Emerson World Class 3000 Instruction Manual Download Page 48

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Instruction Manual

IB-106-300NH Rev. 4.3
May 2005

2-12 Installation

Rosemount Analytical Inc. A Division of Emerson Process Management

World Class 3000

SHIELD

CAL RET

NO GAS

LO GAS

HI GAS

IN CAL

SHIELD

STACK TC -
STACK TC +

PROBE

M V

PROBE MV -

PROBE TC +

PROBE TC -

RD
YE

INTELLIGENT FIELD TRANSMITTER IFT 3000

WORLD CLASS

PROBE

1 2 3 4 5 6

7 8

PROBE

CELL

-VE

CELL

+VE

CHROMEL

ALUMEL

}

HEA

TER

PROBE JUNCTION

BOX WIRING

STACK TC WIRING AS RE

UIRED.

SPECIAL PROBE CABLE BETWEEN PROBE
AND IFT BY ROSEMOUNT ANALYTICAL.

INSTALL JM1 ON INTERCONNECT BOARD.

INSTALL JM6 ON MICROPROCESSOR
BOARD PER FIGURE 2-8.

IF STACK TEMPERATURE NOT USED.

IF MPS 3000 NOT USED.

1 RELAY PER PROBE AVAILABLE FOR
CALIBRATION STATUS INDICATION. (48 V
max, 100 mA max)

CURRENT/VOLTAGE SELECTOR SWITCH
MUST BE SELECTED TO CURRENT (I) FOR
HART COMMUNICATIONS APPLICATIONS.

SET SWITCH SW3A PER FIGURE 2-8.

SWITCH/JUMPER CONFIGURATION FOR REV.
13 AND LATER

NOTES:

ALWAYS DISCONNECT LINE VOLTAGE

ROM INTELLIGENT

IELD TRANSMITTER

ORE C

ANGING JUMPERS.

LINE

VOLTAGE

SECTION

JUMPER

(INSTALL)

PROBE

EATER

VOLTAGE SECTION

JUMPER

(INSTALL)

120 V.A.C.

100 V.A.C.

220 V.A.C.
240 V.A.C.

JM1

3D39122G REV

POWER SUPPLY BOARD

3D39513G, REV 13

MICROPROCESSOR

BOARD

3D39120G REV

INTERCONNECT BOARD

JM8, JM7, JM1

JM3, JM7, JM2

JM6, JM5, JM2
JM6, JM5, JM1

WORLD CLASS PROBE

WORLD CLASS

DIRECT

REPLACEMENT

PROBE

218 PROBE

JM10

JM9

JUMPER CON

IGURATION

5 CONDUCTOR SHIELDED CABLE
PER PROBE #16 AWG BY CUSTOMER

LINE

VOLTAGE

MPS TERMINATION BOARD

MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER (OPTIONAL)

LINE
VOLTAGE

J13 J14

J15

J16

J17

J18

J12

CAL

RET

GAS

CAL

GAS

CAL

RET

GAS

CAL

GAS

CAL

RET

GAS

CAL

GAS

CAL

RET

GAS

CAL

GAS

LOW

GAS

LOW

GAS

LOW

GAS

LOW

GAS

NC C NO NC C NO

NC C NO

LINE OUT

LINE IN

J10

J11

PROBE 1

PROBE 2

PROBE 3

PROBE 4

PROBE 1

PROBE 2

PROBE 3

PROBE 4

PROBE

SOLENOID

PROBE

SOLENOID

PROBE

SOLENOID

PROBE

SOLENOID

HIGH

GAS

SOLENOID

LOW

GAS

SOLENOID

PRESSURE SWITCH

CURRENT/VOLTAGE
SELECTOR SWITCH

GND
STUD

AOUT -
AOUT +

2 CONDUCTOR
SHIELDED CABLE
BY CUSTOMER

JM6

SW2

SW3

OFF

37840006

Figure 2-7. Wiring Layout for IFT Systems without HPS

Summary of Contents for World Class 3000

Page 1: ...Instruction Manual IB 106 300NH Rev 4 3 May 2005 http www raihome com World Class 3000 Oxygen Analyzer with IFT 3000 Intelligent Field Transmitter ...

Page 2: ...lied with the product Inform and educate your personnel in the proper installation operation and mainte nance of the product Install your equipment as specified in the Installation Instructions of the appropriate In struction Manual and per applicable local and national codes Connect all products to the proper electrical and pressure sources To ensure proper performance use qualified personnel to ...

Page 3: ...status codes Section 6 Added new troubleshooting procedures Effective November 2001 Rev 4 1 Page Summary Highlights Updated Highlights of Changes Appendix A page Appendix A Replaced Appendix A Rev 3 6 with Rev 3 7 Effective November 2001 Rev 4 2 Page Summary Highlights Updated Highlights of Changes Appendix A page Page 4 1 Added reference to new Calibration Record sheet Page 4 9 Added new Calibrat...

Page 4: ... 2 9 2 15 Revised Figure 2 10 2 18 2 19 Revised Figure 2 14 sheets 1 and 2 2 22 Revised Figure 2 18 2 24 Revised Figure 2 20 4 4 Revised Figure 4 1 4 6 Revised Figure 4 3 4 7 Revised Figure 4 4 5 2 Revised Figure 5 1 7 1 Changed RMR facility address Appendix A Replaced Appendix A Rev 3 8 with Rev 3 9 Appendix B Replaced Appendix B Rev 2 2 with Rev 2 3 Appendix D Replaced Appendix D Rev 2 4 with Re...

Page 5: ...ell replacement kit part numbers for the probe Effective October 1996 Rev 3 3 Page Summary Page A 6 Added NOTE to Figure A 7 Effective January 1997 Rev 3 4 Page Summary Page A 1 Added warning to read new safety instructions Page A 12 Added protective covers and grounds warning Page A 16 Added protective covers and grounds warning Effective February 1998 Rev 3 5 Page Summary Page A 18 Changed screw...

Page 6: ...ons Figure A 13 and A 14 A 26 Added new cup type diffusion assembly part numbers 4851B89G04 and 4851B90G04 to replacement parts list Deleted stainless steel diffuser assembly from replacement parts list Effective July 2002 Rev 3 8 Page Summary A 13 Added troubleshooting symptoms 5 and 6 to Table A 2 Effective May 2005 Rev 3 9 Page Summary Changed Rosemount to Rosemount Analytical ...

Page 7: ...January 1995 Rev 2 1 Page Summary Page B 3 Updated Figure B 3 Heater Power Supply Block Diagram for IB consistency Effective January 1997 Rev 2 2 Page Summary Page B 1 Added warning to read new safety instructions Page B 3 Corrected Table B 1 specifications list Page B 4 Added protective covers and grounds warning Page B 8 Added protective covers and grounds warning Page B 11 Added expanded fuse d...

Page 8: ......

Page 9: ...aragraph D 11 Adding Probes to the new MPS added Change part numbers for the power supply solenoid valve and test gas flowmeter assembly Add part numbers for reference gas flow meter assembly and all the parts in the probe adder kit Effective January 1995 Rev 2 1 Page Summary Page D 1 Updated Figure D 1 MPS 3000 to include hinge Effective May 1996 Rev 2 2 Page Summary Page D 11 Updated replacement...

Page 10: ...1998 Rev 2 4 Page Summary Changed test gas to calibration gas and reference gas to reference air throughout the appendix Effective May 2005 Rev 2 5 Page Summary Changed Rosemount to Rosemount Analytical D 3 Revised view of check valve in Figure D 3 ...

Page 11: ...ry 1997 Rev 4 3 Page Summary Front matter Added Safety instructions for the wiring and installation of this apparatus Page E 1 Added warning to read new safety instructions Page E 2 Deleted NOTE Page E 4 Added protective covers and grounds warning Page E 8 Added protective covers and grounds warning Page E 15 Added expanded fuse description Effective July 1998 Rev 4 4 Page Summary Changed test gas...

Page 12: ...semount to Rosemount Analytical Changed views of IFT 3000 enclosure Named GUI LED display standard not optional E 2 Revised Electrical Noise specifications E 8 through E 16 Changed all service instructions to reflect new IFT 3000 assembly con figuration Revised replacement parts list ...

Page 13: ... number Effective June 1995 Rev 1 1 Page Summary Figure J 4 Updated figure to include Status group and K3 eff in calculations Effective May 2005 Rev 1 2 Page Summary J 1 Revised Figure J 1 to show Model 375 Communicator J 3 J5 Revised Figure J 2 and J 3 to show location of new microprocessor board switches J 13 Revised RMR facility address ...

Page 14: ......

Page 15: ...erview 3 1 3 2 Configuring the Analog Output 3 1 3 3 Setting Calibration Parameters 3 1 3 4 Setting the O2 Alarm Setpoints 3 2 3 5 Configuring Efficiency Calculations 3 2 3 6 Configuring the Relay Outputs 3 2 4 0 CALIBRATION 4 1 4 1 Analog Output Calibration 4 1 4 2 System Calibration 4 1 5 0 GENERAL USER INTERFACE GUI OPERATION 5 1 5 1 Overview 5 1 5 2 Deluxe Version IFT Displays and Controls 5 2...

Page 16: ... Configuration 2 10 Figure 2 6 IFT Power Supply Board Jumpers 2 11 Figure 2 7 Wiring Layout for IFT Systems without HPS 2 12 Figure 2 8 Microprocessor Board Jumper Configuration 2 13 Figure 2 9 IFT Microprocessor Board 2 14 Figure 2 10 Interconnect Board Jumper Configuration 2 15 Figure 2 11 IFT Interconnect Board Output Connections 2 15 Figure 2 12 Outline of Heater Power Supply 2 16 Figure 2 13 ...

Page 17: ...1 Sample HELP Messages 5 3 Table 5 2 MAIN menu 5 3 Table 5 3 PROBE DATA Sub Menu 5 4 Table 5 4 CALIBRATE O2 Sub Menu 5 10 Table 5 5 SETUP Sub Menu 5 12 Table 5 6 Efficiency Constants 5 14 Table 6 1 IFT Status Codes 6 2 Table 6 2 Heater Troubleshooting 6 3 Table 6 3 Cell Troubleshooting 6 5 Table 6 4 IFT Troubleshooting 6 7 Table 6 5 MPS Troubleshooting 6 8 Table 6 6 Performance Problem Troubleshoo...

