Page 2 - ESSENTIAL INSTRUCTIONS; READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management Rosemount Analytical Inc.Process Analytic Division 6565P Davis Industrial ParkwaySolon, OH 44139T (440) 914 1261F (440) 914 1271E [email protected] http://www.raihome.com ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Rosemount Analytical designs, manufactures an...
Page 3 - HIGHLIGHTS OF CHANGES
HIGHLIGHTS OF CHANGES Effective May, 1999 Rev. 4.0 Page Summary Page P-6 Added new Quick Start Guide. Page 3-1 Added Section 3, Setup. Page 4-1 Removed calibration information from Operation section, and createdSection 4, Calibration. Page 6-2 Expanded explanations of IFT status codes. Section 6 Add...
Page 7 - Added warning to read new safety instructions.
HIGHLIGHTS OF CHANGES APPENDIX B Effective February, 1992 Rev. 2 Page Summary Page B-1 Figure B-1. New HPS 3000 Optional Class 1, Division 1, Group B(IP56) Explosion-Proof Enclosure added. Page B-11 Figure and Index No. column added to Table B-2. Replacement Partsfor Heater Power Supply. Effective J...
Page 10 - Changed “Rosemount” to “Rosemount Analytical”.
HIGHLIGHTS OF CHANGES (CONTINUED) Effective July, 1998 Rev. 2.4 Page Summary --- Changed test gas to calibration gas and reference gas to referenceair throughout the appendix. Effective May, 2005 Rev. 2.5 Page Summary --- Changed “Rosemount” to “Rosemount Analytical”. D-3 Revised view of check valve...
Page 12 - Revised Electrical Noise specifications.
HIGHLIGHTS OF CHANGES (CONTINUED) Effective May, 2005 Rev. 4.6 Page Summary --- Changed “Rosemount” to “Rosemount Analytical”. Changed views ofIFT 3000 enclosure. Named GUI/LED display standard (not optional). E-2 Revised Electrical Noise specifications. E-8 through E-16 Changed all service instruct...
Page 13 - Added statement of reference to the return authorization number.
HIGHLIGHTS OF CHANGES APPENDIX J Effective April, 1995 Rev. 1 Page Summary Page J-13 Added statement of reference to the return authorization number. Effective June, 1995 Rev. 1.1 Page Summary --- Figure J-4. Updated figure to include “Status group” and “K3 eff” incalculations. Effective May, 2005 R...
Page 15 - Instruction Manual; TABLE OF CONTENTS; Setting the O
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management i World Class 3000 TABLE OF CONTENTS PREFACE........................................................................................................................ P-1 Definitions .....
Page 16 - LIST OF ILLUSTRATIONS
Instruction Manual IB-106-300NH Rev. 4.3May 2005 ii Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 7-0 RETURN OF MATERIAL .............................................................................................. 7-1 8-0 APPENDICES ..............................
Page 17 - LIST OF TABLES; CALIBRATE O
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management iii World Class 3000 LIST OF TABLES Table 4-1. Automatic Calibration Parameters ......................................................................... 4-8 Table 5-1. Sample HELP Me...
Page 19 - PREFACE; NOTE; NOTE TO USERS
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management P-1 World Class 3000 NOTE ! Only one probe can be calibrated at a time.Probe calibrations must be scheduledappropriately in multiple probe applications. PREFACE The purpose of this ma...
Page 20 - IMPORTANT; the Operator Manual for instructions.
Instruction Manual IB-106-300NH Rev. 4.3May 2005 P-2 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They ...
Page 21 - GLOSSARY OF TERMS; Intelligent Field Transmitter.
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management P-3 World Class 3000 GLOSSARY OF TERMS Abrasive Shield An optional component that shields the probe from high velocity particulate entrained in the fluegas stream. Automatic Calibrati...
Page 22 - Reference Air
Instruction Manual IB-106-300NH Rev. 4.3May 2005 P-4 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Reference Air Provides a known oxygen concentration to the reference side of the oxygen sensing cell. Semiautomatic Calibration Semiautomatic calibration is perfor...
Page 23 - WHAT YOU NEED TO KNOW; BEFORE INSTALLING AND WIRING A ROSEMOUNT ANALYTICAL; What is the line voltage being supplied to the IFT 3000?; Figure 1. Complete World Class 3000 System
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management P-5 World Class 3000 WHAT YOU NEED TO KNOW BEFORE INSTALLING AND WIRING A ROSEMOUNT ANALYTICAL IFT 3000 INTELLIGENT FIELD TRANSMITTER WITH WORLD CLASS 3000 PROBE 1. What is the line v...
