGES
Effective February, 1992 Rev.
Page
Page
APPENDIX D
HIGHLIGHTS OF CHANGES
Effective June, 1994 Rev.
Page
HIGHLIGHTS OF CHANGES CONTINUED
Effective July, 1998 Rev.
Page
Summary
APPENDIX E
HIGHLIGHTS OF CHANGES
Effective May, 1996 Rev.
Page
Revised Electrical Noise specifications
figuration. Revised replacement parts list
HIGHLIGHTS OF CHANGES CONTINUED
Effective May, 2005 Rev.
APPENDIX J
HIGHLIGHTS OF CHANGES
Effective April, 1995 Rev.
Page
Page
TABLE OF CONTENTS
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SETUP
Instruction Manual
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LIST OF ILLUSTRATIONS
Instruction Manual
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LIST OF TABLES
Instruction Manual
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Instruction Manual
PREFACE
DEFINITIONS
NOTE TO USERS
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SAFETY INSTRUCTIONS
FOR THE WIRING AND INSTALLATION OF THIS APPARATUS
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Instruction Manual
GLOSSARY OF TERMS
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Instruction Manual
Abrasive Shield
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Instruction Manual
Reference Air
Semiautomatic Calibration
WHAT YOU NEED TO KNOW
IFT 3000 INTELLIGENT FIELD TRANSMITTER
WITH WORLD CLASS 3000 PROBE
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QUICK START GUIDE
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Instruction Manual
Use this Quick Start Guide if
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QUICK START GUIDE FOR IFT 3000 SYSTEMS
Instruction Manual
LINE VOLTAGE JUMPER SECTION INSTALL
100 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, JM1
PROBE JUNCTION BOX WIRING
QUICK REFERENCE GUIDE
IFT 3000 INTELLIGENT FIELD TRANSMITTER
Setting up the Analog Output
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HART COMMUNICATOR FAST KEY SEQUENCES
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Instruction Manual
Technical Support Hotline
SECTION DESCRIPTION AND SPECIFICATIONS
1-1COMPONENT CHECKLIST OF TYPICAL
SYSTEM PACKAGE CONTENTS
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Instruction Manual
1-2SYSTEM OVERVIEW a.Scope
b.System Description
c.System Configuration
d.System Features
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Instruction Manual
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Instruction Manual
e. Handling the Oxygen Analyzer
f.System Considerations
Figure 1-2.Typical System Installation
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Instruction Manual
STANDARD
1-6Description and Specifications
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Instruction Manual
Termination in
Instruction Manual
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IB-106-300NHRev. 4.3 May
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1-8Description and Specifications
Instruction Manual
SECTION INSTALLATION
2-1OXYGEN ANALYZER PROBE INSTALLATION
b.Mechanical Installation
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Figure 2-1.Probe Installation Sheet 1 of
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BOTTOM VIEW
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Figure 2-1.Probe Installation Sheet 2 of
Instruction Manual
Figure 2-1.Probe Installation Sheet 3 of
2-4Installation
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Instruction Manual
INSTALLATION FOR METAL WALL STACK OR DUCT
INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION
CONSTRUCTION
Figure 2-1.Probe Installation Sheet 4 of
Figure 2-1.Probe Installation Sheet 5 of
2-6Installation
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Instruction Manual
Probe Installation
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Instruction Manual
Figure 2-2.Orienting the Optional Vee Deflector
d.Service Required
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Instruction Manual
c.Reference Air Package
2-2INTELLIGENT FIELD TRANSMITTER IFT INSTALLATION
a.Mechanical Installation
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Instruction Manual
Instruction Manual
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IB-106-300NHRev. 4.3 May
Figure 2-6.IFT Power Supply Board Jumpers
Installation
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Instruction Manual
2-12Installation
BOX WIRING
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Instruction Manual
Switch SW3
Jumper Configuration
2-3HEATER POWER SUPPLY INSTALLATION
Mechanical Installation
SELECTOR SWITCH
2-14Installation
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Instruction Manual
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Instruction Manual
OUTPUT
JUMPER
Figure 2-12.Outline of Heater Power Supply
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Instruction Manual
NEMA
J8 + - +
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Instruction Manual
WORLD CLASS PROBE
2-18Installation
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Instruction Manual
INTELLIGENT FIELD TRANSMITTER IFT
Installation
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Instruction Manual
FRONT
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Instruction Manual
Figure 2-15.Jumper Selection Label
Figure 2-16.Jumpers on HPS Mother Board
Analytical
SEQUENCER INSTALLATION a.Mechanical Installation
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Instruction Manual
