Instruction Manual
Oxygen Analyzer
with IFT 3000 Intelligent Field Transmitter
World Class
READ THIS PAGE BEFORE PROCEEDING
ESSENTIAL INSTRUCTIONS
Page
HIGHLIGHTS OF CHANGES
Effective May, 1999 Rev.
Summary
Page
HIGHLIGHTS OF CHANGES CONTINUED
Effective May, 2005 Rev.
Summary
Effective May, 1996 Rev.
APPENDIX A
HIGHLIGHTS OF CHANGES
Page
Page
HIGHLIGHTS OF CHANGES CONTINUED
Effective November, 2001 Rev.
Summary
Effective February, 1992 Rev.
APPENDIX B
HIGHLIGHTS OF CHANGES
Page
Page
Effective June, 1994 Rev.
APPENDIX D
HIGHLIGHTS OF CHANGES
Page
Page
HIGHLIGHTS OF CHANGES CONTINUED
Effective July, 1998 Rev.
Summary
Effective May, 1996 Rev.
APPENDIX E
HIGHLIGHTS OF CHANGES
Page
HIGHLIGHTS OF CHANGES CONTINUED
Revised Electrical Noise specifications
figuration. Revised replacement parts list
Effective May, 2005 Rev.
Effective April, 1995 Rev.
APPENDIX J
HIGHLIGHTS OF CHANGES
Page
Page
SETUP
TABLE OF CONTENTS
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Instruction Manual
Instruction Manual
LIST OF ILLUSTRATIONS
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Instruction Manual
LIST OF TABLES
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Instruction Manual
NOTE TO USERS
PREFACE
DEFINITIONS
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SAFETY INSTRUCTIONS
FOR THE WIRING AND INSTALLATION OF THIS APPARATUS
Instruction Manual
Instruction Manual
GLOSSARY OF TERMS
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Abrasive Shield
Reference Air
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Instruction Manual
Semiautomatic Calibration
WITH WORLD CLASS 3000 PROBE
WHAT YOU NEED TO KNOW
IFT 3000 INTELLIGENT FIELD TRANSMITTER
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Instruction Manual
QUICK START GUIDE
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Use this Quick Start Guide if
Instruction Manual
QUICK START GUIDE FOR IFT 3000 SYSTEMS
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220 V.A.C. JM6, JM5, JM2 240 V.A.C. JM6, JM5, JM1
LINE VOLTAGE JUMPER SECTION INSTALL
100 V.A.C. JM3, JM7, JM2 120 V.A.C. JM8, JM7, JM1
PROBE JUNCTION BOX WIRING
Setting up the Analog Output
QUICK REFERENCE GUIDE
IFT 3000 INTELLIGENT FIELD TRANSMITTER
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Instruction Manual
HART COMMUNICATOR FAST KEY SEQUENCES
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Technical Support Hotline
SYSTEM PACKAGE CONTENTS
SECTION DESCRIPTION AND SPECIFICATIONS
1-1COMPONENT CHECKLIST OF TYPICAL
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1-2SYSTEM OVERVIEW a.Scope
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Instruction Manual
b.System Description
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c.System Configuration
d.System Features
Instruction Manual
e. Handling the Oxygen Analyzer
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Instruction Manual
f.System Considerations
Instruction Manual
Figure 1-2.Typical System Installation
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STANDARD
Instruction Manual
1-6Description and Specifications
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Termination in
IB-106-300NHRev. 4.3 May
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Instruction Manual
Instruction Manual
1-8Description and Specifications
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b.Mechanical Installation
SECTION INSTALLATION
2-1OXYGEN ANALYZER PROBE INSTALLATION
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Instruction Manual
Figure 2-1.Probe Installation Sheet 1 of
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BOTTOM VIEW
Instruction Manual
Figure 2-1.Probe Installation Sheet 2 of
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Figure 2-1.Probe Installation Sheet 3 of
2-4Installation
Instruction Manual
CONSTRUCTION
INSTALLATION FOR METAL WALL STACK OR DUCT
INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION
Figure 2-1.Probe Installation Sheet 4 of
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Figure 2-1.Probe Installation Sheet 5 of
2-6Installation
Instruction Manual
Instruction Manual
Probe Installation
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Figure 2-2.Orienting the Optional Vee Deflector
Instruction Manual
d.Service Required
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c.Reference Air Package
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2-2INTELLIGENT FIELD TRANSMITTER IFT INSTALLATION
a.Mechanical Installation
Instruction Manual
IB-106-300NHRev. 4.3 May
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Instruction Manual
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Figure 2-6.IFT Power Supply Board Jumpers
Installation
Instruction Manual
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2-12Installation
BOX WIRING
Instruction Manual
2-3HEATER POWER SUPPLY INSTALLATION
Switch SW3
Jumper Configuration
Mechanical Installation
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SELECTOR SWITCH
2-14Installation
Instruction Manual
OUTPUT
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Instruction Manual
JUMPER
Instruction Manual
Figure 2-12.Outline of Heater Power Supply
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NEMA
Instruction Manual
J8 + - +
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WORLD CLASS PROBE
Instruction Manual
2-18Installation
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INTELLIGENT FIELD TRANSMITTER IFT
Instruction Manual
Installation
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FRONT
Figure 2-15.Jumper Selection Label
