WORLD CLASS 3000 OXYGEN ANALYZER WITH IFT 3000 INTELLIGENT … · 2018-12-26 · INTELLIGENT FIELD...

World Class 3000 Probe

Part No. _______________

Serial No. _______________

Order No. _______________

HPS 3000

Part No. _______________

Serial No. _______________

Order No. _______________

IFT 3000

Part No. _______________

Serial No. _______________

Order No. _______________

MPS 3000

Part No. _______________

Serial No. _______________

Order No. _______________

WORLD CLASS 3000OXYGEN ANALYZERWITH IFT 3000INTELLIGENTFIELD TRANSMITTER

Instruction Bulletin IB-106-300NH Rev. 3.6

IB-106-300NH

HIGHLIGHTS OF CHANGES

Effective May, 1996 Rev. 3

PAGE SUMMARY

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2-2

3-3

4-1

General. Updated text and art to reflect new IFT version.

General. Inserted new note regarding ambient air and high test gas.

Updated Figure 2-1, Probe Installation (sheet 1 of 5)

Updated system status codes.

Updated system status codes.

Effective June, 1996 Rev. 3.1

PAGE SUMMARY

2-3

2-8

2-9

Updated Figure 2-1, Probe Installation (sheet 2 of 5)

Added Caution regarding need for circuit breaker on electrical power supply. Deleted Note on removingprobe.

Added instruction in Caution to change labeling.

Effective October, 1996 Rev. 3.2

PAGE SUMMARY

1-3

3-21

4-1

Added description of the password protection feature for the IFT.

Added password protection information.

Added new status displays for password protection features.

Effective January, 1997 Rev. 3.3

PAGE SUMMARY

iii

2-1

2-8

2-10

2-15

2-19

2-21

2-22

4-1

Added "Safety instructions for the wiring and installation of this apparatus".

Added WARNING to read new safety instructions.

Added NOTE regarding IFT fuse locations and specifications.

Added NOTE regarding IFT fuse locations to Figure 2-7.

Added NOTE regarding HPS fuse locations and specifications.

Added NOTE regarding HPS fuse locations to Figure 2-17.

Added NOTE regarding MPS fuse locations and specifications.

Added NOTE regarding MPS fuse specifications to Figure 2-20.

Added WARNING regarding protective covers and grounds.

IB-106-300NH

HIGHLIGHTS OF CHANGES (continued)

Effective May, 1997 Rev. 3.4

PAGE SUMMARY

iii-xv Added foreign language safety sheets.

Effective February, 1998 Rev. 3.5

PAGE SUMMARY

2-2

3-17

Figure 2-1. Changed calibration gas tube dimensions.

Added note on calibration gas flowmeter.

Effective July, 1998 Rev. 3.6

PAGE SUMMARY

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1-3

3-7

3-21 through 3-26

Changed test gas to calibration gas and reference gas to reference air throughout the instruction bulletin.

Deleted paragraph 1-2.d.10.

Figure 3-2 (Sheet 3 of 5). Deleted password protection information.

Deleted paragraph 3-12 and Figures 3-7 though 3-10.

IB-106-300NHi

ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free ofdefects in workmanship or material. Should any failure to conform to this warranty become apparent during aperiod of one year after the date of shipment, Rosemount shall, upon prompt written notice from the purchaser,correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts. Correctionin the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with respect to thequality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure of Rosemount tocomply with the warranty provisions, whether claims by the purchaser are based in contract or in tort (includingnegligence).

Rosemount does not warrant equipment against normal deterioration due to environment. Factors such ascorrosive gases and solid particulates can be detrimental and can create the need for repair or replacement aspart of normal wear and tear during the warranty period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be subject to the samewarranty as is extended to Rosemount by the original manufacturer.

At the time of installation it is important that the required services are supplied to the system and that theelectronic controller is set up at least to the point where it is controlling the sensor heater. This will ensure, thatshould there be a delay between installation and full commissioning that the sensor being supplied with acpower and reference air will not be subjected to component deterioration.

IB-106-300NHii

NOTE

Only one probe can be calibrated at a time.Probe calibrations must be scheduledappropriately in multiple probe applications.

PURPOSEThe purpose of this manual is to provide a comprehensive understanding of the World Class 3000

Oxygen Analyzer components, functions, installation, and maintenance.

This manual is designed to provide information about the World Class 3000 Oxygen Analyzer. Werecommend that you thoroughly familiarize yourself with the Overview and Installation sections beforeinstalling your emissions monitor.

The overview presents the basic principles of the oxygen analyzer along with its performancecharacteristics and components. The remaining sections contain detailed procedures and information necessaryto install and service the oxygen analyzer.

Before contacting Rosemount concerning any questions, first consult this manual. It describes mostsituations encountered in your equipment's operation and details necessary action.

DEFINITIONSThe following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this

publication.

Highlights an operation or maintenanceprocedure, practice, condition, statement,etc., that if not strictly observed, could resultin injury, death, or long-term health hazardsof personnel.

Highlights an operation or maintenanceprocedure, practice, conditions, statement,etc., that if not strictly observed, could resultin damage to or destruction of equipment, orloss of effectiveness.

NOTE

Highlights an essential operation procedure,condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERSThe number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

IB-106-300NHiii

IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING ANDINSTALLATION OF THIS APPARATUS

The following safety instructions apply specifically to all EUmember states. They should be strictly adhered to in order toassure compliance with the Low Voltage Directive. Non-EUstates should also comply with the following unless supersededby local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external, where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity ofall earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be made through acircuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuitbreaker may also include a mechanically operated isolating switch. If not, then another means ofdisconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakersor switches must comply with a recognized standard such as IEC947. All wiring must conform with anylocal standards.

7. Where equipment or covers are marked with the symbol to the right, hazardous voltagesare likely to be present beneath. These covers should only be removed when power isremoved from the equipment — and then only by trained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is a dangerfrom hot surfaces beneath. These covers should only be removed by trained servicepersonnel when power is removed from the equipment. Certain surfaces may remain hotto the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to theOperator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1,IEC417, and ISO3864.