Page 24 - QUICK START GUIDE; You are using a World Class 3000 probe.
Instruction Manual IB-106-300NH Rev. 4.3May 2005 P-6 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 QUICK START GUIDE Use this Quick Start Guide if ... 1. You are using a World Class 3000 probe. 2. You are NOT using any optional components. Optional components ar...
Page 25 - QUICK START GUIDE FOR IFT 3000 SYSTEMS
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management P-7 World Class 3000 QUICK START GUIDE FOR IFT 3000 SYSTEMS Before using the Quick Start Guide, please read “WHAT YOU NEED TO KNOW BEFOREINSTALLING AND WIRING A ROSEMOUNT ANALYTICAL I...
Page 26 - WORLD CLASS; LINE
Instruction Manual IB-106-300NH Rev. 4.3May 2005 P-8 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 BK GN WH PU SHIELD SHIELD SHIELD STACK TC -STACK TC + PROBE M V + PROBE MV - PROBE TC + PROBE TC - RDYE BL OR BL OR YE RD WORLD CLASS PROBE 1 2 3 4 5 6 7 8 BL PROB...
Page 27 - QUICK REFERENCE GUIDE; Performing a Manual (Semiautomatic) Calibration; Connect the high calibration gas to the probe fitting.; Setting up the Analog Output; Set the SOURCE to O
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management P-9 World Class 3000 QUICK REFERENCE GUIDE IFT 3000 INTELLIGENT FIELD TRANSMITTER Performing a Manual (Semiautomatic) Calibration 1. Connect the high calibration gas to the probe fitt...
Page 28 - HART COMMUNICATOR FAST KEY SEQUENCES; Technical Support Hotline:
Instruction Manual IB-106-300NH Rev. 4.3May 2005 P-10 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 HART COMMUNICATOR FAST KEY SEQUENCES Perform Calibration Analog Output Upper Range Value 2 3 1 3 3 2 4 Trim Analog Output Analog Output Lower Range Value 2 4 3 2 ...
Page 29 - SECTION 1; Intelligent Field Transmitter
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1 World Class 3000 1 3 4 5 6 7 8 9 2 37840019 o HART Communicator FISHER-ROSEMOUNT TM MAN 4275A00 English October 1994 SECTION 1 DESCRIPTION AND SPECI...
Page 30 - SYSTEM OVERVIEW; communications protocol,; Description; P2 is the partial pressure of the oxygen
Instruction Manual IB-106-300NH Rev. 4.3May 2005 1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 1-2 SYSTEM OVERVIEW a. Scope This Instruction Manual has been designedto supply details needed to install, startup,operate, and main...
Page 31 - Configuration
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3 World Class 3000 c. System Configuration The equipment covered in this manual con-sists of three major components: the oxy-gen analyzer (probe), the...
Page 32 - Rosemount Analytical Model
Instruction Manual IB-106-300NH Rev. 4.3May 2005 1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 9. An operator can set up, calibrate, or troubleshoot the IFT in one of twoways: (a) Optional General User Interface (GUI). The GUI ...
Page 33 - TAN; Figure 1-2. Typical System Installation
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5 World Class 3000 S TAN D A RD OP TI O N S DUC T STA C K G ASES C ALIB R ATI O N G AS INST RU MENT AI R S UPP LY (R EF. AI R) PR ESS UR E R E GU LAT ...
Page 37 - SECTION 2; Location; The location of the probe in the stack; Installation; Ensure that all components are avail-
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1 World Class 3000 SECTION 2 INSTALLATION 2-1 OXYGEN ANALYZER (PROBE)INSTALLATION Before starting to install this equip-ment, read the "Safety instructions forwirin...
Page 38 - TT
Instruction Manual IB-106-300NH Rev. 4.3May 2005 2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 ROS EM OU NT C AL G AS R EF AI R FLAN G E D IA. H O LE D IA. ( 4 ) H O LES EQ S PO NB C ANSI 4 5 1 2C 1 7 H 0 1 6 . 00 ( 1 53) 7 . 28 ( 1 85) 6 .1 0 (...
Page 41 - INSTALLATION FOR MASONRY
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5 World Class 3000 NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPTADAPTOR PLATE NOT FURNISHED BY ROSEMOUNTANALYTICAL. INSTALLATION FOR MASONRY WALL STACK CONSTRUCTION IN...