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Instruction Manual
Figure 2-16.Jumpers on HPS Mother Board
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Analytical
SEQUENCER INSTALLATION a.Mechanical Installation
Instruction Manual
c.Electrical Connections
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Instruction Manual
Figure 2-18.MPS Gas Connections
Instruction Manual
Figure 2-19.MPS Probe Wiring
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PROBE
Instruction Manual
2-24Installation
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3-3SETTING CALIBRATION PARAMETERS
SECTION SETUP
3-2CONFIGURING THE ANALOG OUTPUT
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3-6CONFIGURING THE RELAY OUTPUTS
3-4SETTING THE O2 ALARM SETPOINTS
3-5CONFIGURING EFFICIENCY CALCULATIONS
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Instruction Manual
SECTION 4 CALIBRATION
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4-1ANALOG OUTPUT CALIBRATION
2. Calibration Methods
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Instruction Manual
c.Manual Semiautomatic Calibration
IB-106-300NHRev. 4.3 May
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Instruction Manual
Instruction Manual
Figure 4-1.Typical Calibration Setup
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Figure 4-2.Portable Rosemount Analytical
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Instruction Manual
Oxygen Calibration Gas Kit
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Figure 4-3.Typical Portable Calibration Setup
d.Manual Semiautomatic Calibration Procedure
Instruction Manual
Figure 4-4.Typical Automatic Calibration System
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Instruction Manual
Table 4-1.Automatic Calibration Parameters
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Instruction Manual
Rosemount Analytical In Situ O2 Probe
Probe Location Date Placed Into Service
Calibration Record For
Probe Serial Number Probe Tag Number
4-10Calibration
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Instruction Manual
Instruction Manual
SECTION GENERAL USER INTERFACE GUI OPERATION
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5-1OVERVIEW
5-2DELUXE VERSION IFT DISPLAYS AND CONTROLS
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Instruction Manual
INTERNAL VIEW
The SETUP menu is used to configure the IFT
Press ENTER key to access DATA menu
SETUP
5-5QUICK REFERENCE CHART
Instruction Manual
5-9SETUP SUB-MENU
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5-8CALIBRATE O2 SUB-MENU
Instruction Manual
Figure 5-2.Quick Reference Chart Sheet 1 of
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Instruction Manual
Figure 5-2.Quick Reference Chart Sheet 2 of
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5-6General User Interface GUI Operation
SOURCE AOUT TYPE RANGE SETUP USA GBR FRA ESP GER
Figure 5-2.Quick Reference Chart Sheet 3 of
CONTINUED FROM SHEET SETUP COUNTRY
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Instruction Manual
Figure 5-2.Quick Reference Chart Sheet 4 of
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5-8General User Interface GUI Operation
Instruction Manual
Figure 5-2.Quick Reference Chart Sheet 5 of
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CONTINUED FROM SHEET
Instruction Manual
SETUP SETTING
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Table 5-4.CALIBRATE O2 Sub-Menu
Instruction Manual
SETUP SETTING
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Table 5-4.CALIBRATE O2 Sub-Menucontinued
Instruction Manual
Table 5-5.SETUP Sub-Menu
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SUB-MENU
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Table 5-5.SETUP Sub-Menucontinued
selected in the SETUP sub-menu
Instruction Manual
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Table 5-5.SETUP Sub-Menucontinued
Dual Range Setup
Instruction Manual
6-3SYSTEM TROUBLESHOOTING
SECTION TROUBLESHOOTING
6-2SPECIAL TROUBLESHOOTING NOTES a.Grounding
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Table 6-1.IFT Status Codes
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Instruction Manual
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6-4HEATER PROBLEM
Table 6-2.Heater Troubleshooting Problem
Instruction Manual
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Table 6-2.Heater Troubleshooting continued
Problem
Instruction Manual
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6-5CELL PROBLEM
Table 6-3.Cell Troubleshooting Problem
Instruction Manual
Instruction Manual
Table 6-3.Cell Troubleshooting continued Problem
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Status is ResHi or CalEr
Faulty GUI or LDP IFT LED is Flashing
6-6IFT PROBLEM
Table 6-4.IFT Troubleshooting Problem
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6-7MPS PROBLEM
Table 6-5.MPS Troubleshooting Problem
Instruction Manual
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Table 6-6.Performance Problem Troubleshooting
Problem
Instruction Manual
Instruction Manual
6-10Troubleshooting
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Instruction Manual
SECTION RETURN OF MATERIAL
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7-2Return of Material
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Instruction Manual
Instruction Manual
SECTION APPENDICES
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APPENDIX A
Instruction Bulletin
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Figure A-1.Oxygen Analyzer Probe Exploded View
DESCRIPTION
APPENDIX A, REV.