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Instruction Manual
c.Electrical Connections
Figure 2-18.MPS Gas Connections
Figure 2-19.MPS Probe Wiring
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Instruction Manual
PROBE
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2-24Installation
Instruction Manual
SECTION SETUP
3-2CONFIGURING THE ANALOG OUTPUT
3-3SETTING CALIBRATION PARAMETERS
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3-4SETTING THE O2 ALARM SETPOINTS
3-5CONFIGURING EFFICIENCY CALCULATIONS
3-6CONFIGURING THE RELAY OUTPUTS
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SECTION 4 CALIBRATION
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Instruction Manual
4-1ANALOG OUTPUT CALIBRATION
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Instruction Manual
2. Calibration Methods
c.Manual Semiautomatic Calibration
Instruction Manual
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IB-106-300NHRev. 4.3 May
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Figure 4-1.Typical Calibration Setup
Instruction Manual
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Instruction Manual
Figure 4-2.Portable Rosemount Analytical
Oxygen Calibration Gas Kit
Figure 4-3.Typical Portable Calibration Setup
d.Manual Semiautomatic Calibration Procedure
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Instruction Manual
Instruction Manual
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Figure 4-4.Typical Automatic Calibration System
Instruction Manual
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Table 4-1.Automatic Calibration Parameters
Probe Location Date Placed Into Service
Calibration Record For
Rosemount Analytical In Situ O2 Probe
Probe Serial Number Probe Tag Number
Instruction Manual
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4-10Calibration
SECTION GENERAL USER INTERFACE GUI OPERATION
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Instruction Manual
5-1OVERVIEW
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Instruction Manual
5-2DELUXE VERSION IFT DISPLAYS AND CONTROLS
INTERNAL VIEW
Press ENTER key to access DATA menu
SETUP
The SETUP menu is used to configure the IFT
5-5QUICK REFERENCE CHART
5-9SETUP SUB-MENU
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Instruction Manual
5-8CALIBRATE O2 SUB-MENU
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Figure 5-2.Quick Reference Chart Sheet 1 of
Instruction Manual
Figure 5-2.Quick Reference Chart Sheet 2 of
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Instruction Manual
5-6General User Interface GUI Operation
Figure 5-2.Quick Reference Chart Sheet 3 of
CONTINUED FROM SHEET SETUP COUNTRY
SOURCE AOUT TYPE RANGE SETUP USA GBR FRA ESP GER
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Figure 5-2.Quick Reference Chart Sheet 4 of
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Instruction Manual
5-8General User Interface GUI Operation
Figure 5-2.Quick Reference Chart Sheet 5 of
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CONTINUED FROM SHEET
SETUP SETTING
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Instruction Manual
Table 5-4.CALIBRATE O2 Sub-Menu
SETUP SETTING
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Instruction Manual
Table 5-4.CALIBRATE O2 Sub-Menucontinued
Table 5-5.SETUP Sub-Menu
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Instruction Manual
SUB-MENU
Table 5-5.SETUP Sub-Menucontinued
selected in the SETUP sub-menu
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Instruction Manual
Table 5-5.SETUP Sub-Menucontinued
Dual Range Setup
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Instruction Manual
SECTION TROUBLESHOOTING
6-2SPECIAL TROUBLESHOOTING NOTES a.Grounding
6-3SYSTEM TROUBLESHOOTING
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Instruction Manual
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Table 6-1.IFT Status Codes
6-4HEATER PROBLEM
Table 6-2.Heater Troubleshooting Problem
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Instruction Manual
Table 6-2.Heater Troubleshooting continued
Problem
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Instruction Manual
6-5CELL PROBLEM
Table 6-3.Cell Troubleshooting Problem
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Instruction Manual
Table 6-3.Cell Troubleshooting continued Problem
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Instruction Manual
Status is ResHi or CalEr
6-6IFT PROBLEM
Table 6-4.IFT Troubleshooting Problem
Faulty GUI or LDP IFT LED is Flashing
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6-7MPS PROBLEM
Table 6-5.MPS Troubleshooting Problem
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Instruction Manual
Table 6-6.Performance Problem Troubleshooting
Problem
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Instruction Manual
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6-10Troubleshooting
Instruction Manual
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SECTION RETURN OF MATERIAL
Instruction Manual
Instruction Manual
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7-2Return of Material
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SECTION APPENDICES
Instruction Manual
Instruction Bulletin
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APPENDIX A
Figure A-1.Oxygen Analyzer Probe Exploded View
APPENDIX A, REV.