IB-106-300NHiv

BELANGRIJK

Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.

De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aangehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low Voltage Directive) teverzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijndoor plaatselijke of nationale voorschriften.

1. Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten, intern en extern.

2. Na installatie of controle moeten alle veiligheidsdeksels en -aardingen terug geplaatst worden. Ten alle tijdemoet de betrouwbaarheid van de aarding behouden blijven.

3. Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.

4. Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen, hoger dan 75°C.

5. Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd is.

6. Om de veilige werking van dit toestel te verzekeren, moet de voeding door een stroomonderbreker gevoerdworden (min 10A) welke alle draden van de voeding moet onderbreken. De stroomonderbreker mag eenmechanische schakelaar bevatten. Zoniet moet een andere mogelijkheid bestaan om de voedingsspanningvan het toestel te halen en ook duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moetenonderworpen zijn aan een erkende standaard zoals IEC947.

7. Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanningaanwezig. Deze deksels mogen enkel verwijderd worden nadat de voedingsspanning werdafgelegd en enkel door getraind onderhoudspersoneel.

8. Waar toestellen of deksels aangegeven staan met het symbool is er gevaar voor heteoppervlakken. Deze deksels mogen enkel verwijderd worden door getraindonderhoudspersoneel nadat de voedingsspanning verwijderd werd. Sommige oppper-vlakken kunnen 45 minuten later nog steeds heet aanvoelen.

9. Waar toestellen of deksels aangegeven staan met het symbool gelieve het handboek teraadplegen.

10. Alle grafische symbolen gebruikt in dit produkt, zijn afkomstig uit een of meer van devolgende standaards;EN61010-1, IEC417 en ISO3864.

IB-106-300NHv

VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.

Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøjefølges for overholdelse af Lavsspændingsdirektivet og bør også følges i ikke EU-lande medmindre andet erspecificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse forefindes.

2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og jordforbindelser reetableres.

3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.

4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur højere end 75° C.

5. Alle benyttede kabelforskruninger skal have en intern dimension, så passende kabelaflastning kan etableres.

6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse mod indirekte berøring gennem afbryder(min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsitua-tion. Afbryderen skal indholde enmekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes ogmærkes som sådan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947.

7. Hvor udstyr eller dæksler er mærket med dette symbol, er farlige spændinger normaltforekom-mende bagved. Disse dæksler bør kun afmonteres, når forsyningsspændingen erfrakoblet - og da kun af instrueret servicepersonale.

8. Hvor udstyr eller dæksler er mærket med dette symbol, forefindes meget varmeoverflader bagved. Disse dæksler bør kun afmonteres af instrueret servicepersonale, nårforsyningsspænding er frakoblet. Visse overflader vil stadig være for varme at berøre iop til 45 minutter efter frakobling.

9. Hvor udstyr eller dæksler er mærket med dette symbol, se da i betjeningsmanual forinstruktion.

10. Alle benyttede grafiske symboler i dette udstyr findes i én eller flere af følgende standarder:- EN61010-1,IEC417 & ISO3864.

IB-106-300NHvi

BELANGRIJK

Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.

Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldenderichtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstatendienen zich aan het volgende te houden, tenzij de lokale wetgeving anders voorschrijft.

1. Alle voorziene interne- en externe aardaansluitingen dienen op adequate wijze aangesloten te worden.

2. Na installatie,onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels /kappen en aardingenom reden van veiligheid weer aangebracht te worden.

3. Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of IEC 245.

4. Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven 75°C.

5. Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankeringvan de kabel wordt verkregen.

6. Om een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats te vinden viaeen meerpolige automatische zekering (min.10A) die alle spanningvoerende geleiders verbreekt indien eenfoutconditie optreedt. Deze automatische zekering mag ook voorzien zijn van een mechanisch bediendeschakelaar. Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegevenmogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaarsdienen te voldoen aan een erkende standaard zoals IEC 947.

7. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgendesymbool, kunnen zich hieronder spanning voerende delen bevinden die gevaar op kunnenleveren. Deze beschermdeksels/kappen mogen uitsluitend verwijderd worden doorgetraind personeel als de spanning is afgeschakeld.

8. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgendesymbool, kunnen zich hieronder hete oppervlakken of onderdelen bevinden. Bepaaldedelen kunnen mogelijk na 45 min. nog te heet zijn om aan te raken.

9. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgendesymbool, dient men de bedieningshandleiding te raadplegen.

10. Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende standaarden:EN 61010-1, IEC 417 & ISO 3864.

IB-106-300NHvii

TÄRKEÄÄ

Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa.

Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jottatäytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive) yhteensopivuus. Myös EU:hunkuulumattomien valtioiden tulee nou-dattaa tätä ohjetta, elleivät kansalliset standardit estä sitä.

1. Riittävät maadoituskytkennät on tehtävä kaikkiin maadoituspisteisiin, sisäisiin ja ulkoisiin.

2. Asennuksen ja vianetsinnän jälkeen on kaikki suojat ja suojamaat asennettava takaisin pai-koilleen.Maadoitusliittimen kunnollinen toiminta täytyy aina ylläpitää.

3. Jännitesyöttöjohtimien täytyy täyttää IEC227 ja IEC245 vaatimukset.

4. Kaikkien johdotuksien tulee toimia >75°C lämpötiloissa.

5. Kaikkien läpivientiholkkien sisähalkaisijan täytyy olla sellainen että kaapeli lukkiutuu kun-nolla kiinni.

6. Turvallisen toiminnan varmistamiseksi täytyy jännitesyöttö varustaa turvakytkimellä (min 10A), joka kytkeeirti kaikki jännitesyöttöjohtimet vikatilanteessa. Suojaan täytyy myös sisältyä mekaaninen erotuskytkin. Josei, niin jännitesyöttö on pystyttävä katkaisemaan muilla keinoilla ja merkittävä siten että se tunnistetaansellaiseksi. Turvakytkimien tai kat-kaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä.

7. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai allahengenvaarallisen suuruinen jännite. Suojaa ei saa poistaa jänniteen ollessa kytkettynälaitteeseen ja poistamisen saa suorittaa vain alan asian-tuntija.

8. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai allakuuma pinta. Suojan saa poistaa vain alan asiantuntija kun jännite-syöttö on katkaistu.Tällainen pinta voi säilyä kosketuskuumana jopa 45 mi-nuuttia.

9. Mikäli laite tai kosketussuoja on merkitty tällä merkillä katso lisäohjeita käyt-töohjekirjasta

10. Kaikki tässä tuotteessa käytetyt graafiset symbolit ovat yhdestä tai useammasta seuraavis-ta standardeista:EN61010-1, IEC417 & ISO3864.

IB-106-300NHviii

IMPORTANT

Consignes de sécurité concernant le raccordement et l’installation de cet appareil.

Les consignes de sécurité ci-dessous s’adressent particulièrement à tous les états membres de lacommunauté européenne. Elles doivent être strictement appliquées afin de satisfaire aux directivesconcernant la basse tension. Les états non membres de la communauté européenne doivent égalementappliquer ces consignes sauf si elles sont en contradiction avec les standards locaux ou nationaux.

1. Un raccordement adéquate à la terre doit être effectuée à chaque borne de mise à la terre, interne et externe.

2. Après installation ou dépannage, tous les capots de protection et toutes les prises de terre doivent être remisen place, toutes les prises de terre doivent être respectées en permanence.

3. Les câbles d’alimentation électrique doivent être conformes aux normes IEC227 ou IEC245

4. Tous les raccordements doivent pouvoir supporter une température ambiante supérieure à 75°C.

5. Tous les presse-étoupes utilisés doivent avoir un diamètre interne en rapport avec les câbles afin d’assurerun serrage correct sur ces derniers.

6. Afin de garantir la sécurité du fonctionnement de cet appareil, le raccordement à l’alimentation électriquedoit être réalisé exclusivement au travers d’un disjoncteur (minimum 10A.) isolant tous les conducteurs encas d’anomalie. Ce disjoncteur doit également pouvoir être actionné manuellement, de façon mécanique.Dans le cas contraire, un autre système doit être mis en place afin de pouvoir isoler l’appareil et doit êtresignalisé comme tel. Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telleIEC947.

7. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que destensions dangereuses sont présentes. Ces capots ne doivent être démontés que lorsquel’alimentation est coupée, et uniquement par un personnel compétent.

8. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que dessurfaces dangereusement chaudes sont présentes. Ces capots ne doivent être démontés quelorsque l’alimentation est coupée, et uniquement par un personnel compétent. Certainessurfaces peuvent rester chaudes jusqu’à 45 mn.

9. Lorsque les équipements ou les capots affichent le symbole suivant, se reporter au manueld’instructions.

10. Tous les symboles graphiques utilisés dans ce produit sont conformes à un ou plusieurs des standardssuivants: EN61010-1, IEC417 & ISO3864.

IB-106-300NHix

Wichtig

Sicherheitshinweise für den Anschluß und die Installation dieser Geräte.

Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig.Sie müssen strickt eingehalten werden, um der Niederspannungsrichtlinie zu genügen.Nichtmitgliedsstaaten der europäischen Gemeinschaft sollten die national gültigen Normen undRichtlinien einhalten.

1. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden.

2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerät müssen alle Sicherheitsabdeckungen undErdungen wieder installiert werden. Die Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gestörtsein.

3. Die Netzspannungsversorgung muß den Anforderungen der IEC227 oder IEC245 genügen.

4. Alle Verdrahtungen sollten mindestens bis 75 °C ihre Funktion dauerhaft erfüllen.

5. Alle Kabeldurchführungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so gewählt werden,daß diese eine sichere Verkabelung des Gerätes ermöglichen.

6. Um eine sichere Funktion des Gerätes zu gewährleisten, muß die Spannungsversorgung über mindestens 10A abgesichert sein. Im Fehlerfall muß dadurch gewährleistet sein, daß die Spannungsversorgung zum Gerätbzw. zu den Geräten unterbrochen wird. Ein mechanischer Schutzschalter kann in dieses System integriertwerden. Falls eine derartige Vorrichtung nicht vorhanden ist, muß eine andere Möglichkeit zurUnterbrechung der Spannungszufuhr gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden.Ein solcher Mechanismus zur Spannungsunterbrechung muß mit den Normen und Richtlinien für dieallgemeine Installation von Elektrogeräten, wie zum Beispiel der IEC947, übereinstimmen.

7. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, die eine gefährliche(Netzspannung) Spannung führen. Die Abdeckungen dürfen nur entfernt werden, wenndie Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesenGeräten Arbeiten ausführen.

8. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, in bzw. unter denenheiße Teile vorhanden sind. Die Abdeckungen dürfen nur entfernt werden, wenn dieVersorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesenGeräten Arbeiten ausführen. Bis 45 Minuten nach dem Unterbrechen der Netzzufuhrkönnen derartig Teile noch über eine erhöhte Temperatur verfügen.

9. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, bei denen vor demEingriff die entsprechenden Kapitel im Handbuch sorgfältig durchgelesen werdenmüssen.

10. Alle in diesem Gerät verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgendaufgeführten Standards: EN61010-1, IEC417 & ISO3864.

IB-106-300NHx

IMPORTANTE

Norme di sicurezza per il cablaggio e l’installazione dello strumento.

Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione Europea, la cuistretta osservanza è richiesta per garantire conformità alla Direttiva del Basso Voltaggio. Esse si applicanoanche agli stati non appartenenti all’Unione Europea, salvo quanto disposto dalle vigenti normative localio nazionali.

1. Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra interni ed esterni, doveprevisti.

2. Dopo l’installazione o la localizzazione dei guasti, assicurarsi che tutti i coperchi di protezione siano staticollocati e le messa a terra siano collegate. L’integrità di ciscun morsetto di terra deve essere costantementegarantita.