WORLD CLASS 3000 OXYGEN ANALYZER PROBE
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Appendix A Rev. 3.9 May
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Instruction Bulletin
b.Probe Tube Assembly
A-2PROBE ASSEMBLY EXTERIOR
a.Cell and Flange Assembly
c.Snubber Diffusion Assembly
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A-3INNER PROBE ASSEMBLY
Figure A-5.Inner Probe Assembly
Instruction Bulletin
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A-5CABLE ASSEMBLY
A-6PROBE OPTIONS a.Abrasive Shield Assembly
Instruction Bulletin
Instruction Bulletin
Figure A-7.Abrasive Shield Assembly
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Figure A-10.Ceramic Diffusion Assembly
Figure A-8.Ceramic Diffusion/Dust Seal Assembly
b.Ceramic Diffusion Assembly
c.Flame Arrestor Diffusion Assembly
e.Cup-TypeDiffusion Assembly
d.Snubber Diffusion/Dust Seal Assembly
Figure A-12.Snubber Diffusion/Dust Seal Assembly
Figure A-13. Cup-TypeDiffusion/Dust Seal Assembly
Figure A-15.Bypass Probe Option Sheet 1 of
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Instruction Bulletin
Figure A-15.Bypass Probe Option Sheet 2 of
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Instruction Bulletin
A-10Appendices
GROUP
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Instruction Bulletin
PART NO
Table A-2.Fault Finding
PROBE TROUBLESHOOTING
A-8PROBE TROUBLESHOOTING a.Probe Faults
Symptom
Fault
Table A-2.Fault Finding Continued
Symptom
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A-14Appendices
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Instruction Bulletin
Appendices A-15
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Instruction Bulletin
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SERVICE AND NORMAL MAINTENANCE
A-11CELL REPLACEMENT
Instruction Bulletin
Instruction Bulletin
Figure A-18.Cell Wiring Connection
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Figure A-20.Cell Replacement Kit
ELEMENT REPLACEMENT a.General
Instruction Bulletin
Instruction Bulletin
b.Replacement Procedure
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A-13REPLACEMENT OF CONTACT AND
THERMOCOUPLE ASSEMBLY
Instruction Bulletin
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Figure A-23.Heater, Strut, and Backplate Assembly
Inner Probe Assembly
Instruction Bulletin
Appendix A Rev. 3.9 May
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Instruction Bulletin
Instruction Bulletin
a. Installation Procedure
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A-15CALIBRATION GAS AND REFERENCE AIR
Instruction Bulletin
Figure A-25.High Temperature - Corrosive
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Environment Kit
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REPLACEMENT PARTS
Table A-3.Replacement Parts for Probe
Instruction Bulletin
Instruction Bulletin
Table A-3.Replacement Parts for Probe Continued
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Figure and Index No
DESCRIPTION
APPENDIX B, REV. HPS 3000 HEATER POWER SUPPLY
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Instruction Bulletin
Instruction Bulletin
Figure B-2.Heater Power Supply, Interior
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FRONT
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Table B-1.Specifications for Heater Power Supply
Figure B-3.Heater Power Supply Block Diagram
Instruction Bulletin
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HPS 3000 TROUBLESHOOTING
B-4HPS 3000 TROUBLESHOOTING
Instruction Bulletin
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SYMPTOM
Figure B-4.HPS Troubleshooting Flowchart, #1
Instruction Bulletin
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SYMPTOM
Figure B-5.HPS Troubleshooting Flowchart, #2
Instruction Bulletin
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SYMPTOM
Figure B-6.HPS Troubleshooting Flowchart, #3
Instruction Bulletin
maintenance of the HPS 3000 Heater Power
SERVICE AND NORMAL MAINTENANCE
This section describes service and routine
Supply Field Module. Replacement parts
Instruction Bulletin
B-9DAUGHTER BOARD REPLACEMENT
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Instruction Bulletin
Figure B-7.Heater Power Supply, Exploded View
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B-10Appendices
Instruction Bulletin
REPLACEMENT PARTS
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LEGEND FOR FIGURE B-7
B-12Appendices
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Instruction Bulletin
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APPENDIX D, REV
MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER
DESCRIPTION
Appendix D Rev. 2.5 May
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Instruction Bulletin
Figure D-3.Typical Automatic Calibration System
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Instruction Bulletin
Appendices D-3
BEBCO MODEL Z-PURGE
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Instruction Bulletin
REAR VIEW
Table D-2.Fault Finding
MPS 3000 TROUBLESHOOTING
D-4TROUBLESHOOTING
SYMPTOM
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SYMPTOM
Figure D-5.MPS Troubleshooting Flowchart
Instruction Bulletin
SOLENOID VALVE REPLACEMENT
SERVICE AND NORMAL MAINTENANCE
D-6FUSE REPLACEMENT
D-7POWER SUPPLY REPLACEMENT
D-8Appendices
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Instruction Bulletin
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D-9PRESSURE REGULATOR MAINTENANCE
Pressure Adjustments
Instruction Bulletin
Instruction Bulletin
D-10FLOWMETER ADJUSTMENTS
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D-11ADDING PROBES TO THE MPS
Instruction Bulletin
REPLACEMENT PARTS
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FIGURE and
D-12Appendices
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Instruction Bulletin
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APPENDIX E, REV.