Page 18: ...Instruction Manual IB 106 300NH Rev 4 3 May 2005 iv Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 ...

Page 19: ...maining sections contain detailed proce dures and information necessary to install and service the oxygen analyzer DEFINITIONS The following definitions apply to WARNINGS CAUTIONS and NOTES found throughout this publication Highlights an operation or maintenance procedure practice condition state ment etc If not strictly observed could result in injury death or long term health hazards of personne...

Page 20: ...on of this equipment connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation The circuit breaker may also include a mechanically operated isolating switch If not then another means of disconnecting the equipment from the supply must be provided and clearly marked as such Circuit breakers or switche...

Page 21: ... and constant values to ensure that the system is correctly reading the process gas O2 values Cold Junction Compensation A method for compensating for the small voltage developed at the junction of the thermocouple leads in the probe junction box Dead Band The range through which a signal can be varied without initiating a response In the IFT 3000 dead band is used to prevent an oxygen signal near...

Page 22: ...clude 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 mu...

Page 23: ...OUNT ANALYTICAL IFT 3000 INTELLIGENT FIELD TRANSMITTER WITH WORLD CLASS 3000 PROBE 1 What is the line voltage being supplied to the IFT 3000 Write the line voltage here __________ 2 Use the following drawing Figure 1 to identify which parts of the World Class 3000 system are included in your system Components in the shaded area are optional components Figure 1 Complete World Class 3000 System ...

Page 24: ...ing any optional components Optional components are shown in the shaded area in Figure 1 3 You are familiar with the installation requirements for the IFT 3000 Intelligent Field Trans mitter and World Class 3000 probe 4 You are familiar with the procedures for changing the jumpers located in the IFT 3000 as described in Section 2 Installation If you cannot use the Quick Start Guide turn to Section...

Page 25: ...pply board microprocessor board and interconnect board as shown in Figure 2 4 Install the IFT 3000 in the desired location Refer to Section 2 paragraph 2 2a for informa tion on selecting a location for the IFT 3000 5 Wire the probe to the IFT as shown in Figure 2 6 Connect line voltage to the IFT as shown in Figure 2 7 Apply power to the IFT 3000 Allow sufficient time for the probe to reach normal...

Page 26: ... VOLTAGE JUMPERS ON IFT POWER SUPPLY BOARD INSTALL JUMPER ACROSS TERMINALS 13 AND 14 INSTALL JUMPER ACROSS TERMINALS 7 AND 8 NOTES LINE VOLTAGE SECTION LINE VOLTAGE SECTION JUMPER INSTALL JUMPER INSTALL 120 V A C 120 V A C 100 V A C 100 V A C 220 V A C 220 V A C 240 V A C 240 V A C J1 J5 J6 J1 JM1 J2 J3 J4 J5 J6 J7 J8 J9 3D39122G REV POWER SUPPLY BOARD 3D39120G REV INTERCONNECT BOARD JM8 JM7 JM1 J...

Page 27: ...ENTER 11 When the oxygen reading has stabilized at the process value press ENTER Setting up the Analog Output 1 Press the SETUP key 2 Select the Analog Output sub menu 3 Set the SOURCE to O2 For information on configuring the analog output for Efficiency or Dual Range O2 refer to Section V Operation 4 Set the AOUT TYPE to the desired setting Note that the setting must agree with the position of th...

Page 28: ...2 1 1 1 View Analog Output 1 2 1 Technical Support Hotline For assistance with technical problems please call the Customer Support Center CSC The CSC is staffed 24 hours a day 7 days a week Phone 1 800 433 6076 In addition to the CSC you may also contact Field Watch Field Watch coordinates Rosemount Analytical s field service throughout the US and abroad Phone 1 800 654 RSMT 1 800 654 7768 Rosemou...

Page 29: ...l World Class 3000 Oxygen Analyzer with IFT 3000 Intelligent Field Transmitter should contain the items shown in Figure 1 1 Record the part number serial number and order number for each com ponent of your system in the table located on the first page of this manual 1 Intelligent Field Transmitter 2 Instruction Manual 3 Multiprobe Calibration Gas Sequencer Optional 4 Heater Power Supply Optional 5...

Page 30: ...l cell which consists of a small yttria stabilized zirconia disc Both sides of the disc are coated with porous metal electrodes When operated at the proper temperature the millivolt output voltage of the cell is given by the following Nernst equation EMF KT log10 P1 P2 C Where 1 P2 is the partial pressure of the oxygen in the measured gas on one side of the cell 2 P1 is the partial pressure of the...

Page 31: ...earized voltage or current The heater power supply HPS can provide an interface between the IFT and the probe The HPS contains a transformer for sup plying proper voltage to the probe heater The enclosure has been designed to meet NEMA 4X IP56 specifications for water tightness an optional enclosure to meet Class 1 Division 1 Group B IP56 explo sion proof is also available Systems with multiprobe ...

Page 32: ...e and software which permit HART communications e Handling the Oxygen Analyzer It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to pre vent possible equipment damage The oxygen analyzer is designed for industrial application Treat each component of the system with care to avoid physical damage The probe contai...

Page 33: ...ON GAS INSTRUMENT AIR SUPPLY REF AIR PRESSURE REGULATOR FLOWMETER INTELLIGENT FIELD TRANSMITTER MULTIPROBE CALIBRATION GAS SEQUENCER REFERENCE AIR CALIBRATION GAS HEATER POWER SUPPLY OXYGEN ANALYZER PROBE INTELLIGENT FIELD TRANSMITTER OXYGEN ANALYZER PROBE ADAPTER PLATE ADAPTER PLATE STACK DUCT GASES CAL GAS 1 CAL GAS 2 INST AIR SUPPLY LINE VOLTAGE LINE VOLTAGE 27270001 Figure 1 2 Typical System I...

Page 34: ...or Options 1200 Ft 364 m Max 4 Twisted Pair Plus 2 Twisted Pair for Options 1200 Ft 364 m Max 5 Conductor 1000 Ft 309 m Max Modular Design Up to 4 Probes IFT 3000 IFT 3000 IFT 3000 Intelligent Field Transmitter NEMA 4X Enclosure Line Voltage 100 to 120 Volt 220 to 240 Volt Intelligent Field Transmitter NEMA 4X Enclosure Line Voltage 100 to 120 Volt 220 to 240 Volt Intelligent Field Transmitter NEM...

Page 35: ...rom the HPS A source of instrument air is required at the probe for reference air use Since the probe is equipped with an in place calibration feature provision should be made for con necting calibration gas tanks to the oxygen analyzer when the probe is to be calibrated If the calibration gas bottles will be perma nently hooked up a check valve is required next to the calibration fittings on the ...

Page 36: ...Instruction Manual IB 106 300NH Rev 4 3 May 2005 1 8 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 ...

Page 37: ...efore either make necessary repairs or install the probe upstream of any leakage 3 Ensure that the area is clear of ob structions internal and external that will interfere with installation Allow ade quate clearance for removal of probe Figure 2 1 4 If the probe is to be mounted outside subject to rain and snow conditions make sure the back of the probe out side of the duct is insulated to prevent...

Page 38: ...OPE CAL GAS ANSI DIN JIS 1 4 IN TUBE 6 MM TUBE 6 MM TUBE REF AIR 0 062 THK GASKET FURNISHED IN XIT ADAPTER ACCESSORY ANSI JIS DIN 3535B18H02 3635B48H01 3535B45H01 4512C34 4512C35 4512C36 INSULATE IF EXPOSED TO AMBIENT WEATHER CONDITIONS ELEC CONN 1 2 CONDUIT 16 406 34 864 106 2692 142 3607 DIM A 27 3 694 45 3 1151 117 3 2980 153 3 3894 DIM B TABLE II INSTALLATION REMOVAL 18 IN 3 FT 70 1778 81 3 20...

Page 39: ...DIM D DIM E 3 FT 6 FT 9 FT 12 FT 27 686 63 1600 81 3 2065 67 1 1704 103 1 2619 139 1 3533 99 2515 117 3 2980 153 3 3894 135 3429 45 3 1151 31 1 790 TABLE III REMOVAL INSTALLATION NOMINAL MEASUREMENTS NOTE DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES 0 06 THK GASKET FURNISHED IN HARDWARE PACKAGE P N 3535B58G02 ANSI P N 3535B58G04 JIS P N 3535B58G06 DIN 37840002 FLANGE DIAMETER 8 HOLES D...

Page 40: ... 6 00 153 9 00 229 0 625 11 4 75 121 7 50 191 4 75 121 0 625 11 7 5 191 9 25 235 M 16 x 2 3 94 100 7 48 190 5 708 145 M 16 x 2 6 50 165 9 25 235 M 12 x 1 75 4 92 125 7 894 200 5 118 130 M 20 x 2 5 NOTE PART NUMBERS FOR ADAPTOR PLATES INCLUDE ATTACHING HARDWARE NOTE PART NUMBERS FOR ADAPTOR PLATES INCLUDE ATTACHING HARDWARE ADAPTOR PLATE FOR 3 6 9 AND 12 FT ABRASIVE SHIELD INSTALLATIONS SEE SHEET 2...

Page 41: ...114 O D REF PIPE 4 00 SCHED 40 PIPE SLEEVE NOT BY ROSEMOUNT LENGTH BY CUSTOMER ANALYTICAL MASONRY STACK WALL OUTSIDE WALL SURFACE JOINT MUST BE AIRTIGHT MTG HOLES SHOWN ROTATED 45 OUT OF TRUE POSITION o FIELD WELD PIPE TO ADAPTOR PLATE BOLT ADAPTOR PLATE TO OUTSIDE WALL SURFACE NOTE DIMENSIONS IN INCHES WITH MILLIMETERS IN PARENTHESES 2 50 63 5 MIN DIA HOLE IN WALL STACK OR DUCT METAL WALL WELD OR...

Page 42: ... ASSY BY ROSEMOUNT ANALYTICAL 2 HOLES 0 625 16 DIA FOR 0 50 12 DIA BOLT ABRASIVE SHIELD NOTE BRACING IS FOR VERTICAL AND HORIZONTAL PROBE INSTALLATION 1 00 25 MAX 0 375 10 1 00 25 4 12 105 4 12 105 60 MAX o 30 MIN o 5 62 143 5 62 143 36 00 914 EXTERNAL BRACING REQUIRED FOR 9 FT AND 12 FT 2 75 M AND 3 66 M PROBES AS SHOWN ABOVE 37840005 BOTH BRACE CLAMP ASSEMBLIES ARE THE SAME INSTALLATION AND LOCA...