WORLD CLASS 3000 OXYGEN ANALYZER PROBE
DESCRIPTION
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Instruction Bulletin
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Appendix A Rev. 3.9 May
A-2PROBE ASSEMBLY EXTERIOR
a.Cell and Flange Assembly
b.Probe Tube Assembly
c.Snubber Diffusion Assembly
A-3INNER PROBE ASSEMBLY
Figure A-5.Inner Probe Assembly
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Instruction Bulletin
A-5CABLE ASSEMBLY
A-6PROBE OPTIONS a.Abrasive Shield Assembly
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Instruction Bulletin
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Figure A-7.Abrasive Shield Assembly
Instruction Bulletin
Figure A-8.Ceramic Diffusion/Dust Seal Assembly
b.Ceramic Diffusion Assembly
Figure A-10.Ceramic Diffusion Assembly
c.Flame Arrestor Diffusion Assembly
d.Snubber Diffusion/Dust Seal Assembly
Figure A-12.Snubber Diffusion/Dust Seal Assembly
e.Cup-TypeDiffusion Assembly
Figure A-13. Cup-TypeDiffusion/Dust Seal Assembly
Instruction Bulletin
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Figure A-15.Bypass Probe Option Sheet 1 of
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Figure A-15.Bypass Probe Option Sheet 2 of
A-10Appendices
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Instruction Bulletin
GROUP
PART NO
PROBE TROUBLESHOOTING
A-8PROBE TROUBLESHOOTING a.Probe Faults
Table A-2.Fault Finding
Symptom
Table A-2.Fault Finding Continued
Symptom
Fault
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A-14Appendices
Instruction Bulletin
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Appendices A-15
SERVICE AND NORMAL MAINTENANCE
A-11CELL REPLACEMENT
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Instruction Bulletin
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Figure A-18.Cell Wiring Connection
Instruction Bulletin
Figure A-20.Cell Replacement Kit
ELEMENT REPLACEMENT a.General
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Instruction Bulletin
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b.Replacement Procedure
Instruction Bulletin
A-13REPLACEMENT OF CONTACT AND
THERMOCOUPLE ASSEMBLY
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Instruction Bulletin
Figure A-23.Heater, Strut, and Backplate Assembly
Inner Probe Assembly
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Instruction Bulletin
Instruction Bulletin
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Appendix A Rev. 3.9 May
a. Installation Procedure
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Instruction Bulletin
A-15CALIBRATION GAS AND REFERENCE AIR
Figure A-25.High Temperature - Corrosive
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Instruction Bulletin
Environment Kit
REPLACEMENT PARTS
Table A-3.Replacement Parts for Probe
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Instruction Bulletin
Table A-3.Replacement Parts for Probe Continued
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Instruction Bulletin
Figure and Index No
APPENDIX B, REV. HPS 3000 HEATER POWER SUPPLY
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DESCRIPTION
Instruction Bulletin
Figure B-2.Heater Power Supply, Interior
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Instruction Bulletin
FRONT
Table B-1.Specifications for Heater Power Supply
Figure B-3.Heater Power Supply Block Diagram
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Instruction Bulletin
HPS 3000 TROUBLESHOOTING
B-4HPS 3000 TROUBLESHOOTING
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Instruction Bulletin
SYMPTOM
Figure B-4.HPS Troubleshooting Flowchart, #1
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Instruction Bulletin
SYMPTOM
Figure B-5.HPS Troubleshooting Flowchart, #2
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Instruction Bulletin
SYMPTOM
Figure B-6.HPS Troubleshooting Flowchart, #3
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Instruction Bulletin
SERVICE AND NORMAL MAINTENANCE
This section describes service and routine
maintenance of the HPS 3000 Heater Power
Supply Field Module. Replacement parts
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B-9DAUGHTER BOARD REPLACEMENT
Instruction Bulletin
Figure B-7.Heater Power Supply, Exploded View
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Instruction Bulletin
B-10Appendices
REPLACEMENT PARTS
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Instruction Bulletin
LEGEND FOR FIGURE B-7
Instruction Bulletin
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B-12Appendices
APPENDIX D, REV
MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER
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DESCRIPTION
Instruction Bulletin
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Appendix D Rev. 2.5 May
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Instruction Bulletin
Figure D-3.Typical Automatic Calibration System
Appendices D-3
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Instruction Bulletin
BEBCO MODEL Z-PURGE
REAR VIEW
MPS 3000 TROUBLESHOOTING
D-4TROUBLESHOOTING
Table D-2.Fault Finding
SYMPTOM
SYMPTOM
Figure D-5.MPS Troubleshooting Flowchart
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Instruction Bulletin
SERVICE AND NORMAL MAINTENANCE
D-6FUSE REPLACEMENT
SOLENOID VALVE REPLACEMENT
D-7POWER SUPPLY REPLACEMENT
Instruction Bulletin
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D-8Appendices
D-9PRESSURE REGULATOR MAINTENANCE
Pressure Adjustments
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Instruction Bulletin
D-10FLOWMETER ADJUSTMENTS
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Instruction Bulletin
D-11ADDING PROBES TO THE MPS
REPLACEMENT PARTS
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Instruction Bulletin
FIGURE and
Instruction Bulletin
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D-12Appendices
APPENDIX E, REV.