Page 43 - If using the optional ceramic diffusor; Insert probe through the opening in the
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7 World Class 3000 4. If using the optional ceramic diffusor element, the vee deflector must be cor-rectly oriented. Before inserting theprobe, check the direction of f...
Page 44 - c. Reference Air Package
Instruction Manual IB-106-300NH Rev. 4.3May 2005 2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 c. Reference Air Package After the oxygen analyzing (probe) unit isinstalled, connect the reference air set tothe probe junction box. The reference ai...
Page 45 - For installations where the cable run is; Figure 2-4. Outline of Intelligent Field Transmitter
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9 World Class 3000 2-2 INTELLIGENT FIELD TRANSMITTER (IFT)INSTALLATION a. Mechanical Installation The outline drawing of the IFT module inFigure 2-4 shows mounting cent...
Page 46 - The power cable should comply with; Figure 2-5. Power Supply Board Jumper Configuration
Instruction Manual IB-106-300NH Rev. 4.3May 2005 2-10 Installation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Do not install jumper JM6 on the mi-croprocessor board, or JM1 on the in-terconnect board, if an HPS isinstalled in the system. This will resultin sy...
Page 47 - Figure 2-6. IFT Power Supply Board Jumpers
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount 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 Supp...
Page 48 - Figure 2-7. Wiring Layout for IFT Systems without HPS
Instruction Manual IB-106-300NH Rev. 4.3May 2005 2-12 Installation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 BK GN WH PU SHIELD SHIELD CAL RET NO GAS LO GAS HI GAS IN CAL SHIELD SHIELD STACK TC -STACK TC + PROBE M V + PROBE MV - PROBE TC + PROBE TC - RDYE BL...
Page 51 - OUTPUT; HPS; Figure 2-10. Interconnect Board Jumper Configuration
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-15 World Class 3000 OUTPUT JUMPER HPS Remove JM1 Probe (No HPS) Install JM1 Figure 2-10. Interconnect Board Jumper Configuration 2 2 1 1 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 ...
Page 52 - NEMA 4X; Figure 2-12. Outline of Heater Power Supply; Electrical connections should be made; The power cable should comply with
Instruction Manual IB-106-300NH Rev. 4.3May 2005 2-16 Installation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 CLASS 1, DIVISION 1, GROUP B ENCLOSURE #10-32 UNF 2ATHREADED INSERT(0.31 x 0.31 FROM CORNER OF PLATE) 0.13" (3.3) THK U. L. APPROVEDGASKET 7.00 (...
Page 55 - FRONT; Figure 2-14. Heater Power Supply Wiring Connections
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical 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 ...
Page 56 - Before supplying power to the heater; Figure 2-16. Jumpers on HPS Mother Board
Instruction Manual IB-106-300NH Rev. 4.3May 2005 2-20 Installation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 ALWAYS DISCONNECT LINE VOLTAGE F ROM H EATER POWER SUPPLY AND ANALOG ELECTRONICS (I F USED) BE F ORE C H ANGING JUMPERS. JUMPER CON F IGURATIONS LINE...
Page 57 - Connect the reference air supply to; Analytical
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-21 World Class 3000 2-4 MULTIPROBE CALIBRATION GASSEQUENCER INSTALLATION a. Mechanical Installation The outline drawing of the MPS module inFigure 2-17 shows mounting c...
Page 58 - Connections
Instruction Manual IB-106-300NH Rev. 4.3May 2005 2-22 Installation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 3. Connect the low O 2 calibration gas to LOW GAS. The calibration gas pres-sure should be set at 20 psi (138 kPa). 4. Connect the REF AIR OUT to the...
Page 61 - SECTION 3; CONFIGURING THE ANALOG OUTPUT; SETTING CALIBRATION PARAMETERS; Press the SETUP key on the GUI keypad.
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Setup 3-1 World Class 3000 SECTION 3 SETUP 3-1 OVERVIEW This section provides information on configuringthe IFT 3000 Intelligent Field Transmitter. Thissection assumes that you are fa...
Page 62 - SETTING THE O; The IFT has a high and low O; CONFIGURING THE RELAY OUTPUTS
Instruction Manual IB-106-300NH Rev. 4.3May 2005 3-2 Setup Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 automatic calibrations, set the Auto Cal pa-rameter to Yes. f. The Output Tracks setting determineswhether the analog output tracks the oxy-gen reading durin...