Page 43: ...e ori ented in any direction 6 If the system has an abrasive shield check the dust seal packings The joints in the two packings must be staggered 180 Also make sure that the packings are in the hub grooves as the probe slides into the 15 forcing cone in the abrasive shield NOTE If process temperatures will exceed 392 F 200 C use anti seize com pound on stud threads to ease future removal of probe ...

Page 44: ...tled standard air with step down regulator c Bottled compressed gas mixture 20 95 oxygen in nitrogen d Other equivalent clean dry oil free air supply TO PROBE HEAD REF AIR SET 263C152G01 1 FLOWMETER 0 2 2 0 SCFH 771B635H02 2 2 PRESSURE GAGE 0 15 PSIG 275431 006 3 COMBINATION FILTER REG 0 30 PSIG 4505C21G01 NOTE DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES 1 2 3 4 81 122 17 FLOW SET POI...

Page 45: ...it breakers or switches must comply with a recognized standard such as IEC 947 NOTE Refer to Figure 2 6 for fuse locations and specifications 1 The IFT can be configured for 100 120 220 or 240 line voltages For 120 Vac usage install JM8 JM7 and JM1 on the power supply board For 220 Vac usage install jumpers JM6 JM5 JM2 refer to Figure 2 5 and Figure 2 6 2 For installations where the cable run is l...

Page 46: ...not be smaller than 16 gauge 3 amp 6 Before supplying power to the IFT ver ify that the jumpers have been properly set in the IFT Figure 2 5 Figure 2 8 and Figure 2 10 7 Terminal strip J5 on the power supply board is used for supplying the IFT with power Terminal strip J6 on the power supply board is used to supply the probe heater with power if an HPS is not used Figure 2 6 ALWAYS DISCONNECT LINE...

Page 47: ...semount Analytical Inc A Division of Emerson Process Management Installation 2 11 World Class 3000 FUSES FUSES NOTE ALL FUSES F1 THROUGH F5 ARE 5A 250 VAC ANTI SURGE CASE SIZE 5 X 20 MM TYPE T TO IEC127 SCHURTER Figure 2 6 IFT Power Supply Board Jumpers ...

Page 48: ...M INTELLIGENT FIELD TRANSMITTER BEFORE CHANGING JUMPERS LINE VOLTAGE SECTION JUMPER INSTALL PROBE HEATER VOLTAGE SECTION JUMPER INSTALL 120 V A C 100 V A C 220 V A C 240 V A C J1 J5 J6 J1 JM1 J2 J3 J4 J5 J6 J7 J8 J9 3D39122G REV POWER SUPPLY BOARD 3D39513G REV 13 MICROPROCESSOR BOARD 3D39120G REV INTERCONNECT BOARD JM8 JM7 JM1 JM3 JM7 JM2 JM6 JM5 JM2 JM6 JM5 JM1 WORLD CLASS PROBE WORLD CLASS DIREC...

Page 49: ...such as chart recorders Relay outputs are typi cally sent to annunciators 3 Relays K1 and K2 are user configur able from the probe SETUP sub menu Table 5 5 Typically these are used to indicate O2 values above or below specified tolerances OK relay is ener gized when unit is functioning properly 4 All wiring must conform to local and national codes 5 Analog output requires shielded cable with the s...

Page 50: ...R123 R120 C55 R114 TP2 R122 Q13 D18 TP99 R126 C12 C64 TP101 R121 R87 R85 TP73 U23 U28 R107 Z2 Z4 C48 C47 TP84 Q8 C54 R104 R100 R88 U27 U30 TP96 TP89 R125 TP77 TP85 R95 R103 C8 TP79 TP76 R91 R85 R86 TP72 TP82 R83 R101 C83 R109 U16 C36 C40 U9 U20 R77 TP63 C9 C29 U6 U33 U5 U3 U8 SW2 U25 D14 RL1 RL3 RL2 C59 TP78 TP80 R98 R93 C56 C58 R90 D16 D15 C57 R105 R102 J4 TP105 R153 R156 R161 Q15 Q14 R157 D20 C7...

Page 51: ...7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24 OK COM OK NO K1 COM K1 NO K2 COM K2 NO ANOUT ANOUT STACK T C STACK T C PROBE T C PROBE T C PROBE MV PROBE MV OK NC K1 NC K2 NC CAL INIT 2 CAL INIT 1 CALRET NOGAS LOGAS HIGAS INCAL RELAY RELAY AD590 AD590 TRIAC TRIAC JM1 UNDER SHIELD NOTES DENOTES SHIELD CONNECTION OK RELAY IS ENERGIZED WHEN UNIT IS ...

Page 52: ... installa tion diagram Figure 2 13 The wiring terminals are divided into two layers the bottom FROM PROBE terminals should be connected first the top FROM ELECTRONICS terminals should be connected last Figure 2 14 Each terminal strip has a protective cover which must be removed when making connections To remove the terminal covers remove two slotted screws holding cover in place Always reinstall t...

Page 53: ...ECTRONICS SELECTION JUMPER PROBE HEATER VOLTAGE SECTION REMOVE JM3 JM6 DIGITAL NEXT GENERATION WORLD CLASS PROBE JM7 NOTES 1 2 3 4 5 6 7 8 BL PROBE MV PROBE MV PROBE TC PROBE TC OR YE RD GN E R H WH BK GN CELL VE OR CELL VE YE CHROMEL RD ALUMEL GN BK BK HEATER PROBE JUNCTION BOX WIRING A B 37840007 RELAY WIRE IS OPTIONAL RELAY CAN BE BYPASSED WITH JUMPER JM 2 IF NOT WIRED TO THE IFT 1 2 STACK TC W...

Page 54: ...ITTER BEFORE CHANGING JUMPERS LINE VOLTAGE SECTION JUMPER INSTALL PROBE HEATER VOLTAGE SECTION JUMPER INSTALL 100 V A C 120 V A C 220 V A C 200 V A C 240 V A C J1 J5 J6 3D39122G REV POWER SUPPLY BOARD JM3 JM7 JM2 JM8 JM7 JM1 JM6 JM5 JM2 JM4 JM5 JM2 JM6 JM5 JM1 NOT USED REMOVE JM9 JM10 JUMPER CONFIGURATION E N L LINE VOLTAGE NOT USED INTELLIGENT FIELD TRANSMITTER IFT 3000 3D39513G REV 13 MICROPROCE...

Page 55: ...Inc A Division of Emerson Process Management Installation 2 19 World Class 3000 TRANSFORMER TRANSFORMER SCREW 2 PER COVER TERMINAL COVERS FRONT SIDE TERMINAL STRIP FROM ELECTRONICS TERMINAL STRIP FROM ELECTRONICS 29850005 Figure 2 14 Heater Power Supply Wiring Connections ...

Page 56: ... supplying power to the heater power supply verify that jumpers JM3 JM6 are removed and JM7 is installed If relay wire Figure 2 13 note 1 is in stalled JM2 must be removed from HPS Mother Board Figure 2 16 4 Before supplying power to the heater power supply verify that the jumpers on the mother board Figure 2 16 are properly configured Jumpers JM3 and JM6 should be removed and JM7 should be instal...

Page 57: ... 18 shows the bottom of the MPS where the gas connections are made 1 4 inch threaded fittings are used 1 Connect the reference air supply to INSTR AIR IN The air pressure regu lator valve is set at the factory to 20 psi 138 kPa If the reference air pressure should need readjustment turn the knob on the top of the valve until the desired pressure is obtained 2 Connect the high O2 calibration gas to...

Page 58: ...alibration If more than one probe system is being used the additional probes and electric packages would be wired similar to the first probe NOTE Refer to Figure 2 19 for fuse locations and specifications 1 Run the line voltage through the bulk head fitting on the bottom of the MPS where marked LINE IN Figure 2 18 Connect the line voltage as shown in Figure 2 19 to the LINE IN terminal on the MPS ...

Page 59: ...BE 3 PROBE 4 PROBE 1 SOLENOID PROBE 2 SOLENOID PROBE 3 SOLENOID PROBE 4 SOLENOID HIGH GAS SOLENOID LOW GAS SOLENOID PRESSURE SWITCH J2 J3 J4 J5 J6 J7 J8 J9 J1 MH1 MH2 MH4 MH3 3D39120G REV CAL RET NO GAS LO GAS HI GAS IN CAL IFT INTERCONNECT BOARD NOTE FUSES FOR 115 VOLT MPS UNIT ARE FAST ACTING 1A 250 VAC SIZE 1 4 IN DIA X 1 1 4 IN LG GLASS BODY NON TIME DELAY BUSSMAN PART NO BK AGC 1 ROSEMOUNT AN...

Page 60: ...n completing installation make sure that the probe is turned on and operating prior to firing up the combustion process Damage can result from having a cold probe exposed to the process gases Power down all probes during outages Sensor chamber is heated to 736 C Further if ducts will be washed down during the outage remove the probes to prevent water damage ...

Page 61: ...Xfer Fnct to either linear or log output You can also specify the O2 values repre sented by the high and low analog out put values 3 Source Set to Dual Rng O2 Range setup allows you to set the transfer function Xfer Fnct to either linear or log output You can also specify the O2 values represented by the high and low analog output values for both the nor mal and high range The Mode Setup sub menu ...

Page 62: ...Alarm and Lo Alarm values are the set tings for the high and low oxygen concentration alarms respectively The Alarm DB parameter allows the setting of an alarm dead band When a dead band is set the O2 value must change by the dead band value before the alarm will re set For example if the Hi Alarm is set to 8 00 and the dead band is set to 0 25 the O2 con centration must drop to below 7 75 before ...

Page 63: ... cali bration is necessary the system can be equipped with the optional MPS 3000 Multi probe Calibration Gas Sequencer for fully automatic calibration at regular intervals Without an MPS the probes must be cali brated manually semiautomatically b Probe Calibration 1 Previous Calibration Constants Functionality There are three sets of registers used to store calibration constants These are Latest C...