3. I cavi di alimentazione della rete devono essere secondo disposizioni IEC227 o IEC245.

4. L’intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore a 75°C.

5. Le dimensioni di tutti i connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggioal cavo.

6. Per garantire un sicuro funzionamento dello strumento il collegamento alla rete di alimentazione principaledovrà essere eseguita tramite interruttore automatico (min.10A), in grado di disattivare tutti i conduttori dicircuito in caso di guasto. Tale interruttore dovrà inoltre prevedere un sezionatore manuale o altrodispositivo di interruzione dell’alimentazione, chiaramente identificabile. Gli interruttori dovranno essereconformi agli standard riconosciuti, quali IEC947.

7. Il simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenzadi elevati voltaggi. Tali coperchi di protezione devono essere rimossi esclusivamente dapersonale qualificato, dopo aver tolto alimentazione allo strumento.

8. Il simbolo riportato sullo strumento o sui coperchi di protezione indica rischio di contattocon superfici ad alta temperatura. Tali coperchi di protezione devono essere rimossiesclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento.Alcune superfici possono mantenere temperature elevate per oltre 45 minuti.

9. Se lo strumento o il coperchio di protezione riportano il simbolo,fare riferimento alle istruzioni del manuale Operatore.

10. Tutti i simboli grafici utilizzati in questo prodotto sono previsti da uno o più dei seguenti standard:EN61010-1, IEC417 e ISO3864.

IB-106-300NHxi

VIKTIG

Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret.

Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØS-avtalen.Instruksjonene skal følges nøye slik at installasjonen blir i henhold til lavspenningsdirektivet. Den børogså følges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder.

1. Passende jordforbindelser må tilkobles alle jordingspunkter, interne og eksterne hvor disse forefinnes.

2. Etter installasjon eller feilsøking skal alle sikkerhetsdeksler og jordforbindelser reetableres.Jordingsforbindelsene må alltid holdes i god stand.

3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.

4. Alle ledningsforbindelser skal være konstruert for en omgivelsestemperatur høyere en 750C.

5. Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnåes.

6. For å oppnå sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom enstrømbryter (minimum 10A) som vil bryte spenningsforsyningen til alle elektriske kretser ved enfeilsituasjon. Strømbryteren kan også inneholde en mekanisk operert bryter for å isolere instrumentet fraspenningsforsyningen. Dersom det ikke er en mekanisk operert bryter installert, må det være en annen måteå isolere utstyret fra spenningsforsyningen, og denne måten må være tydelig merket. Kretsbrytere ellerkontakter skal oppfylle kravene i en annerkjent standard av typen IEC947 eller tilsvarende.

7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det sannsynligat disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyninger frakoblet utstyret, og da bare av trenet servicepersonell.

8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate, er detsannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes nårspenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. Noenoverflater kan være for varme til å berøres i opp til 45 minutter etter spenningsforsyningfrakoblet.

9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer tilinstruksjonsmanualen for instrukser.

10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av følgende standarder: EN61010-1,IEC417 & ISO3864.

IB-106-300NHxii

IMPORTANTE

Instruções de segurança para ligação e instalação deste aparelho.

As seguintes instruções de segurança aplicam-se especificamente a todos os estados membros da UE.Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tensão.Relativamente aos estados que não pertençam à UE, deverão cumprir igualmente a referida directiva,exceptuando os casos em que a legislação local a tiver substituído.

1. Devem ser feitas ligações de terra apropriadas a todos os pontos de terra, internos ou externos.

2. Após a instalação ou eventual reparação, devem ser recolocadas todas as tampas de segurança e terras deprotecção. Deve manter-se sempre a integridade de todos os terminais de terra.

3. Os cabos de alimentação eléctrica devem obedecer às exigências das normas IEC227 ou IEC245.

4. Os cabos e fios utilizados nas ligações eléctricas devem ser adequados para utilização a uma temperaturaambiente até 75º C.

5. As dimensões internas dos bucins dos cabos devem ser adequadas a uma boa fixação dos cabos.

6. Para assegurar um funcionamento seguro deste equipamento, a ligação ao cabo de alimentação eléctricadeve ser feita através de um disjuntor (min. 10A) que desligará todos os condutores de circuitos durante umaavaria. O disjuntor poderá também conter um interruptor de isolamento accionado manualmente. Casocontrário, deverá ser instalado qualquer outro meio para desligar o equipamento da energia eléctrica,devendo ser assinalado convenientemente. Os disjuntores ou interruptores devem obedecer a uma normareconhecida, tipo IEC947.

7. Sempre que o equipamento ou as tampas contiverem o símbolo, é provável a existência detensões perigosas. Estas tampas só devem ser retiradas quando a energia eléctrica tiversido desligada e por Pessoal da Assistência devidamente treinado.

8. Sempre que o equipamento ou as tampas contiverem o símbolo, há perigo de existência desuperfícies quentes. Estas tampas só devem ser retiradas por Pessoal da Assistênciadevidamente treinado e depois de a energia eléctrica ter sido desligada. Algumassuperfícies permanecem quentes até 45 minutos depois.

9. Sempre que o equipamento ou as tampas contiverem o símbolo, o Manual deFuncionamento deve ser consultado para obtenção das necessárias instruções.

10. Todos os símbolos gráficos utilizados neste produto baseiam-se em uma ou mais das seguintes normas:EN61010-1, IEC417 e ISO3864.

IB-106-300NHxiii

IMPORTANTE

Instrucciones de seguridad para el montaje y cableado de este aparato.

Las siguientes instrucciones de seguridad , son de aplicacion especifica a todos los miembros de la UE y seadjuntaran para cumplir la normativa europea de baja tension.

1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en aquellos terminalesprevistos al efecto.

2. Una vez finalizada las operaciones de mantenimiento del equipo, se deben volver a colocar las cubiertas deseguridad aasi como los terminales de tierra. Se debe comprobar la integridad de cada terminal.

3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245.