Page 63 - SECTION 4; ANALOG OUTPUT CALIBRATION; in the gas stream. The; Calibration
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-1 World Class 3000 SECTION 4 CALIBRATION 4-1 ANALOG OUTPUT CALIBRATION For the analog output to perform within the pub-lished specifications, it must be manually cali-br...
Page 64 - Calibration Methods; Two tanks of precision cali-
Instruction Manual IB-106-300NH Rev. 4.3May 2005 4-2 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 2. Calibration Methods There are three calibration methods:manual (semiautomatic), manually ini-tiated automatic, and fully automatic.Manual (semiautom...
Page 65 - If gas bottles will be perma-
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-3 World Class 3000 255 Brimley RoadScarborough, Ontario,Canada416/266-3161 SCOTT ENVIRONMENTALTECHNOLOGY, INC.SCOTT SPECIALTYGASES 2600 Cajon Blvd.San Bernardino, CA 924...
Page 66 - Set the calibration gas pres-; Portable Oxygen Calibration
Instruction Manual IB-106-300NH Rev. 4.3May 2005 4-4 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 PROBE (END VIEW) CALIBRATION IN-PLACE FITTING CHECKVALVE FLOW METER LEAK TIGHT VALVES 37840014 NOTE: PROBE CALIBRATION GAS FITTING HAS A SEAL CAP WHICH...
Page 67 - Figure 4-2. Portable Rosemount Analytical; Extra gas bottles are available
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-5 World Class 3000 37840018 CALIBRATION GAS KIT #1 (P/N 6296A27G01) Analytical Figure 4-2. Portable Rosemount Analytical Oxygen Calibration Gas Kit 2 Extra gas bottles a...
Page 68 - Figure 4-3. Typical Portable Calibration Setup; Press SETUP to display the SETUP; e. Fully Automatic Calibration; Calibration Gases For Fully Automatic
Instruction Manual IB-106-300NH Rev. 4.3May 2005 4-6 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 0.4% O 2 8.0% O 2 37840013 CALIBRATE IN PLACE CONNECTION CHECK VALVE PUSHBUTTON REGULATOR WITH CONTENTS GAGE - SET 5 SCFH REFERENCE AIRCONNECTION CALIB...
Page 69 - Figure 4-4. Typical Automatic Calibration System
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-7 World Class 3000 PROBE (END VIEW) IFT CALIBRATION GAS HPS OPTIONAL CHECK VALVE PROBESIGNAL CONNECTIONS MPS-IFTSIGNALCONNECTIONS MPS INSTRUMENT AIR IN CALIBRATION GAS 1...
Page 70 - Table 4-1. Automatic Calibration Parameters; Set to YES
Instruction Manual IB-106-300NH Rev. 4.3May 2005 4-8 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table 4-1. Automatic Calibration Parameters Auto Cal YES/NO Set to YES Output Tracks YES/NO Set as desired to con- figure analog outputtracking. Cal In...
Page 71 - value to begin migrating back to the process value.; value to settle out at the process value.
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-9 World Class 3000 Calibration Record For Rosemount Analytical In Situ O 2 Probe Probe Serial Number: Probe Tag Number: Probe Location: Date Placed Into Service: Date Sl...
Page 73 - SECTION 5
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management General User Interface (GUI) Operation 5-1 World Class 3000 SECTION 5 GENERAL USER INTERFACE (GUI) OPERATION 5-1 OVERVIEW Ensure that the oxygen analyzer, heater powersupply, and inte...
Page 74 - DELUXE VERSION IFT DISPLAYS AND CONTROLS; EXTERNAL VIEW; Figure 5-1. Deluxe Version IFT Displays and Controls
Instruction Manual IB-106-300NH Rev. 4.3May 2005 5-2 General User Interface (GUI) Operation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 5-2 DELUXE VERSION IFT DISPLAYS AND CONTROLS 37840022 EN TE R ES C DA TA CA L SE TU P HE LP EXTERNAL VIEW INTERNAL VIEW NOTE...
Page 76 - CALIBRATE O
Instruction Manual IB-106-300NH Rev. 4.3May 2005 5-4 General User Interface (GUI) Operation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 5-8 CALIBRATE O 2 SUB-MENU The CALIBRATE O 2 sub-menu (Table 5-4) is used to enter the calibration mode. To accessthe CALIBR...