Page 64: ...ic Calibration There are two options for supplying calibration gases to the probe during semiautomatic calibration The first A uses refillable bottles and adjustable 2 stage pressure regulators the second B uses disposable bottles and a fixed single stage regulator to provide a mixed flow Normally the first method A will have a higher cost and not be portable The second B is less costly portable a...

Page 65: ... kPa 4 One instrument air pressure regulator 20 psi 138 kPa maximum and a supply of clean dry instrument air 5 Two zero leakage shutoff valves 6 Miscellaneous oil free tubing and fittings b Calibration 1 A typical calibration setup is shown in Figure 4 1 Care must be taken that all fittings are tight and free from oil or other organic contaminants Small openings can cause back diffusion of oxygen ...

Page 66: ...138 kPa for both gases The reference air should be flowing as in normal operation 3 Refer to paragraph 4 2d of this section for Manual Semi automatic Calibration setup and procedure using the IFT 4 Calibration gases will be switched on and off using the shutoff valves Test Method B Oxygen Calibration Gas and Service Kit a Required Equipment Do not use 100 nitrogen as a zero gas It is suggested tha...

Page 67: ... nitrogen in dispos able bottle 3 A check valve is required at the probe between the cali bration fitting and the gas line to prevent the migration of process gases down the cali bration gas line b Calibration with a Portable Rose mount Analytical Oxygen Calibra tion Gases Kit 1 A typical portable calibration setup is shown in Figure 4 3 For manual semiautomatic calibration remove cap plug from th...

Page 68: ...et the cursor on Auto Cal Press ENTER Set Auto Cal to NO if not already done 2 Press the CAL key Select PERFORM CALIBRATION sub menu Press EN TER to start Manual Calibration will appear on the LCD display Press ENTER to start Follow the data queues Refer to Table 5 4 CALI BRATE O2 Sub menu e Fully Automatic Calibration 1 Calibration Gases For Fully Automatic Calibration For fully automatic calibra...

Page 69: ...L CHECK VALVE PROBE SIGNAL CONNECTIONS MPS IFT SIGNAL CONNECTIONS MPS INSTRUMENT AIR IN CALIBRATION GAS 1 HIGH O2 CALIBRATION GAS 2 LOW O 2 37840012 NOTE THE MPS CAN BE USED WITH UP TO FOUR PROBES ONLY ONE PROBE CAN BE CALIBRATED AT A TIME PROBE CALIBRATIONS MUST BE SCHEDULED IN MULTIPLE PROBE APPLICATIONS NOTE SHOWN WITH HPS OPTION REFERENCE AIR Figure 4 4 Typical Automatic Calibration System ...

Page 70: ...r of minutes and seconds Abort Time 0 00 Set the amount of time allowed between key functions before the calibration procedure is aborted in number of minutes and seconds Res Alarm ____ Set the desired resis tance alarm between 50 to 10 000 ohms 2 Fully Automatic Calibration Setup In order for the IFT system to calibrate automatically the parameters from the CALIBRATE sub menu shown in Table 4 1 i...

Page 71: ...Probe Tag Number Probe Location Date Placed Into Service Date Slope Constant Impedance Responseinitial Responsefinal Notes Responseinitial When the second calibration gas is turned off note the number of seconds required for the O2 value to begin migrating back to the process value Responsefinal When the second calibration gas is turned off note the number of seconds required for the O2 value to s...

Page 72: ...Instruction Manual IB 106 300NH Rev 4 3 May 2005 4 10 Calibration Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 ...

Page 73: ...also known as the General User Interface GUI version This IFT contains an LED display liquid crystal display panel and an eight key pad from which the probe and electronics can be configured calibrated and troubleshooted b HART Communicator Interface Devices The HART communications protocol can interface with any of the above IFT ver sions To interface a HART communicator with an IFT one of three ...

Page 74: ... number 2 HELP Context sensitive HELP is displayed when this key is pressed 3 DATA DATA key is used to access DATA menu 4 CAL CAL key used to access CALIBRATE menu 5 SETUP SETUP key used to access SETUP menu 6 ESC The escape key is used to exit to a high level menu or to abort a parameter change 7 The decrease key is used to move the cursor asterisk when scrolling through lists or to decrease a pa...

Page 75: ...libration gas pressure is low h CalEr Calibration error i ResHi Resistance is above the high limit j OK System is functioning correctly 5 5 QUICK REFERENCE CHART The quick reference chart Figure 5 2 is de signed to help you get where you want to be in the menu system The chart shows all the avail able menu and sub menu options for the IFT Follow the lines to determine which menu choices to make Mo...

Page 76: ... at any time To select the parameter to be changed move the cursor to the desired pa rameter using the arrow keys Press ENTER to select that parameter To change the value for that parameter use the arrow keys to increase or decrease the value Press ENTER to save changes There are six selections available on the SETUP sub menu Calibration O2 Calculation O2 Alarms Efficiency Calc Relay Outputs and A...

Page 77: ...22 PROBE DATA DIAGNOSTIC DATA VOLTAGES PROCESS DATA TEMPERATURE Cell Stack Cold Junct Cell Cell T C Stk T C Cold Jnt OUTPUT VALUES Analog K1 State K2 State LATEST CALIBRATION Slope Constant Resist PREVIOUS CAL Slope Constant Resist Next Cal Slope Constant Resist CALIBRATION STATUS CALIBRATE O2 VIEW CONSTANTS PERFORM CALIBRATION O2 Efficiency Stack Temp Figure 5 2 Quick Reference Chart Sheet 1 of 5...

Page 78: ...INT RESET SLOPE AND CONST 34 5 mV D 57 5 mV D 20 0 mV 20 0 mV 736 C 843 C o o 0 1000 O2 25 00 O2 0 00 O2 25 00 O2 ENABLE CALC K1 VALUE K2 VALUE K3 VALUE Yes No 0 0000 1 000 0 0000 20 00 K1 SETUP K2 SETUP EVENT 1 EVENT 2 EVENT 3 EVENT 1 EVENT 2 EVENT 3 Off In Cal Hi O2 Lo O2 Htr Fail Cal Fail TG Low Cell Res High Range HI ALARM LO ALARM ALARM DB SETUP CALIBRATION O2 CALIBRATION O2 ALARMS EFFICIENCY...

Page 79: ...gement General User Interface GUI Operation 5 7 World Class 3000 CONTINUED FROM SHEET 2 SETUP CONTINUED FROM SHEET 2 ANALOG OUTPUTS SOURCE AOUT TYPE RANGE SETUP O2 Efficiency Dual Rng O2 HART 4 20 mA 0 20 mA 0 10 V See sheet 5 USA GBR FRA ESP GER COUNTRY 27270004 Figure 5 2 Quick Reference Chart Sheet 3 of 5 ...

Page 80: ...00 CONTINUED FROM SHEET 2 CALIBRATION HIGH GAS LOW GAS AUTO CAL OUTPUT TRACKS CAL INTRVL NEXT CAL GAS TIME PURGE TIME RES ALARM 0 1000 O2 25 00 O2 0 1000 O2 25 00 O2 Yes No Yes No Off 1H 365 D OH 1 hour to 365 days and no hours 1 hour to 365 days and no hours Disabled 1H 365 D OH 00 30 20 00 00 30 20 00 50 10000 Ω Ω 16860025 Figure 5 2 Quick Reference Chart Sheet 4 of 5 ...

Page 81: ... O2 25 00 O2 0 000 O2 25 00 O2 0 000 O2 25 00 O2 0 000 O2 25 00 O2 0 000 O2 25 00 O2 0 000 O2 25 00 O2 0 000 O2 25 00 O2 Range Setup Source not set to Dual Rng O2 Range Setup Source set to Dual Rng O2 NORMAL RANGE VALUES HIGH END HIGH END LOW END LOW END XFER FNCT XFER FNCT RANGE VALUES DUAL RANGE SETUP MODE SETUP HIGH RANGE VALUES RANGE MODE HIGH IN CAL SWITCHES AT Normal Auto High Yes No 1686002...

Page 82: ...nt testing phase in min sec Cell mV ______mV Cell voltage of the probe Resistance Check Time Left 0 00 Resistance check in progress Cell _____mV _____C Calibration Complete Purging 0 00 Cell voltage and probe temperature Gas lines are being purged of cali bration gas Cell _____mV _____C Calibration Complete Cell voltage and probe temperature Auto Cal in Probe Setup is NO Press ENTER to start Manua...

Page 83: ... _____mV Resist _____ohms Slope for probe from latest calibration Latest calibration offset for probe Latest calibration resistance of probe Previous Calibration Slope _____mV D Constant _____mV Resist _____ohms Slope for probe from previous calibration Previous calibration offset for probe Previous calibration resistance of probe Calibration Status N A Next Cal XD XH Time until next calibration i...

Page 84: ... Alarm 50 W 10 kW Resistance alarm set from 50 to 10 000 ohms O2 Calculation Slope ____ mV D Constant ____ mV Set Point ____ C Set value between 34 5 and 57 5 Set value between 20 0 and 20 0 mV Set either 736 for World Class 3000 probes or 843 for 218 probes Ensure the correct voltage is selected when using HPS 3000 with either World Class 3000 probes or 218 probes Refer to Figure 2 13 Jumper Sele...

Page 85: ...exceeds high limit High analog output range is selected Analog Output SOURCE O2 Efficiency Dual Rng O2 Select the measurement value to be represented on the analog output AOUT TYPE HART 4 20mA 0 20mA 0 10V Select one of the listed options to define upper and lower limits of probe analog output Only a selection that matches the position of the analog output selector switch on the microprocessor boa...

Page 86: ...her the High Range or the Normal Range based on the present O2 value and the Mode Setup Values High Forces the output to the High Range High in Cal Yes No Selecting Yes will cause the High Range to be used whenever the probe is being calibrated Switches at 0 000 O2 25 00 O2 Enters the switching point between the High and Nor mal Ranges O2 values above this point will use the High Range and values ...

Page 87: ... found in a boiler room or control room Noise suppres sion circuits are employed on all field termi nations and main inputs When fault finding the electrical noise being generated in the immediate circuitry of a faulty system should be evaluated All cable shields must be connected to earth c Loose Integrated Circuits The IFT uses a microprocessor and sup porting integrated circuits Should the elec...