4. Todo el cableado sera adecuado para una temperatura ambiental de 75ºC.

5. Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables.

6. Para un manejo seguro del equipo, la alimentacion electrica se realizara a traves de un interruptormagnetotermico ( min 10 A ), el cual desconectara la alimentacion electrica al equipo en todas sus fasesdurante un fallo. Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio.

7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa,dicho alojamiento solamente se abrira una vez que se haya interrumpido la alimentacionelectrica al equipo asimismo la intervencion sera llevada a cabo por personal entrenadopara estas labores.

8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con altatemperatura, por tanto se abrira una vez que se haya interrumpido la alimentacionelectrica al equipo por personal entrenado para estas labores, y al menos se esperaraunos 45 minutos para enfriar las superficies calientes.

9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el manual deinstrucciones.

10. Todos los simbolos graficos usados en esta hoja, estan de acuerdo a las siguientes normas EN61010-1,IEC417 & ISO 3864.

IB-106-300NHxiv

VIKTIGT

Säkerhetsföreskrifter för kablage och installation av denna apparat.

Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varjeavseende för att överensstämma med Lågspännings direktivet. Icke EU medlemsländer skall också följanedanstående punkter, såvida de inte övergrips av lokala eller nationella föreskrifter.

1. Tillämplig jordkontakt skall utföras till alla jordade punkter, såväl internt som externt där så erfordras. 2. Efter installation eller felsökning skall samtliga säkerhetshöljen och säkerhetsjord återplaceras. Samtliga

jordterminaler måste hållas obrutna hela tiden. 3. Matningsspänningens kabel måste överensstämma med föreskrifterna i IEC227 eller IEC245. 4. Allt kablage skall vara lämpligt för användning i en omgivningstemperatur högre än 75ºC. 5. Alla kabelförskruvningar som används skall ha inre dimensioner som motsvarar adekvat kabelförankring. 6. För att säkerställa säker drift av denna utrustning skall anslutning till huvudströmmen endast göras genom en

säkring (min 10A) som skall frånkoppla alla strömförande kretsar när något fel uppstår. Säkringen kan ävenha en mekanisk frånskiljare. Om så inte är fallet, måste ett annat förfarande för att frånskilja utrustningenfrån strömförsörjning tillhandahållas och klart framgå genom markering. Säkring eller omkopplare måsteöverensstämma med en gällande standard såsom t ex IEC947.

7. Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för livsfarlig

spänning i närheten. Dessa höljen får endast avlägsnas när strömmen ej är ansluten tillutrustningen - och då endast av utbildad servicepersonal.

8. När utrustning eller hölje är markerad med vidstående symbol föreligger risk för

brännskada vid kontakt med uppvärmd yta. Dessa höljen får endast avlägsnas av utbildadservicepersonal, när strömmen kopplats från utrustningen. Vissa ytor kan vara mycketvarma att vidröra även upp till 45 minuter efter avstängning av strömmen.

9. När utrustning eller hölje markerats med vidstående symbol bör instruktionsmanualen

studeras för information. 10. Samtliga grafiska symboler som förekommer i denna produkt finns angivna i en eller flera av följande

föreskrifter:- EN61010-1, IEC417 & ISO3864.

IB-106-300NHxv/xvi

IB-106-300NHxvii

TABLE OF CONTENTS

Section Page

Rosemount Warranty .......................................................................................................................................... i

I. DESCRIPTION ................................................................................................................................................. 1-11-1. Component Checklist of Typical System (Package Contents) ............................................................... 1-11-2. System Overview .................................................................................................................................... 1-2

II. INSTALLATION .............................................................................................................................................. 2-12-1. Oxygen Analyzer (Probe) Installation .................................................................................................... 2-12-2. Intelligent Field Transmitter (IFT) Installation ...................................................................................... 2-82-3. Heater Power Supply Installation ........................................................................................................... 2-122-4. Multiprobe Calibration Gas Sequencer Installation ............................................................................... 2-20

III. GENERAL USER INTERFACE (GUI) OPERATION ........................................................................... 3-13-1. Overview................................................................................................................................................. 3-13-2. Deluxe Version IFT Displays and Controls............................................................................................ 3-23-3. Help Key ................................................................................................................................................. 3-33-4. Status Line............................................................................................................................................... 3-33-5 Quick Reference Chart............................................................................................................................ 3-33-6. Main Menu.............................................................................................................................................. 3-33-7 PROBE DATA Sub-Menu .................................................................................................................... 3-43-8. CALIBRATE O2 Sub-Menu................................................................................................................... 3-143-9. SETUP Sub-Menu .................................................................................................................................. 3-143-10. Analog Output Calibration...................................................................................................................... 3-143-11. System Calibration.................................................................................................................................. 3-14

IV. SYSTEM TROUBLESHOOTING ................................................................................................................ 4-14-1. Overview................................................................................................................................................. 4-14-2. Special Troubleshooting Notes............................................................................................................... 4-14-3. System Troubleshooting ......................................................................................................................... 4-1

V. RETURNING EQUIPMENT TO THE FACTORY ................................................................................ 5-1

APPENDIX A. WORLD CLASS 3000 OXYGEN ANALYZER (PROBE)