Page 82 - SELECTION
Instruction Manual IB-106-300NH Rev. 4.3May 2005 5-10 General User Interface (GUI) Operation Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table 5-4. CALIBRATE O 2 Sub-Menu SUB-MENU SELECTION SETUP SETTING (SEE TABLE 3-5) DISPLAY DESCRIPTION PerformCalibration A...
Page 83 - Next Cal XD XH
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management General User Interface (GUI) Operation 5-11 World Class 3000 Table 5-4. CALIBRATE O 2 Sub-Menu (continued) SUB-MENU SELECTION SETUP SETTING (SEE TABLE 3-5) DISPLAY DESCRIPTION ViewCon...
Page 87 - SECTION 6
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-1 World Class 3000 SECTION 6 TROUBLESHOOTING 6-1 OVERVIEW The system troubleshooting describes how toidentify and isolate faults which may develop inthe Oxygen Analy...
Page 89 - HEATER PROBLEM; The displayed O; Problem; Cause
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-3 World Class 3000 6-4 HEATER PROBLEM For all heater troubleshooting, allow at least 30minutes for the operating temperature to stabi-lize. After the warmup period, ...
Page 91 - CELL PROBLEM; The status line may read: Low O; Status is LowO
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-5 World Class 3000 6-5 CELL PROBLEM For cell troubleshooting, as in heater problems,you should allow at least 30 minutes for operat-ing temperature to stabilize. Aft...
Page 93 - IFT PROBLEM
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-7 World Class 3000 6-6 IFT PROBLEM When an IFT problem is suspected, look at theLED on the microprocessor board. The LEDmay be OFF, ON, or flashing. Refer to Table 6...
Page 94 - MPS PROBLEM; reading can be 0% to
Instruction Manual IB-106-300NH Rev. 4.3May 2005 6-8 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 6-7 MPS PROBLEM MPS problems can occur with a status of C Err,R Hi, TGLow. The O 2 reading can be 0% to 99%, and probe data will be in the normalra...
Page 95 - Table 6-6. Performance Problem Troubleshooting; display is unstable.
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-9 World Class 3000 6-8 PERFORMANCE PROBLEM (PROCESSRESPONSE IS SUSPECT) O 2 readings may not always agree with known process conditions. Such a discrepancy can bethe...
Page 97 - SECTION 7
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 7-1 World Class 3000 SECTION 7 RETURN OF MATERIAL 7-1 If factory repair of equipment is required, pro-ceed as follows: a. Secure a return authorization number froma...
Page 99 - SECTION 8; APPENDIX B. HPS 3000 HEATER POWER SUPPLY
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management 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 CALI...
Page 100 - Instruction Bulletin; APPENDIX A
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-0 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 2 3 NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASE SEPARATELY. FOR LIST OF AVAILABLE PARTS, SEE TABLE A-3. 29 1 27 28 25 24 26 20 19 17 7 8 15 13 ...
Page 101 - WORLD CLASS 3000 OXYGEN ANALYZER (PROBE)
Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-1 World Class 3000 APPENDIX A, REV. 3.9 WORLD CLASS 3000 OXYGEN ANALYZER (PROBE) DESCRIPTION Read the “Safety instructions for thewiring and installation of this appara-t...
Page 102 - Temperature limits in process
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table A-1. Specifications for Oxygen Analyzing Equipment. 1, 2 Probe lengths, nominal .....................................................................
Page 104 - INNER PROBE ASSEMBLY; A tube to carry reference air to the cell.
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 d. Cell - General The components which make up the cell aremachined to close tolerances andassembled with care to provide accurateoxygen measurements. A...
Page 105 - PROBE JUNCTION BOX; jacket and; and; PROBE OPTIONS
Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-5 World Class 3000 C ALIB R ATI O N G AS FITTIN G PRO BE JU N C TI O N B O X CO VE R TE R MINAL ST R I P R EFE R EN C E AI R FITTIN G 272700 1 6 Figure A-6. Probe Junctio...
Page 106 - VIEW A
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 VIEW A VIEW B A B A B 15 o 2 .187 1 ON INSIDE BREAK FOR SMOOTH ROUNDED EDGE ON BOTH ENDS OF CHAMFER .187 6.00 125 .45 MIN 90 o 3.584 3.554 SKIN CUT FACE...
Page 111 - Extended Temperature By-Pass Arrangements (2400
Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-11 World Class 3000 Extended Temperature By-Pass Arrangements (2400 ° F; 1300 ° C) PART NO. GROUP CODE DESCRIPTION 1U0571 G01 3’ By-pass Package with ANSI bolt pattern. 1...