Page 88: ...libration value LowO2 The measured O2 value is below the low O2 alarm limit The problem may be in the probe or the process HiO2 The measured O2 value is above the high O2 alarm limit The problem may be in the probe or the process NoGas Test gas pressure is too low Pressure switches are set to trigger this alarm at 12 to 16 psig 83 to 110 kPa gage Test gas regulators are usually set at 20 to 25 psi...

Page 89: ...TC 28 4 mV Cold Junction 273 to 330 mV normal O2 Display 0 1 Blown fuse or faulty wiring Check all fuses and wiring for continuity and repair as needed Verify that input power jumpers are installed correctly Check jumpers for proper configuration in IFT and HPS if used 2 Heater failure In HPS with power OFF check heater resistance at J2 terminals R H For 44 V heater resis tance should be 11 to 14 ...

Page 90: ...g error thermocouple wires reversed Verify TC wiring at junction box terminal and electronics The yellow chromel line connects to terminal 3 The red alumel line connects to terminal 4 Trace line through the HPS if used and the electronics Reverse wires if needed 2 Faulty thermocouple At a cold junction reference of 77 F 25 C the probe TC should read about 29 3 mV Replace faulty thermocouple 3 Faul...

Page 91: ... a calibration before trouble shooting the cell Refer to Table 6 3 to troubleshoot cell related problems Table 6 3 Cell Troubleshooting Problem Cause Corrective Action Status is LowO2 Cell mV 127 mV 1 Faulty cell connection or open If the cell circuit is open the cell output will show about 127 mV Check cable connection between the probe and the electronics Check that the probe spring presses the ...

Page 92: ...r and clean the unit in an ultrasonic bath 5 Faulty cell Low sensor cell output when test gas is applied If test gas flow is good and there is low cell signal replace the cell or call the SCAN line for assistance Typical cell output Test Gas mV 8 0 18 to 25 0 4 76 to 86 6 Cell performance degraded from aging Replace the sensor cell if its resistance has increased beyond 1 kOhm and the slope calcul...

Page 93: ...if needed 3 Microprocessor board fault Replace microprocessor board IFT LED is steady ON Heater or cell wiring problem 1 Faulty wiring Check thermocouple and heater wires and connections for continuity Repair as needed 2 Jumpers set up wrong JM1 on interconnect board JM6 on microprocessor board or JM9 and JM10 on power supply board are configured incorrectly Check that jumpers are set up as follow...

Page 94: ...t gas regulator pressure to 20 psig 138 kPa gage to avoid nuisance alarms Replace faulty switch with a new one if test gas supply is good Status is ResHi or CalEr Cell mV is between 20 to 120 mV The CalEr occurs when the slope calculated from the last calibration was out of range CalEr can be caused by leaks a faulty diffusor or sensor cell erroneous test gas values or not enough test gas time Eac...

Page 95: ...ccur in the silicon rubber hose in the probe junction box Replace hose 4 Air ingress from leaky duct Check condition of duct gas lines and fittings If duct has air ingress upstream of probe re site the probe or fix the leak 5 Analog output or recorder fault Measure analog output in voltage or milliamps as set up on the analog output board and soft ware If analog output is not in range replace the ...

Page 96: ...Instruction Manual IB 106 300NH Rev 4 3 May 2005 6 10 Troubleshooting Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 ...

Page 97: ...The environment in which the equip ment has been operating housing weather vibration dust etc 3 Site from which equipment was removed 4 Whether warranty or nonwarranty service is requested 5 Complete shipping instructions for re turn of equipment 6 Reference the return authorization number d Enclose a cover letter and purchase order and ship the equipment according to the instructions provided in ...

Page 98: ...Instruction Manual IB 106 300NH Rev 4 3 May 2005 7 2 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 ...

Page 99: ...t Appendices 8 1 World Class 3000 SECTION 8 APPENDICES APPENDIX A WORLD CLASS 3000 OXYGEN ANALYZER PROBE APPENDIX B HPS 3000 HEATER POWER SUPPLY APPENDIX D MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER APPENDIX E IFT 3000 INTELLIGENT FIELD TRANSMITTER APPENDIX J HART COMMUNICATOR MODEL 375D9E IFT 3000 APPLICATIONS ...

Page 100: ...SSEMBLED 21240005 APPENDIX A 1 Heater Strut and Backplate Assembly 2 Diffusion Assembly 3 Retainer Screw 4 Cell and Flange 5 Corrugated Seal 6 Probe Tube Assembly 7 Screw 8 Washer 9 Cover Chain Screw 10 Cover Chain 11 Probe Junction Box Cover 12 Cover Gasket 13 Wiring Diagram 14 O Ring 15 Terminal Block Screws 16 Terminal Block 17 Terminal Block Marker 18 Terminal Block Mounting Plate 19 Probe Jun...

Page 101: ...the wiring and installation of this appara tus at the front of this Instruction Bulletin Failure to follow the safety instructions could result in serious injury or death A 1 OXYGEN ANALYZER PROBE GENERAL The Oxygen Analyzer Probe Figure A 1 con sists of three component groups probe exterior inner probe and probe junction box Figure A 2 PROBE EXTERIOR SENSING CELL INSTALLED PROBE INTERIOR PROBE JU...

Page 102: ...0 95 O2 regulated to 5 psi 34 kPa Calibration gas mixtures Rosemount Hagan Calibration Gas Kit Part No 6296A27G01 contains 0 4 O2N2 Nominal and 8 O2N2 Nominal Calibration gas flow 5 scfh 141 6 L hr HPS 3000 Power supply 100 110 220 10 Vac at 50 60 Hz HPS 3000 Power requirement 200 VA HPS 3000 Ambient Operating Temperature 32 to 120 F 0 to 50 C Ambient operating temperature Probe Junction Box 300 F...

Page 103: ...re is also a tube to carry calibration gas from the probe junction box to the process side of the cell during calibration PROBE TUBE CORRUGATED SEAL CELL AND FLANGE ASSEMBLY 21240007 Figure A 3 Cell and Tube Assemblies c Snubber Diffusion Assembly The snubber diffusion assembly protects the cell from heavy particles and isolates the cell from changes in temperature The snubber diffusion assembly t...

Page 104: ...d after repair or replacement of cell pad and wire heater and thermocouple or after disassembly of the probe A 3 INNER PROBE ASSEMBLY The inner probe assembly Figure A 5 consists of six main parts a Ceramic support rod with four holes running through the length The holes serve as insulated paths for the cell signal wire and thermocouple wires b A heater that is helically wrapped on a quartz suppor...

Page 105: ...less steel tubing delivers this gas to the process side of the cell In a healthy cell the difference in oxygen pressure from the process side to the reference side of the cell will cause a millivolt output proportional to the difference in oxygen levels The electronics unit can use the two millivolt outputs caused by the two calibration gases for either automatic or semi automatic calibration Do n...

Page 106: ...R 187 6 00 125 45 MIN 90o 3 584 3 554 SKIN CUT FACE FOR 90 o 22 5 o DIA ON A 7 50 DIA B C REF 745 755 0 75 THRU 4 PLS EQ SP ON 4 75 B C NOTES 1 WELD ON BOTH SIDES WITH EXPANDING CHILL BLOCK 2 BEFORE WELDING BUTT ITEM 2 OR 4 WITH ITEM 1 AS SHOWN 187 16860033 Figure A 7 Abrasive Shield Assembly NOTE In highly abrasive applications rotate the shield 90 degrees at normal service intervals to present a...

Page 107: ...Used for over 25 years the ceramic diffu sion assembly provides a greater filter sur face area for the probe P0011 Figure A 9 Flame Arrestor Diffusion Dust Seal Assembly 19280010 Figure A 10 Ceramic Diffusion Assembly c Flame Arrestor Diffusion Assembly Where a high concentration of unburned fuel is present in the exhaust gases a flame arrestor diffusion assembly Figure A 9 and Figure A 11 is reco...

Page 108: ...able temperature of 1300 F 704 C a bypass sensor package can be employed The bypass system uses an 18 inch 457 mm or 3 foot 0 92 m probe mounted externally on the stack or duct The process or exhaust gases are di rected out to the probe through a passive sampling system using inconel tubes Flue gas flow induces the movement of gases into through and out of the bypass unit The bypass arrangement do...

Page 109: ...D TUBING 2 SCFH AT 3 PSIG MAX CLEAN DRY AIR REQUIRED FITTING IS LOCATED ON FAR SIDE LAG TO ENSURE GAS TEMPERATURE DOES NOT GO BELOW DEW POINT OR EXCEED 500 C o INSTALL WITH ANALYZER IN A VERTICALLY DOWNWARDS DIRECTION ONLY FLUE GAS OPERATING TEMPERATURE RANGE 1200 TO 1800 F 650 TO 980 C o o o o RECOMMENDED TWO INCH THK INSULATION THERMAL CONDUCTIVITY K EQUALS 0 5 FOR INSULATION DIMENSIONS ARE IN I...

Page 110: ...TION DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES 20 FT 6 1 M STD CABLE A A 01 06 07 08 GASKET AND HARDWARE 05 09 10 4 3 6 DRAIN PLATE WELDED TO STACK 2 1 REF AIR CAL GAS ELECT CABLE VIEW A A GROUP NOTE A 3 FT 914 4 GAS TUBE PICK UP B 6 FT 1828 8 GAS TUBE PICK UP C 9 FT 2743 2 GAS TUBE PICK UP 4 026 102 26 I D DIRECTION OF FLOW 14 15 16 11 12 13 02 03 04 FLANGE o o o o o 1 2 3 4 5 6 7 ...

Page 111: ...NSI bolt pattern 1U0571 G02 6 By pass Package with ANSI bolt pattern 1U0571 G03 9 By pass Package with ANSI bolt pattern 1U0571 G04 3 By pass Package with JIS bolt pattern 1U0571 G05 6 By pass Package with JIS bolt pattern 1U0571 G06 9 By pass Package with JIS bolt pattern 1U0571 G07 3 By pass Package with DIN bolt pattern 1U0571 G08 6 By pass Package with DIN bolt pattern 1U0571 G09 9 By pass Pac...

Page 112: ...on gas is turned off b Table A 2 provides a guide to fault finding for the above symptoms c Figure A 16 and Figure A 17 provide an al ternate approach to finding probe related problems Table A 2 Fault Finding Symptom Check Fault Remedy 1 No response to oxy gen concentration change when Thermocouple continuity Thermocouple failure Replace thermocouple or return probe to Rosemount Analytical Heater ...