APPENDIX B. HPS 3000 HEATER POWER SUPPLY FIELD MODULE

APPENDIX D. MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER

APPENDIX E. IFT 3000 INTELLIGENT FIELD TRANSMITTER

APPENDIX J. HART® COMMUNICATOR, MODEL 275D9E IFT APPLICATIONS

IB-106-300NHxviii

LIST OF ILLUSTRATIONS

Figure Page

1-1 Typical System Package ..................................................................................................................................... 1-11-2 Typical System Installation................................................................................................................................. 1-51-3 World Class 3000 Typical Application with Intelligent Field Transmitters...................................................... 1-62-1 Probe Installation ................................................................................................................................................ 2-22-2 Orienting the Optional Vee Deflector................................................................................................................. 2-72-3 Air Set, Plant Air Connection ............................................................................................................................. 2-72-4 Outline of Intelligent Field Transmitter .............................................................................................................. 2-82-5 Power Supply Board Jumper Configuration....................................................................................................... 2-92-6 Signal Wire Routing............................................................................................................................................ 2-92-7 IFT Power Supply Board Jumpers...................................................................................................................... 2-102-8 Wiring Layout for IFT 3000 System without HPS............................................................................................. 2-112-9 Microprocessor Board Jumper Configuration.................................................................................................... 2-122-10 IFT Microprocessor Board ................................................................................................................................. 2-132-11 Interconnect Board Jumper Configuration ......................................................................................................... 2-142-12 IFT Interconnect Board Output Connections ..................................................................................................... 2-142-13 Outline of Heater Power Supply......................................................................................................................... 2-152-14 Wiring Layout for Complete IFT 3000 System with HPS................................................................................. 2-162-15 Heater Power Supply Wiring Connections......................................................................................................... 2-182-16 Jumper Selection Label....................................................................................................................................... 2-192-17 Jumpers on HPS Mother Board.......................................................................................................................... 2-192-18 MPS Module ....................................................................................................................................................... 2-202-19 MPS Gas Connections ........................................................................................................................................ 2-212-20 MPS Probe Wiring.............................................................................................................................................. 2-223-1 Deluxe Version IFT Displays and Controls........................................................................................................ 3-23-2 Quick Reference Chart........................................................................................................................................ 3-53-3 Typical Calibration Setup .................................................................................................................................. 3-173-4 Portable Rosemount Oxygen Calibration Gas Kit.............................................................................................. 3-183-5 Typical Portable Calibration Setup..................................................................................................................... 3-183-6 Typical Automatic Calibration System............................................................................................................... 3-20

LIST OF TABLES

Table Page

3-1 Sample HELP Messages..................................................................................................................................... 3-33-2 MAIN Menu....................................................................................................................................................... 3-33-3 PROBE DATA Sub-Menu ............................................................................................................................... 3-43-4 CALIBRATE O2 Sub-Menu.............................................................................................................................. 3-103-5 SETUP Sub-Menu ............................................................................................................................................. 3-113-6 Efficiency Constants ........................................................................................................................................... 3-14

IB-106-300NH1-1

SECTION I. DESCRIPTION

1-1. COMPONENT CHECKLIST OF TYPICALSYSTEM (PACKAGE CONTENTS) A typicalRosemount World Class 3000 Oxygen Analyzer withIFT 3000 Intelligent Field Transmitter should containthe items shown in Figure 1-1. Record the part number,serial number, and order number for each component ofyour system in the table located on the first page of thismanual.

ITEM DESCRIPTION1 Intelligent Field Transmitter2 Instruction Bulletin3 Multiprobe Calibration Gas Sequencer

(Optional)4 Heater Power Supply (Optional)5 Oxygen Analyzer (Probe)6 System Cable7 Adapter Plate with mounting

hardware and gasket8 Reference Air Set

(If MPS not supplied)9 HART® Communicator Package (Optional)

o

HART Communicator

FISHER-ROSEMOUNTTM

MAN 4275A00English

October 1994

1

3

4

5

6

7

8

9

2

21190001

Figure 1-1. Typical System Package

IB-106-300NH1-2

1-2. SYSTEM OVERVIEW.

a. Scope. This Instruction Bulletin has beendesigned to supply details needed to install,startup, operate, and maintain the RosemountWorld Class 3000 Oxygen Analyzer withIFT 3000 Intelligent Field Transmitter. TheIntelligent Field Transmitter (IFT) can beinterfaced with one World Class 3000 probe. TheIFT provides all necessary intelligence forcontrolling the probe and optional MPS 3000Multiprobe Calibration Gas Sequencer.Appendices at the back of this manual detail eachcomponent and option from the standpoint oftrouble-shooting, repair, and spare parts.

Operator/Technician interface to the IFT can beprovided from the displays and keypads on thefront panel, and remotely through HART®

communications protocol, utilizing the 4-20 mAoutput signal from the IFT interconnect board.HART Communicator IFT applications aredetailed in Appendix J.

b. System Description. The Rosemount OxygenAnalyzer (Probe) is designed to measure the netconcentration of oxygen in an industrial process;i.e., the oxygen remaining after all fuels have beenoxidized. The probe is permanently positionedwithin an exhaust duct or stack and performs itstask without the use of a sampling system.

The equipment measures oxygen percentage byreading the voltage developed across a heatedelectrochemical cell, which consists of a smallyttria-stabilized, zirconia disc. Both sides of thedisc are coated with porous metal electrodes.When operated at the proper temperature, themillivolt output voltage of the cell is given by thefollowing Nernst equation:

EMF = KT log10(P1/P2) + C

Where:

1. P2 is the partial pressure of the oxygen in themeasured gas on one side of the cell,

2. P1 is the partial pressure of the oxygen in thereference air on the other side,

3. T is the absolute temperature,4. C is the cell constant,5. K is an arithmetic constant.

NOTE

For best results, use clean, dry, instrumentair (20.95% oxygen) as a reference air.

When the cell is at operating temperature and thereare unequal oxygen concentrations across the cell,oxygen ions will travel from the high partialpressure of oxygen side to the low partial pressureside of the cell. The resulting logarithmic outputvoltage is approximately 50 mV per decade.Because the magnitude of the output isproportional to the logarithm of the inverse of thesample of the oxygen partial pressure, the outputsignal increases as the oxygen concentration of thesample gas decreases. This characteristic enablesthe oxygen analyzer to provide exceptionalsensitivity at low oxygen concentrations.

Oxygen analyzer equipment measures net oxygenconcentration in the presence of all the products ofcombustion, including water vapor. Therefore, itmay be considered an analysis on a "wet" basis. Incomparison with older methods, such as the Orsatapparatus, which provides an analysis on a "dry"gas basis, the "wet" analysis will, in general,indicate a lower percentage of oxygen. Thedifference will be proportional to the water contentof the sampled gas stream.

c. System Configuration. The equipment coveredin this manual consists of three major components:the oxygen analyzer (probe), the intelligent fieldtransmitter (IFT), and an optional heater powersupply (HPS). The HPS is required where thecable run between the probe and the electronics isgreater than 150 ft (45 m). There is also anoptional multiprobe calibration gas sequencer(MPS) to facilitate automatic calibration of theprobe.