Page 112 - PROBE TROUBLESHOOTING
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 PROBE TROUBLESHOOTING A-7 OVERVIEW The probe troubleshooting section describeshow to identify and isolate faults which may de-velop in the probe assemb...
Page 113 - Symptom
Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-13 World Class 3000 Table A-2. Fault Finding (Continued) Symptom Check Fault Remedy 2. System responds to oxygen concentrationchanges but does notgive correct indication ...
Page 116 - SERVICE AND NORMAL MAINTENANCE; PROBE EXPOSED TO THE PROCESS GASES.
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-16 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 NOTE ! SERVICE AND NORMAL MAINTENANCE UPON COMPLETING INSTALLATION, MAKE SURE THAT THE PROBE IS TURNED ON AND OPERATING PRIOR TO FIRING UP THE COMBUSTI...
Page 117 - notch which may be used; If the contact
Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-17 World Class 3000 C ELL EXTENSI O N WI R E (OR AN G E ) B O MB TAIL CO NNE C T OR IN CO NEL C ELL WI R E (C LEA R SLEEVIN G) HEATE R WI R ES ( BLA C K SLEEVIN G) THE R ...
Page 118 - Figure A-19. Removal of Optional Diffusor
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-18 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 OPTIONAL CERAMIC DIFFUSION ELEMENT VEE DEFLECTOR HUB PIN WRENCH SETSCREW RETAINER CEMENT PORT CEMENT FILLET 21240026 Figure A-19. Removal of Optional D...
Page 119 - Procedure
Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-19 World Class 3000 Damage to the diffusion element may be-come apparent during calibration. Compareprobe response with previous response. Abroken diffusion element will ...
Page 120 - Assemble retainer and diffusion hub; A-13 REPLACEMENT OF CONTACT AND
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-20 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 11. Wipe a heavy layer of anti-seize com- pound onto the threads and matingsurfaces of the diffusion hub andretainer. 12. Assemble retainer and diffusi...
Page 123 - A-15 CALIBRATION GAS AND REFERENCE AIR; Disconnect and lock out power to digi-
Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-23 World Class 3000 1 2 4 3 11 5 6 7 8 9 10 21240012 1. Snubber Diffusion Element 2. Socket Hd Cap Screw [0.25 in.-28 x 0.063 (16 mm)] 3. Cell and Flange Assembly 4. Corr...
Page 124 - First install the stainless steel tubing on; Environment Kit
Instruction Bulletin Appendix A Rev. 3.9May 2005 A-24 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Do not use sealant when installing thestainless steel tubes. Gas samplesmay become contaminated. 2. First install the stainless steel tubing on the fit...
Page 125 - REPLACEMENT PARTS; Figure and
Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-25 World Class 3000 REPLACEMENT PARTS Table A-3. Replacement Parts for Probe Figure and Index No. Part Number Description Figure A-22Figure A-22Figure A-22Figure A-22Figu...
Page 127 - HPS 3000 HEATER POWER SUPPLY; Figure B-1. HPS 3000 Heater Power Supply Field Module
Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-1 World Class 3000 APPENDIX B, REV. 2.3 HPS 3000 HEATER POWER SUPPLY DESCRIPTION Read the “Safety instructions for thewiring and installation of this appara-tus” at the f...
Page 129 - Table B-1. Specifications for Heater Power Supply
Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-3 World Class 3000 Table B-1. Specifications for Heater Power Supply Environmental Classification .................................................. NEMA 4X (IP56) Option...
Page 131 - SYMPTOM
Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-5 World Class 3000 HEATER DOES NOT HEAT UP (DOES NOT INCREASE IN OUTPUT). SET METER* FOR 50 VAC. PLACE PROBES ON TERMINAL BLOCK J2, “FROM PROBE”, PROBE HEATER. METER INDI...
Page 134 - SERVICE AND NORMAL MAINTENANCE; FUSE REPLACEMENT; MOTHER BOARD REPLACEMENT; Turn off power to system.
Instruction Bulletin Appendix B Rev. 2.3May 2005 B-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 SERVICE AND NORMAL MAINTENANCE B-5 OVERVIEW This section describes service and routinemaintenance of the HPS 3000 Heater PowerSupply Field Module. Repla...
Page 135 - DAUGHTER BOARD REPLACEMENT
Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-9 World Class 3000 i. Making a note of the location and color ofeach wire, disconnect wires from terminalstrip on mother board. j. Remove four screws (9) holding motherbo...