Page 113: ...stalled 3 System does not give accurate indication of applied calibration gas Ceramic diffusion element Diffusion element cracked broken or missing Replace diffusion element 4 System takes a long time to return to flue gas value after calibra tion gas is turned off Diffusion element Plugged diffusion element Change diffusion element or snubber diffusion element Check calibration gas fit ting Leak ...

Page 114: ...Instruction Bulletin Appendix A Rev 3 9 May 2005 A 14 Appendices Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 Figure A 16 Flowchart of Probe Related Problems 1 ...

Page 115: ...Instruction Bulletin Appendix A Rev 3 9 May 2005 Rosemount Analytical Inc A Division of Emerson Process Management Appendices A 15 World Class 3000 Figure A 17 Flowchart of Probe Related Problems 2 ...

Page 116: ...on Bulle tin applicable to your electronics package A 11 CELL REPLACEMENT This paragraph covers oxygen sensing cell re placement Do not attempt to replace the cell until all other possibilities for poor performance have been considered If cell replacement is needed order cell replacement kit Table A 3 The cell replacement kit contains a cell and flange assembly corrugated seal setscrews socket hea...

Page 117: ...anner wrenches from probe disassembly kit Table A 3 to turn hub free from retainer Inspect diffusion element If damaged re place element d Loosen four socket head cap screws from the cell and flange assembly and remove the assembly and the corrugated seal The cell flange has a notch which may be used to gently pry the flange away from the probe Note that the contact pad inside the probe will somet...

Page 118: ...sembly Torque to 55 in lbs 4 N m i Apply anti seize compound to threads of cell assembly hub and setscrews Reinstall hub on cell assembly Using pin spanner wrenches torque to 10 ft lbs 14 N m If applicable reinstall vee deflector orienting apex toward gas flow Secure with setscrews and anti seize compound Torque to 25 in lbs 2 8 N m j On systems equipped with an abrasive shield install dust seal g...

Page 119: ...osen setscrews Figure A 19 using hex wrench from special tools kit Table A 3 and remove vee deflector Inspect setscrews If damaged replace with M 6 x 6 stainless setscrews coated with anti seize compound 3 On systems equipped with abrasive shield remove dual dust seal gaskets 4 Use spanner wrenches from special tools kit Table A 3 to turn hub free from retainer 5 Put hub in vise Break out old diff...

Page 120: ...em perature Probe components can be as hot as 800 F 427 C This can cause severe burns Disconnect and lock out power before working on any electrical components There is voltage up to 115 Vac a Disconnect and lock out power to electron ics Using heat resistant gloves and cloth ing remove probe junction box cover Squeezing tabs on hose clamps remove hoses from probe junction box Figure A 21 Remove f...

Page 121: ...tact and thermocouple assembly h Carefully guide new contact and thermo couple assembly through V strut assembly leaf spring 4 Figure A 23 spring 9 spring clip 10 held open by squeezing tabs and tube supports 11 13 until spring clip reaches pencil mark i Reinstall insulating gasket on backplate re place two screws O rings lockwashers and flat washers connecting probe junction box to inner probe as...

Page 122: ...trical components There is voltage up to 115 Vac NOTE This replacement may be done without removing the probe from the duct a Disconnect and lock out power to electron ics Using heat resistant gloves and cloth ing remove probe cover Squeezing tabs on hose clamps and remove hoses from probe junction box Figure A 21 Remove four screws and lockwashers 7 10 Figure A 24 that hold probe junction box and...

Page 123: ...d probe junction box cover f Power up system Monitor thermocouple output It should stabilize at set point 0 2 mV Recalibrate probe per Instruction Bulle tin applicable to your electronics package A 15 CALIBRATION GAS AND REFERENCE AIR LINES FOR HIGH TEMPERATURE CORROSIVE ENVIRONMENT OPERATION A high temperature corrosive environment kit is available when the probe is exposed to these types of oper...

Page 124: ...eel tubing on the fitting at the bottom of the probe junction box Install the other end of the stainless steel tube onto the tube going to the probe Figure A 25 NOTE If abrasive conditions of high ash con tent and high velocity exist an abra sive shield is recommended To balance out the wear on the shield ro tate the shield 90 every time the probe is powered down for service STAINLESS STEEL TUBING...

Page 125: ...Strut and Backplate Assembly 3 ft 0 9 m Heater V Strut and Backplate Assembly 6 ft 1 8 m Heater V Strut and Backplate Assembly 9 ft 2 7 m Heater V Strut and Backplate Assembly 12 ft 3 6 m Contact and Thermocouple Assembly 18 in 45 6 cm Contact and Thermocouple Assembly 3 ft 0 9 m Contact and Thermocouple Assembly 6 ft 1 8 m Contact and Thermocouple Assembly 9 ft 2 7 m Contact and Thermocouple Asse...

Page 126: ...r Vee Deflector Assembly For use with standard or dust seal type ceramic diffusers Diffusion Element Replacement Kit Horizontal and Vertical Brace Clamp Assembly 9 and 12 foot 2 7 and 3 6 m probe High Temperature Corrosive Environment Kit Snubber Diffusion Assembly Dust Seal Snubber Diffusion Assembly Cup Type Diffusion Assembly 5 microns Cup Type Diffusion Assembly 40 microns Cup Type Diffusion A...

Page 127: ... with a number of different elec tronics packages The HPS is available in a NEMA 4X IP56 non hazardous enclosure or an optional Class 1 Division 1 Group B IP56 explo sion proof enclosure Figure B 1 The heater power supply Figure B 2 consists of a mother board daughter board and a transformer for supplying correct voltage to the probe heater The mother and daughter boards contain terminal strips fo...

Page 128: ...2 Appendices Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 TRANSFORMER TRANSFORMER TERMINAL COVERS FRONT SIDE TERMINAL STRIP FROM ELECTRONICS TERMINAL STRIP FROM PROBE 35730002 Figure B 2 Heater Power Supply Interior ...

Page 129: ...lts needed to power the probe heater The relay Figure B 3 can be used to remotely turn the probe on or off manu ally A triac module is used to turn the heater on or off depending on probe temperature When used with the CRE 3000 Control Room Electronics or IFT 3000 Intelligent Field Trans mitter the HPS uses a cold junction tempera ture compensation feature This allows for the use of a less expensi...

Page 130: ...ower to the heater NOTE When using the HPS 3000 with an existing electronics package such as Models 218 218A 225 or TC200 the electronics will not have the in put output capacity to support all of the functions mentioned in this section Refer to Instruction Bulletin IB 106 300NE HPS 3000 TROUBLESHOOTING B 3 OVERVIEW The HPS 3000 troubleshooting section de scribes how to identify and isolate faults...

Page 131: ...D BE NOMINALLY 12 OHMS SET METER TO 250 VAC PLACE METER PROBES ON J2 FROM ELECTRONICS ANALOG HEATER METER SHOULD REGISTER A PULSATING NOMINAL 115 VAC YES DISCONNECT POWER TO HPS AND PROBE ELECTRONICS CHECK ALL FOUR FUSES IN HPS FUSES BLOWN IN HPS NO NO CHECK THAT LINE VOLTAGE IS CORRECT BY SELECTING CORRECT JUMPERS ACCORDING TO CHART ON INSIDE OF HPS COVER REPLACE BLOWN FUSES HEATER IS OPEN REPLAC...

Page 132: ...ERMINALS IF THERE IS A PULSATING NOMINAL 115 VAC CHECK FROM PROBE TERMINALS AT PROBE HEATER IF THERE IS A PULSATING NOMINAL 44 VOLTS CHECK PROBE ELECTRONICS SETPOINT HAS BEEN CHANGED ACCORDING TO APPLICABLE ELECTRONICS PACKAGE IB SET METER ON 50 VAC SCALE CHECK IF PROBE HEATER VOLTAGE SELECTION JUMPER JM7 INSTALLED REMOVE JM8 CONNECT THE WIRING ACCORDING TO THE DECALS ON THE TERMINAL COVERS IF THE...

Page 133: ...son Process Management Appendices B 7 World Class 3000 PROBE HEATER START TO HEAT UP AND THEN LOOSES TEMPERATURE MODEL TC200 ONLY CHECK PARAMETER 35 ON TC200 IF THE NUMBER IS NEGATIVE THEN SOMEWHERE THE THERMOCOUPLE WIRES ARE REVERSED SYMPTOM 35730005 Figure B 6 HPS Troubleshooting Flowchart 3 ...

Page 134: ...overs and ground leads could result in serious injury or death a Turn off power to system b Loosen captive screws retaining HPS cover Remove cover c Remove hex nut 25 Figure B 7 from top of transformer assembly Remove retaining plate 24 and gasket 22 d Disconnect transformer harness plug from mother board e Remove old transformer Place new trans former in position and reconnect harness plug as not...

Page 135: ...on Reconnect transformer harness plug to mother board q Reinstall HPS cover B 9 DAUGHTER BOARD REPLACEMENT When turning power off at the HPS also turn off the respective probe at associated electronics When service on the HPS is completed restore power at the HPS and the associated electronics a Turn off power to system b Loosen captive screws retaining HPS cover Remove cover c Remove screws on ei...

Page 136: ...0 Appendices Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 35730006 NOTE NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASE SEPARATELY FOR LIST OF AVAILABLE PARTS SEE TABLE B 2 Figure B 7 Heater Power Supply Exploded View ...

Page 137: ...ex Nut REPLACEMENT PARTS Table B 2 Replacement Parts for Heater Power Supply FIGURE and INDEX NO PART NUMBER DESCRIPTION Figure B 1 Figure B 1 Figure B 1 Figure B 1 Figure B 1 Figure B 1 Figure B 7 13 Figure B 7 12 Figure B 7 7 Figure B 7 23 Figure B 7 23 3D39129G01 3D39129G02 3D39129G03 1U05667G01 1U05667G02 1U05667G03 1L01293H02 3D39080G02 3D39078G01 1M02961G01 1M02961G02 Non Hazardous HPS 120 V...

Page 138: ...Instruction Bulletin Appendix B Rev 2 3 May 2005 B 12 Appendices Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 ...

Page 139: ...ronics The MPS Figure D 2 consists of an air pres sure regulator a terminal board a flowmeter assembly one for each probe up to four per MPS HI GAS solenoid LO GAS solenoid a manifold and a power supply Each flowmeter assembly contains a probe solenoid An optional Z purge arrangement is available for hazardous area classification See Application Data Bulletin AD 106 300B 37840015 Analytical Figure...

