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