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