Page 137 - LEGEND FOR FIGURE B-7; REPLACEMENT PARTS; Table B-2. Replacement Parts for Heater Power Supply
Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-11 World Class 3000 LEGEND FOR FIGURE B-7 1. Enclosure Cover 2. Screw 3. Lockwasher 4. Terminal Cover 5. Stand Off 6. Lockwasher 7. Daughter Board 8. Terminal Cover 9. Sc...
Page 139 - MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER; Figure D-1. MPS 3000 Multiprobe Calibration Gas
Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-1 World Class 3000 APPENDIX D, REV 2.5 MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER DESCRIPTION Read the “Safety instructions for thewiring and installation of this appa...
Page 141 - Figure D-3. Typical Automatic Calibration System
Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-3 World Class 3000 PROBE (END VIEW) IFT CALIBRATION GAS HPS OPTIONAL CHECK VALVE PROBE SIGNAL CONNECTIONS MPS-IFT SIGNAL CONNECTIONS MPS INSTRUMENT AIR IN CALIBRATION GAS...
Page 142 - BEBCO
Instruction Bulletin Appendix D Rev. 2.5May 2005 D-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 REFERENCE PURGE An aly tical NOTE: DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES. 3 "BEBCO" PURGE W ARNING NOTICE SUPPLIED WITH BEBCO...
Page 144 - Figure D-5. MPS Troubleshooting Flowchart
Instruction Bulletin Appendix D Rev. 2.5May 2005 D-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 YES YES NO NO SYMPTOM SOLENOID IS OPERATING NORMALLY. ENSURE THAT A SUFFICIENT SUPPLY OF CALIBRATION GAS IS AVAILABLE. CALL FOR FACTORY ASSISTANCE. SET ...
Page 145 - POWER SUPPLY REPLACEMENT; Turn off power to the system.; SOLENOID VALVE REPLACEMENT; Turn off power to the system.
Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-7 World Class 3000 SERVICE AND NORMAL MAINTENANCE D-5 OVERVIEW This section describes service and routinemaintenance of the MPS 3000 Multiprobe Cali-bration Gas Sequencer...
Page 146 - Figure D-6. Multiprobe Calibration Gas Sequencer, Exploded View
Instruction Bulletin Appendix D Rev. 2.5May 2005 D-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 An aly tical 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 ...
Page 147 - LEGEND FOR FIGURE D-6
Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-9 World Class 3000 LEGEND FOR FIGURE D-6 1. Enclosure 2. Screw 3. Plug 4. Cable Grip 5. Fitting 6. Hose Adapter 7. Pressure Switch 8. Plug 9. Solenoid Valve 10. Screw 11....
Page 148 - D-10 FLOWMETER ADJUSTMENTS
Instruction Bulletin Appendix D Rev. 2.5May 2005 D-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 D-10 FLOWMETER ADJUSTMENTS There are two flowmeters per flowmeter assem-bly. The top flowmeter is factory set to 5 scfh.The bottom flowmeter is set to ...
Page 149 - Table D-3. Replacement Parts for the Multiprobe Test Gas Sequencer
Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-11 World Class 3000 REPLACEMENT PARTS Table D-3. Replacement Parts for the Multiprobe Test Gas Sequencer FIGURE andINDEX No. PART NUMBER DESCRIPTION Figure D-6, 58 1A9790...
Page 151 - IFT 3000 INTELLIGENT FIELD TRANSMITTER; Figure E-1. IFT 3000 Intelligent Field Transmitter; value. The LED display has indicator
Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-1 World Class 3000 APPENDIX E, REV. 4.6 IFT 3000 INTELLIGENT FIELD TRANSMITTER DESCRIPTION Read the “Safety instructions for thewiring and installation of this appara-tus...
Page 152 - THEORY OF OPERATION; or ±3% of reading, whichever is greater using
Instruction Bulletin Appendix E Rev. 4.6May 2005 E-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 f. Z-Purge (optional) A Z-purge arrangement is available for ap-plications requiring hazardous area classifi-cation. See Application Data Bulletin AD106...
Page 153 - PROBE
Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of 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 P...
Page 157 - Table E-2. GUI Equipped IFT Fault Finding; Possible failure within IFT. Check LED on microprocessor board.
Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-7 World Class 3000 Table E-2. GUI Equipped IFT Fault Finding SYMPTOM COMPONENT FAILURE 1. Display is blank. Possible failure within IFT. Check LED on microprocessor board...