c.Power Supply Board
IFT 3000 INTELLIGENT FIELD TRANSMITTER
f.Z-Purgeoptional
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Instruction Bulletin
E-2THEORY OF OPERATION
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HEATER POWER SUPPLY OPTIONAL IFT
Figure E-2.System Block Diagram
Instruction Bulletin
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IFT 3000 TROUBLESHOOTING
E-4IFT TROUBLESHOOTING
Instruction Bulletin
Instruction Bulletin
Figure E-3.IFT Troubleshooting Flowchart, #1
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Appendices E-5
SYMPTOM - GENERAL USER INTERFACE OR
SYMPTOM - MICROPROCESSOR BOARD LED IS STEADY ON
Figure E-4.IFT Troubleshooting Flowchart, #2
Figure E-5.IFT Troubleshooting Flowchart, #3
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Table E-2.GUI Equipped IFT Fault Finding
SYMPTOM
Instruction Bulletin
1.Captive Screw 2.Enclosure Cover
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Instruction Bulletin
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SERVICE AND NORMAL MAINTENANCE
E-6REMOVE POWER AND OPEN COVER
Instruction Bulletin
Instruction Bulletin
Figure E-7.Microprocessor Assembly –
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Exploded View
Instruction Bulletin
E-12REPLACE POWER SUPPLY BOARD
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E-9REPLACE MICROPROCESSOR BOARD
Figure E-8.Electronics Chassis – Exploded View
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Instruction Bulletin
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E-15INSTALL ELECTRONICS CHASSIS
E-14REPLACE HEATER AND THERMOSWITCH
Instruction Bulletin
27.Captive Screw 28.Power Supply Board
Figure E-9.Electronics Chassis Installation
25.Microprocessor Assembly 26.Protective Cover
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Figure E-10.Replacing the GUI Assembly
E-16REPLACE GUI ASSEMBLY OR
E-17CLOSE COVER AND RESTORE POWER
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Instruction Bulletin
REPLACEMENT PARTS
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FIGURE and INDEX No
J-1COMPONENT CHECKLIST OF TYPICAL
APPENDIX J, REV HART COMMUNICATOR MODEL 275/375
IFT 3000 APPLICATIONS
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Physical Specifications
J-3SPECIFICATIONS
Table J-1.HART Communicator Specifications
Functional Specifications
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INSTALLATION
J-4HART COMMUNICATOR SIGNAL LINE CONNECTIONS
Instruction Bulletin
b.Method 2, For Load Resistance < 250 Ohms
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Instruction Bulletin
HART COMMUNICATOR PC CONNECTIONS
Appendices J-5
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Instruction Bulletin
Instruction Bulletin
OPERATION
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J-6 OFF-LINEAND ON-LINEOPERATIONS
Appendices J-7
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Instruction Bulletin
J-8Appendices
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Instruction Bulletin
Appendices J-9
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Instruction Bulletin
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TROUBLESHOOTING
J-9TROUBLESHOOTING FLOWCHART
Instruction Bulletin
Appendices J-11
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J-12Appendices
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Instruction Bulletin
Instruction Bulletin
RETURNING EQUIPMENT TO THE FACTORY
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J-14Appendices
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Instruction Bulletin
SECTION INDEX
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Instruction Manual
ROSEMOUNT ANALYTICAL WARRANTY
3656 3784/5-05
World Class 3000 Probe
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Instruction Manual