Probes are available in five length options, givingthe user the flexibility to use an in situ penetrationappropriate to the size of the stack or duct. Theoptions on length are 18 in. (457 mm), 3 ft(0.91 m), 6 ft (1.83 m), 9 ft (2.7 m), or 12 ft(3.66 m).

The IFT contains electronics that control probetemperature (in conjunction with the optionalHPS), supply power, and provide isolated outputsthat are proportional to the measured oxygenconcentration. The oxygen sensing cell ismaintained at a constant temperature bymodulating the duty cycle of the probe heater. TheIFT accepts millivolt signals generated by thesensing cell and produces outputs to be used byremotely connected devices. The IFT output isisolated and selectable to provide linearizedvoltage or current.

IB-106-300NH1-3

The heater power supply (HPS) can provide aninterface between the IFT and the probe. The HPScontains a transformer for supplying proper voltageto the probe heater. The enclosure has beendesigned to meet NEMA 4X (IP56) specificationsfor water tightness; an optional enclosure to meetClass 1, Division 1, Group B (IP56) explosionproof is also available.

Systems with multiprobe and multiple IFTapplications may employ an optional MPS 3000Multiprobe Calibration Gas Sequencer. The MPS3000 provides automatic calibration gassequencing for up to four probes and IFTs toaccommodate automatic calibration.

d. System Features.

1. Unique and patented electronic cell protectionaction that automatically protects sensor cellwhen the analyzer detects reducingatmospheres.

2. Output voltage and sensitivity increase as theoxygen concentration decreases.

3. User friendly, menu driven operator interfacewith context-sensitive on-line help.

4. Field replaceable cell.

5. Analyzer constructed of rugged 316 LSS forall wetted parts.

6. The intelligent field transmitter (IFT) can belocated up to 150 ft (45 m) from the probewhen used without optional heater powersupply (HPS). When the system includes theoptional HPS, the HPS can be located up to150 ft (45 m) from the probe and the IFT maybe located up to 1200 ft (364 m) from theHPS.

7. All electronic modules are adaptable to 100,120, 220, and 240 line voltages.

8. Five languages may be selected for use withthe Intelligent Field Transmitter:

English ItalianFrench SpanishGerman

9. An operator can set up, calibrate, ortroubleshoot the IFT in one of two ways:

(a) Optional General User Interface(GUI). The GUI is housed within theIFT electronics enclosure and makes useof an LCD and keypad.

(b) Optional HART Interface. The IFT's4-20 mA output line transmits an analogsignal proportional to oxygen level. Theline also carries all information normallyaccessed by use of the General UserInterface LCD and keypad. This infor-mation can be accessed through thefollowing:

1 Rosemount Model 275 HandheldCommunicator - The handheldcommunicator requires DeviceDescriptor (DD) software specificto the World Class 3000 product.The DD software will be suppliedwith many model 275 units, but canalso be programmed into existingunits at most Fisher-Rosemountservice offices.

2 Personal Computer (PC) - The useof a personal computer requiresCornerstone software with ModuleLibrary (ModLib) specific to theWorld Class 3000 product.

3 Selected Distributed Control Sys-tems - The use of distributed controlsystems requires input/output (I/O)hardware and software which permitHART communications.

IB-106-300NH1-4

e. Handling the Oxygen Analyzer.

It is important that printed circuit boardsand integrated circuits are handled onlywhen adequate antistatic precautions havebeen taken to prevent possible equipmentdamage.

The oxygen analyzer is designed forindustrial application. Treat each componentof the system with care to avoid physicaldamage. The probe contains componentsmade from ceramics, which are susceptible toshock when mishandled.

NOTE

Retain packaging in which the oxygenanalyzer arrived from the factory in caseany components are to be shipped toanother site. This packaging has beendesigned to protect the product.

f. System Considerations. Prior to installation ofyour Rosemount World Class 3000 OxygenAnalyzer with Intelligent Field Transmitter makesure that you have all of the components necessaryto make the system installation. Ensure that all thecomponents are properly integrated to make thesystem functional.

Once you have verified that you have all thecomponents, select mounting locations anddetermine how each component will be placed in

terms of available power supply, ambienttemperatures, environmental considerations,convenience, and serviceability. A typical systeminstallation is illustrated in Figure 1-2. Figure 1-3shows a typical system wiring. For details oninstalling the individual components of the system,refer to Section II, Installation.

After selecting the probe mounting location,provision should be made for a platform where theprobe can be easily serviced. The intelligent fieldtransmitter (IFT) can be located up to 150 ft(45 m) cabling distance from the probe when usedwithout optional heater power supply (HPS).When the system includes the optional HPS, theHPS can be located up to 150 ft (45 m) cablingdistance from the probe and the IFT may belocated up to 1200 ft (364 m) cabling distancefrom the HPS.

A source of instrument air is required at the probefor reference air use. Since the probe is equippedwith an in-place calibration feature, provisionshould be made for connecting calibration gastanks to the oxygen analyzer when the probe is tobe calibrated.

If the calibration gas bottles will be permanentlyhooked up, a check valve is required next to thecalibration fittings on the probe junction box. Thisis to prevent breathing of calibration gas line andsubsequent flue gas condensation and corrosion.The check valve is in addition to the stop valve inthe calibration gas kit or the solenoid valve in themultiprobe calibration gas sequencer units.

An optional Z-purge arrangement is available forapplications where hazardous area classificationmay be required (See Application Data BulletinAD 106-300B).