Page 140: ...cer Environmental Classification NEMA 4X IP56 Humidity Range 95 Relative Humidity Humidity Range 95 Relative Humidity Ambient Temperature Range 20 to 160 F 30 to 71 C Vibration 5 m sec2 10 to 500 xyz plane External Electrical Noise Minimum Interference Piping Distance Between MPS 3000 and Probe Maximum 300 feet 91 m Cabling Distance Between MPS 3000 and Electronics Package Maximum 1000 feet 303 m ...

Page 141: ... CHECK VALVE PROBE SIGNAL CONNECTIONS MPS IFT SIGNAL CONNECTIONS MPS INSTRUMENT AIR IN CALIBRATION GAS 1 HIGH O2 CALIBRATION GAS 2 LOW O 2 37840012 NOTE THE MPS CAN BE USED WITH UP TO FOUR PROBES ONLY ONE PROBE CAN BE CALIBRATED AT A TIME PROBE CALIBRATIONS MUST BE SCHEDULED IN MULTIPLE PROBE APPLICATIONS NOTE SHOWN WITH HPS OPTION REFERENCE AIR Figure D 3 Typical Automatic Calibration System ...

Page 142: ...TICE 3 2 PLCS PARTS LIST ITEM 01 02 03 04 NOTE PART NAME MPS ASSEMBLY Z PURGE UNIT Z PURGE UNIT TUBE FITTING DWG AML AML DWG DEFINER SIZE REFERENCE INFORMATION GROUP NOTE MAT L CODE PART NUMBER OR REF DWG 3D39425GXX 1A98474H01 1A98474H02 771B870H05 GROUP G01 A R 1 2 G02 A R 1 2 W O PRESSURE LOSS SWITCH W PRESSURE LOSS SWITCH 1 4 TUBE TO 1 4 S S PARTS LIST UNITS INCHES NOTES DETAIL SWITCH CONTACT R...

Page 143: ...to replace covers and ground leads could result in seri ous injury or death D 4 TROUBLESHOOTING Table D 2 provides a guide to fault finding fail ures within the MPS The flowchart in Figure D 5 provides an alternate approach to fault finding MPS related problems Table D 2 Fault Finding SYMPTOM CHECK FAULT REMEDY 1 Power to solenoid calibration gas not released to probe Calibration gas Insufficient ...

Page 144: ...ACE PROBES ON TERMINAL BLOCK J2 CAL RET AND J1 HI GAS INSTALL NEW CALIBRATION GAS BOTTLES SOLENOID IS RECEIVING 24 VDC YES REPLACE SOLENOID NO PLACE PROBES FROM METER ON J11 METER INDICATES 24 VDC YES REPLACE TERMINAL BOARD NO FUSES BLOWN IN MPS NO PLACE PROBES FROM METER ON J1 LINE 1 AND LINE 2 SET METER FOR 200 VAC YES REPLACE BLOWN FUSES METER INDICATES 110 VAC AT J1 YES REPLACE POWER SUPPLY NO...

Page 145: ...sen two captive screws holding the inner cover 16 Lower the inner cover d Disconnect the 24V connector from J11 on the termination board 34 e Remove two screws 39 and washers 38 holding the terminal cover 37 Remove the terminal cover f Tag and remove wires from terminals 1 and 4 or 5 of the transformer in the power supply 58 g Remove two nuts 60 and washers 59 from the screws holding the power sup...

Page 146: ...ess Management World Class 3000 Analytical 37840017 49 49 50 53 53 41 31 54 14 34 54 1 17 16 18 15 26 27 42 48 46 42 40 30 30 22 35 36 37 21 32 4 33 58 57 59 60 56 21 44 45 19 20 42 51 43 52 47 62 61 55 2 3 38 39 25 24 23 28 29 5 63 64 6 7 9 8 13 12 11 10 Figure D 6 Multiprobe Calibration Gas Sequencer Exploded View ...

Page 147: ...pply 59 Washer 60 Nut 61 Screw 62 Washer 63 Solenoid 64 Solenoid e Loosen the retaining ring in the middle of the solenoid and remove the top part f With a spanner wrench or padded pliers remove the remaining part of the solenoid from the manifold 11 g Separate the new solenoid and screw the smaller part into the manifold h Place the top part of the solenoid into posi tion and tighten the retainin...

Page 148: ...he existing unit s Insert a hacksaw blade into the slots surrounding the positions for two flowme ters and saw out the knockout tabs e From the front of the inner cover install a flowmeter P N 771B635H01 into the top hole and a flowmeter P N 771B635H02 into the bottom hole From the backside se cure with brackets provided f Remove four brass screw plugs CAL GAS IN CAL GAS OUT REF AIR IN and REF AIR...

Page 149: ... 4 Dia x 1 1 4 Lg glass body non time delay Buss man part no BK AGC 1 Figure D 6 40 138799 014 Fuse fast acting 0 5A 250 Vac size 1 4 Dia x 1 1 4 Lg glass body non time delay Bussman part no BK AGC 1 2 Figure D 6 17 771B635H01 Flowmeter Assembly Calibration Gas Figure D 6 18 771B635H02 Flowmeter Assembly Reference Air 1A98631 Probe Adder Kit Figure D 6 51 1A97953H01 Hose Adapter 4847B46H01 Tubing ...

Page 150: ...Instruction Bulletin Appendix D Rev 2 5 May 2005 D 12 Appendices Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 ...

Page 151: ...Transmitter a Microprocessor Board The microprocessor board contains EEPROM RAM and a timer The micro processor board also controls the probe heater The IFT can be used in conjunction with or without an optional HPS 3000 Heater Power Supply providing power to the heater depending upon the user s application b Interconnect Board The interconnect board is used for all com munications from the IFT to...

Page 152: ...The IFT receives this sig nal and translates it into a user specified form for display and or output Table E 1 Specifications for Intelligent Field Transmitter Environmental Classification NEMA 4X IP56 Humidity Range 95 Relative Humidity Ambient Temperature Range 20 to 122 F 30 to 50 C Vibration 5 m sec2 10 to 500 xyz plane Electrical Noise EN 61326 Class A Installation Category Overvoltage Catego...

Page 153: ...f Emerson Process Management Appendices E 3 World Class 3000 PROBE ZERO CROSSING DETECTOR TRIAC RELAY TO HEATER COLD JUNCTION TEMP PROBE TC STACK TC CELL LINE RELAY TRIAC AD590 PROBE TC STACK TC CELL MV HEATER POWER SUPPLY OPTIONAL IFT TRANSFORMER 37840024 Figure E 2 System Block Diagram ...

Page 154: ...SHING Microprocessor normal b Equipment Status LCD Displays The status line of the GUI will display one system status display one at a time in priority sequence as indicated in the fol lowing list To troubleshoot an equipment fault refer to COMPONENT FAILURE indi cations applicable to the display message SYMPTOM in Table E 2 1 Off The probe has been turned off because the IFT cannot control the he...

Page 155: ...Instruction Bulletin Appendix E Rev 4 6 May 2005 Rosemount Analytical Inc A Division of Emerson Process Management Appendices E 5 World Class 3000 Figure E 3 IFT Troubleshooting Flowchart 1 ...

Page 156: ...E TROUBLESHOOTING APPENDIX A SECTION 2 CHECK THAT JUMPERS JM6 ON MICROPROCESSOR BOARD AND JM1 ON INTERCONNECT BOARD ARE REMOVED REFER TO APPENDIX B SECTION 2 FOR JUMPER LOCATIONS DISCONNECT POWER AND INSTALL JUMPERS CORRECTLY REFER TO FIGURE 2 5 OF MAIN IB SECTION NO NO SYMPTOM MICROPROCESSOR BOARD LED IS STEADY ON 27270021 Figure E 4 IFT Troubleshooting Flowchart 2 END OF FLOWCHART 2 SYMPTOM GENE...

Page 157: ... Ap pendix D for additional troubleshooting procedures 5 HiO2 is displayed Possible failure within the probe Ensure the high alarm level has been en tered correctly Refer to Probe Troubleshooting in Appendix A for additional troubleshooting procedures 6 LowO2 is displayed Possible failure within the probe Ensure the low alarm parameter has been entered correctly Refer to Probe Troubleshooting in A...

Page 158: ...Class 3000 37840025 14 8 9 4 3 11 10 12 5 13 6 1 2 1 7 1 Captive Screw 2 Enclosure Cover 3 Fuseholder Cap 4 Fuse 5 Amp 5 Electronics Chassis 6 Enclosure 7 Ribbon Cable 8 Ribbon Cable 9 Connector Plug 10 Screw 11 Washer 12 Microprocessor Assembly 13 Protective Cover 14 Captive Screw Figure E 6 Intelligent Field Transmitter Exploded View ...

Page 159: ...d lock out power before working on any electrical components There is voltage up to 240 Vac and could cause personal injury a Turn off power to the system Lock out and tag out power at the main disconnect box b Loosen two captive screws 1 Figure E 6 and open enclosure cover 2 E 7 REPLACE FUSE The power supply board contains six identical 5 amp fuses Perform the following procedure to check or repl...

Page 160: ...vision of Emerson Process Management World Class 3000 37840026 1 2 3 4 5 6 7 9 8 10 11 1 Screw 2 Plastic Washer 3 Microprocessor Board 4 Interconnect Board 5 Mounting Plate 6 Screw 7 Internal Lock Washer 8 Screw 9 Hex Nut 10 Fan 11 Connector Plug Figure E 7 Microprocessor Assembly Exploded View ...

Page 161: ...ating connectors e Secure interconnect board 4 to mount ing plate 5 with screws 6 and washers 7 f Reconnect tagged jumper wires to mating terminals of interconnect board 4 E 11 REPLACE FAN a Remove screws 8 Figure E 7 self locking hex nuts 9 and fan 10 from mounting plate 5 b Cut fan lead wires only at connector side of installed heat shrink c Strip 0 5 to 0 6 in 13 to 15 mm of wire insulation fro...