c.Power Supply Board
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IFT 3000 INTELLIGENT FIELD TRANSMITTER
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Instruction Bulletin
f.Z-Purgeoptional
E-2THEORY OF OPERATION
HEATER POWER SUPPLY OPTIONAL IFT
Figure E-2.System Block Diagram
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Instruction Bulletin
IFT 3000 TROUBLESHOOTING
E-4IFT TROUBLESHOOTING
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Figure E-3.IFT Troubleshooting Flowchart, #1
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Instruction Bulletin
Appendices E-5
SYMPTOM - MICROPROCESSOR BOARD LED IS STEADY ON
Figure E-4.IFT Troubleshooting Flowchart, #2
SYMPTOM - GENERAL USER INTERFACE OR
Figure E-5.IFT Troubleshooting Flowchart, #3
Table E-2.GUI Equipped IFT Fault Finding
SYMPTOM
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Instruction Bulletin
Instruction Bulletin
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1.Captive Screw 2.Enclosure Cover
SERVICE AND NORMAL MAINTENANCE
E-6REMOVE POWER AND OPEN COVER
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Instruction Bulletin
Figure E-7.Microprocessor Assembly –
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Instruction Bulletin
Exploded View
E-12REPLACE POWER SUPPLY BOARD
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Instruction Bulletin
E-9REPLACE MICROPROCESSOR BOARD
Instruction Bulletin
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Figure E-8.Electronics Chassis – Exploded View
E-15INSTALL ELECTRONICS CHASSIS
E-14REPLACE HEATER AND THERMOSWITCH
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Instruction Bulletin
Figure E-9.Electronics Chassis Installation
25.Microprocessor Assembly 26.Protective Cover
27.Captive Screw 28.Power Supply Board
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E-16REPLACE GUI ASSEMBLY OR
E-17CLOSE COVER AND RESTORE POWER
Figure E-10.Replacing the GUI Assembly
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REPLACEMENT PARTS
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Instruction Bulletin
FIGURE and INDEX No
APPENDIX J, REV HART COMMUNICATOR MODEL 275/375
IFT 3000 APPLICATIONS
J-1COMPONENT CHECKLIST OF TYPICAL
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J-3SPECIFICATIONS
Table J-1.HART Communicator Specifications
Physical Specifications
Functional Specifications
INSTALLATION
J-4HART COMMUNICATOR SIGNAL LINE CONNECTIONS
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Instruction Bulletin
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Instruction Bulletin
b.Method 2, For Load Resistance < 250 Ohms
HART COMMUNICATOR PC CONNECTIONS
Instruction Bulletin
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Appendices J-5
OPERATION
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Instruction Bulletin
J-6 OFF-LINEAND ON-LINEOPERATIONS
Instruction Bulletin
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Appendices J-7
Instruction Bulletin
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J-8Appendices
Instruction Bulletin
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Appendices J-9
TROUBLESHOOTING
J-9TROUBLESHOOTING FLOWCHART
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Instruction Bulletin
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Appendices J-11
Instruction Bulletin
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J-12Appendices
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RETURNING EQUIPMENT TO THE FACTORY
Instruction Bulletin
Instruction Bulletin
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J-14Appendices
SECTION INDEX
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Instruction Manual
ROSEMOUNT ANALYTICAL WARRANTY
3656 3784/5-05
Instruction Manual
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World Class 3000 Probe