Page 159 - REMOVE POWER AND OPEN COVER
Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-9 World Class 3000 SERVICE AND NORMAL MAINTENANCE E-5 OVERVIEW Use the instructions in this section of the ap-pendix to repair the Intelligent Field Transmitter.Disassemb...
Page 160 - Exploded View
Instruction Bulletin Appendix E Rev. 4.6May 2005 E-10 Appendices Rosemount Analytical Inc. A Division 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 W...
Page 161 - REPLACE MICROPROCESSOR BOARD
Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-11 World Class 3000 E-9 REPLACE MICROPROCESSOR BOARD a. Remove four screws (1, Figure E-7) andwashers (2). Pull very carefully on the microproc-essor board to ensure that...
Page 163 - E-13 REPLACE TRANSFORMER; Place electronics
Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-13 World Class 3000 E-13 REPLACE TRANSFORMER a. Unplug transformer connector plugs (notshown) from power supply board (4, FigureE-8). b. Remove four screws (9), flat wash...
Page 164 - Figure E-9. Electronics Chassis Installation
Instruction Bulletin Appendix E Rev. 4.6May 2005 E-14 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management 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 ...
Page 165 - E-16 REPLACE GUI ASSEMBLY OR; Cable
Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-15 World Class 3000 37840028 7 6 4 3 2 1 5 E-16 REPLACE GUI ASSEMBLY OR RIBBON CABLE Use the following instructions to replace the GUIassembly or the mating ribbon cable....
Page 166 - FIGURE and INDEX No
Instruction Bulletin Appendix E Rev. 4.6May 2005 E-16 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 REPLACEMENT PARTS Table E-3. Replacement Parts for the Intelligent Field Transmitter. FIGURE and INDEX No PART NUMBER DESCRIPTION Figure E-8, 13 1N0494...
Page 167 - DESCRIPTION; COMMUNICATOR PACKAGE; A typical Model 275D9E HART; OVERVIEW; Case; Communicator Package, Model 275D9E
Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-1 World Class 3000 APPENDIX J, REV 1.2 HART COMMUNICATOR MODEL 275/375 IFT 3000 APPLICATIONS DESCRIPTION J-1 COMPONENT CHECKLIST OF TYPICALHART ® COMMUNICATOR PACKAGE A t...
Page 168 - action keys; Functional Specifications; without error
Instruction Bulletin Appendix J Rev. 1.2May 2005 J-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 b. Device Description The HART (Highway Addressable RemoteTransducer) Communicator is a hand-heldcommunications interface device. It provides acommon co...
Page 169 - INSTALLATION; Ohms
Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-3 World Class 3000 INSTALLATION J-4 HART COMMUNICATOR SIGNAL LINECONNECTIONS The HART Communicator can connect to theIFT analog output signal line at any wiring ter-minat...
Page 170 - At a convenient point, break the analog
Instruction Bulletin Appendix J Rev. 1.2May 2005 J-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Explosions can result in death or seri-ous injury. Do not make connectionsto the HART Communicator's serialport or NiCad recharger jack in an ex-plosive...
Page 172 - OPERATION
Instruction Bulletin Appendix J Rev. 1.2May 2005 J-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 OPERATION J-6 OFF-LINE AND ON-LINE OPERATIONS The HART Communicator can be operated bothoff-line and on-line. Off-line operations are thosein which the ...
Page 176 - TROUBLESHOOTING; TROUBLESHOOTING FLOWCHART.
Instruction Bulletin Appendix J Rev. 1.2May 2005 J-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 TROUBLESHOOTING J-8 OVERVIEW If the HART Communicator fails to functionproperly, verify that the unit's battery pack andmemory module are correctly ass...
Page 179 - RETURNING EQUIPMENT TO THE FACTORY
Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-13 World Class 3000 RETURNING EQUIPMENT TO THE FACTORY J-10 If factory repair of equipment is required, pro-ceed as follows: a. Secure a return authorization number froma...
Page 181 - SECTION 9
Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 9-1 World Class 3000 SECTION 9 INDEX This index is an alphabetized listing of parts, terms, and procedures for the World Class 3000 Instruction Manual.Each item listed in t...
Page 183 - ROSEMOUNT ANALYTICAL WARRANTY
365 6 3784/5-05 ROSEMOUNT ANALYTICAL WARRANTY Rosemount Analytical warrants that the equipment manufactured and sold by it will, upon ship-ment, be free of defects in workmanship or material. Should any failure to conform to this war-ranty become apparent during a period of one year after the date o...
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