Page 162: ...rld Class 3000 37840027 1 2 3 13 9 11 10 14 12 7 5 3 6 5 4 15 8 5 1 Screw 2 Protective Cover 3 Standoff 4 Power Supply Board 5 Screw 6 Plastic Washer 7 Internal Lock Washer 8 Electronics Chassis 9 Screw 10 Flat Washer 11 Lock Washer 12 Ground Wire 13 Transformer 14 Heater 15 Nylon Standoff Figure E 8 Electronics Chassis Exploded View ...

Page 163: ...l of electronics chassis 8 Using alcohol solvent and putty knife re move damaged heater and thermoswitch assembly c Cut heater lead wires only approximately two inches 50 mm from fan and heater connector plug d Strip 0 5 to 0 6 in 13 to 15 mm of insula tion from heater leads of connector plug e Install one 2 in 50 mm length of heat shrink tubing onto each lead of new heater 14 f Connect and solder...

Page 164: ...t World Class 3000 37840032 12 6 7 9 8 10 3 11 4 1 2 1 5 13 16 Captive Screw 17 Enclosure Cover 18 Electronics Chassis 19 Enclosure 20 Ribbon Cable 21 Ribbon Cable 22 Connector Plug 23 Screw 24 Washer 25 Microprocessor Assembly 26 Protective Cover 27 Captive Screw 28 Power Supply Board Figure E 9 Electronics Chassis Installation ...

Page 165: ...n cable 1 from back of GUI assembly 5 Replace damaged GUI as sembly or ribbon cable d Plug ribbon cable 1 into back of GUI as sembly 5 e Install GUI assembly 5 on inside surface of enclosure cover 6 f Secure GUI assembly with washers 4 and screws 3 Install caps 2 g Reconnect ribbon cable 1 cable to micro processor assembly 10 Figure E 9 E 17 CLOSE COVER AND RESTORE POWER a Close enclosure cover 6 ...

Page 166: ... 8 13 1N04946G01 Transformer Figure E 7 4 3D39120G01 Interconnect Board Figure E 8 4 3D39122G01 Power Supply Board Figure E 7 3 3D39513G02 Microprocessor Board Figure E 10 5 1L04279H01 GUI Assembly Figure E 6 4 1L01293H02 Fuse 5A 250 Vac anti surge case size 5 x 20 mm type T to IEC127 Schurter Figure E 8 14 1A97964H08 Heater 120V Figure E 8 14 1A97964H09 Heater 240V Figure E 7 10 1L03862H01 Fan 12...

Page 167: ...icator is recommended J 2 UNIT OVERVIEW a Scope This Instruction Bulletin supplies details needed to install and operate the HART Communicator in relation to the World Class 3000 Intelligent Field Transmitter Informa tion on troubleshooting the communicator is also included 1 2 3 4 5 6 7 o HART Communicator FISHER ROSEMOUNTTM MAN 4275A00 English October 1994 8 9 10 686001 1 Lead Set with Connector...

Page 168: ...ONS HART Communicator Specifications Table J 1 contains physical functional and environmental information about the communicator Use Table J 1 to ensure the unit is operated in suitable en vironments and that the proper battery charging options are used Table J 1 HART Communicator Specifications Physical Specifications Display 8 line liquid crystal display with a line width of 21 characters 128 x ...

Page 169: ...cations in which the signal line load re sistance is less than 250 ohms refer to method 2 a Method 1 For Load Resistance 250 Ohms Refer to Figure J 2 and the following steps to connect the HART Communicator to a signal line with 250 ohms or more of load resistance INTELLIGENT FIELD TRANSMITTER IFT 3000 J1 JM1 J2 J3 J4 J5 J6 J7 J8 J9 LOOP CONNECTORS O 4 20 MA SIGNAL LINE 2 HART COMMUNICATOR MODEL 2...

Page 170: ... less than 250 ohms load re sistance Explosions can result in death or seri ous injury Do not make connections to the HART Communicator s serial port or NiCad recharger jack in an ex plosive atmosphere 1 Program IFT analog output to 4 20 mA Select the current mode using the cur rent voltage selector switch on the mi croprocessor board in the IFT 2 At a convenient point break the analog output 4 20...

Page 171: ...AL LOOP MUST BE BROKEN TO INSERT THE OPTIONAL 250 OHM LOAD RESISTOR NOTE LOOP CONNECTORS O 4 20 MA SIGNAL LINE 2 HART COMMUNICATOR MODEL 275 375 ANALOG OUTPUT DEVICE HART COMMUNICATOR REAR PANEL JM8 3D39513G REV 13 MICROPROCESSOR BOARD 10 J1 JM6 J2 J3 SW2 SW3 A B C D ON OFF 37840019 MICROPROCESSOR BOARD CURRENT VOLTAGE SELECTION SWITCH TO CURRENT POSITION INTERCONNECT BOARD ANALOG OUTPUT RL 250Ω F...

Page 172: ... the on line mode the communicator is con nected to the 4 20 mA analog output signal line The communicator is connected in parallel to the IFT or in parallel to the 250 ohm load resistor The opening menu displayed on the LCD is different for on line and off line operations When powering up a disconnected off line communicator the LCD will display the Main Menu When powering up a connected on line ...

Page 173: ...O cell Cell TC Stack TC CJmV 2 VIEW FLD DEV mV Not Applicable VIEW STATUS SELF TEST Not Applicable LOOP TEST Loop test method Cal Mode Optrak TG PERFORM O CAL CalState 2 PERFORM O CAL 2 O CALIBRATE 2 CalState TimeRemain Present TG Present O2 O CAL STATUS 2 Cal slope Cal const CellRes LAST CALCONSTANTS Reset CalConstants method RESET CALCONSTANTS D A trim method D A TRIM O Cal method 2 DEVICE SETUP...

Page 174: ...fer fnctn PV mge ANALOG OUTPUT HART OUTPUT RELAY OUTPUTS O2 EFFICIENCY HighTG LowTG Cal Mode OPtrak TG Cal Intrvl NxtCalTime TGtime PurgeTime ResAirSP HiAlarmSP LoAlarmSP Deadband SENSORS SIGNAL CONDITION OUTPUT CONDITION CALCULATIONS O CALIBRATION 2 O ALARMS 2 CONTINUED FROM SHEET 1 BASIC SETUP DETAILED SETUP PV AO AO Alrm typ LOOP TEST D A TRIM Poll addr Num req preams K1 K2 Slope Constant Heate...

Page 175: ...ev Software rev Universal rev Cal mode Optrak TG Cal Intrvl Tgtime PurgeTime ResAirSP LowTG HighTG Cal slope Cal const CellRes HeaterSP Slope Constant Eff enabled K1 efficncy K2 efficncy K3 efficncy Normal URV Normal LRV Hi mg URV Hi mg LRV O RngeMode HiRnginCal RngeSwtSP HiAlarmSP LoAlarmSP Deadband K1 input1 K1 input2 K1 input3 K2 input1 K2 input2 K2 input3 Poll addr Num req preams 2 DEVICE INFO...

Page 176: ...rly verify that the unit s battery pack and memory module are correctly assembled to the communicator Check the communicator s model number For IFT applications HART Communicator model number 275D9E must be used If the HART Communicator model num ber is correct and if it is properly assembled the troubleshooting flowchart Figure J 5 may be useful to find and correct problems J 9 TROUBLESHOOTING FL...

Page 177: ...FT POWERED IS IFT EXPERIENCING FAULTS DOES IFT HAVE MICROPROCESSOR BOARD REV 3039513G CLEAR IFT OF ALL FAULT CONDITIONS YES YES YES YES YES YES YES GO TO SHEET 2 OF 2 REPLACE BATTERIES IF APPLICABLE RECHARGE NiCad BATTERIES VERIFY HART IS CONFIGURED FOR IFT REFERENCE OFF LINE CONFIGURATION HART POCKET SIZED MANUAL RECONFIGURE HART UNIT FOR IFT CONTACT SERVICE REPRESENTATIVE SUPPLY POWER TO IFT NO ...

Page 178: ...ruction Bulletin Appendix J Rev 1 2 May 2005 J 12 Appendices Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 Figure J 5 Model 275D9E Troubleshooting Flowchart Sheet 2 of 2 ...

Page 179: ...which the equip ment has been operating housing weather vibration dust etc 3 Site from which equipment was removed 4 Whether warranty service or non warranty service is requested 5 Complete shipping instructions for return of equipment 6 Reference the return authorization number d Enclose a cover letter and purchase order and ship the faulty equipment according to the instructions provided in the ...

Page 180: ...Instruction Bulletin Appendix J Rev 1 2 May 2005 J 14 Appendices Rosemount Analytical Inc A Division of Emerson Process Management World Class 3000 ...

Page 181: ...on Gas Out 2 22 Cell Constant 1 2 Ceramic Diffusor 2 1 Chart Recorders 2 13 Check Valve 1 7 4 3 D DATA 5 2 Diagnostic Data 5 3 Dust Seal Packings 2 7 E Electrical Noise 6 1 Electrostatic Discharge 6 1 G Gas Kit 4 5 Gas Mixture 2 8 4 2 4 6 Gas Stratification 2 1 General User Interface 1 4 5 1 Grounding 6 1 GUI 6 1 H HART Communications 1 2 5 1 HART Communicator 1 1 HART Interface 1 4 Heater Power S...

Page 182: ...n Process Management World Class 3000 Q Quick Reference Chart 5 3 R Reference Air 1 1 2 8 2 21 S Semiautomatic Calibration 2 22 4 2 4 6 SETUP Sub Menu 5 4 Status Line 5 3 Stop Valve 1 7 T TGH 5 2 TGL 5 2 Troubleshooting 6 1 V Vee Deflector 2 7 W Wiring Layout 2 12 2 17 2 18 Z Zirconia Disc 1 2 Z purge 1 7 ...

Page 183: ...urchaser s sole remedy ies for any failure of Rosemount Analytical to comply with the warranty provisions whether claims by the purchaser are based in contract or in tort including negligence Rosemount Analytical does not warrant equipment against normal deterioration due to environ ment Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or...

Page 184: ... 49 6055 884 0 F 49 6055 884 209 EUROPE MIDDLE EAST AND AFRICA Emerson Process Management Shared Services Limited Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 GAS CHROMATOGRAPHY CENTER AND LATIN AMERICA Emerson Process Management Rosemount Analytical 9753 Pinelake Drive Houston TX 77055 T 713 467 6000 F 713 827 3329 World Class 3000 World Class 3000 Probe...

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