IB-106-300NH1-5

STANDARD

OPTIONS

DUCT

STACK

GASES

CALIBRATIONGAS

INSTRUMENTAIR SUPPLY(REF. AIR)

PRESSUREREGULATOR

FLOWMETER

INTELLIGENTFIELD TRANSMITTER

MULTIPROBECALIBRATION GAS

SEQUENCER

REFERENCE AIR

CALIBRATIONGAS

HEATERPOWERSUPPLY

OXYGENANALYZER(PROBE)

INTELLIGENT FIELDTRANSMITTER

OXYGENANALYZER(PROBE)

ADAPTERPLATE

ADAPTERPLATE

STACK

DUCT

GASES

CA

LG

AS

1

CA

LG

AS

2IN

ST.

AIR

SU

PP

LY

LINEVOLTAGE

LINEVOLTAGE

27270001

Figure 1-2. Typical System Installation

IB-106-300NH1-6

MPS 3000

CALIBRATION GASSEQUENCER

HPS 3000

HPS 3000

(OPTIONAL)

(OPTIONAL)

Explosion ProofRequired only forHazardous AreaApplications, otherwiseuse NEMA 4X.Lengths Exceeding150 ft (45 m).

2-Conductor T/CWire [150 Ft (45 m) Max]

(optional)Line Voltage

Line Voltage

Line Voltage

Line Voltage

HART Model 275Hand HeldInterface

Customer's Laptop withCornerstone Software

Customer's DistributedControl System

with HARTInterface Capability

Line Voltage

Line Voltage

2-Conductor T/CWire [150 Feet (45 m) Max]

(optional)

7-Conductor Cable[150 Feet (45 m) Max]

2-Calibration Gas Linesby Customer[300 Ft (90 m) Max]

4 Twisted Pair, plus 2 Twisted Pairfor Options [1200 Ft (364 m) Max]

4 Twisted Pair Plus 2 Twisted Pairfor Options [1200 Ft (364 m) Max]

5 Conductor[1000 Ft (309 m) Max]

Modular DesignUp to 4 Probes

IFT 3000

IFT 3000

IFT 3000

Intelligent Field TransmitterNEMA 4X Enclosure

Line Voltage100 to 120 Volt220 to 240 Volt





Stack Thermocouple(optional)

Stack Thermocouple(optional)

World Class 3000Probe



Termination inControl Room

7-Conductor Cable[150 Ft (45 m) Max]

7-Conductor Cable[150 Ft (45 m) Max]

Heater Power Supply[Optional,

Required for > 150 Ft (45 m)]

2-Calibration Gas Linesby Customer

[300 Ft (90 m) Max]

Calibration Gasby

Customer

(HPS not required for lengths of less than 150 feet)

HPS 3000

4-20 mA Output(Twisted Pair)

27270002

Figure 1-3. World Class 3000 Typical Application with Intelligent Field Transmitters

IB-106-300NH2-1

SECTION II. INSTALLATION

2-1. OXYGEN ANALYZER (PROBE)INSTALLATION.

Before starting to install this equipment, readthe "Safety instructions for the wiring andinstallation of this apparatus" at the front ofthis Instruction Bulletin. Failure to follow thesafety instructions could result in seriousinjury or death.

a. Selecting Location.

1. The location of the probe in the stack or flueis most important for maximum accuracy inthe oxygen analyzing process. The probe mustbe positioned so that the gas it measures isrepresentative of the process. Best results arenormally obtained if the probe is positionednear the center of the duct (40 to 60%insertion). A point too near the edge or wallof the duct may not provide a representativesample because of the possibility of gasstratification. In addition, the sensing pointshould be selected so that the process gastemperature falls within a range of 50° to1300°F (10° to 704°C). Figure 2-1 providesmechanical installation references.

2. Check the flue or stack for holes and airleakage. The presence of this condition willsubstantially affect the accuracy of the oxygenreading. Therefore, either make necessaryrepairs or install the probe upstream of anyleakage.

3. Ensure that the area is clear of obstructionsinternal and external that will interfere withinstallation. Allow adequate clearance forremoval of probe (Figure 2-1).

4. If the probe is to be mounted outside, subjectto rain and snow conditions, make sure theback of the probe (outside of the duct) isinsulated to prevent the formation of flue gascondensate in the calibration gas lines.

Do not allow the temperature of the probejunction box to exceed 300°F (149°C) ordamage to the unit may result. If the probejunction box temperature exceeds 300°F(149°C), the user must fabricate a heat shieldor provide adequate cooling air to the probejunction box.

b. Mechanical Installation.

1. Ensure that all components are available forinstallation of the probe. Ensure that thesystem cable is the required length. Ifequipped with the optional ceramic diffusorelement, ensure that it is not damaged.

2. The probe may be installed intact as it isreceived. It is recommended that youdisassemble the adapter plate for eachinstallation.

NOTE

An abrasive shield is recommended for highvelocity particulate in the flue stream (suchas those in coal fired boilers, kilns, andrecovery boilers). Vertical and horizontalbrace clamps are provided for 9 ft and 12 ft(2.75 m and 3.66 m) probes to providemechanical support of the probe. Refer toFigure 2-1, sheet 5.

3. Weld or bolt adapter plate (Figure 2-1) ontothe duct.

IB-106-300NH2-2

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Figure 2-1. Probe Installation (Sheet 1 of 5)

IB-106-300NH2-3

SN

UB

BE

RD

IFF

US

ION

/D

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90

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0.0

6T

HK

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ISH

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(P/N

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35

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02

-A

NS

I)(P

/N3

53

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JIS

)(P

/N3

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DIN

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27

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IB-106-300NH2-4

22

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(mm

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DIM

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NS

IN.

(mm

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NS

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/N4

51

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34

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(P/N

35

35

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02

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/N4

51

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(P/N

35

35

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(22

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00

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o

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16

86

00

21


IB-106-300NH2-5

NOTE: ALL MASONRY STACK WORK AND JOINTS EXCEPTADAPTOR PLATE NOT FURNISHED BY ROSEMOUNT.

INSTALLATION FOR MASONRYWALL STACK CONSTRUCTION

INSTALLATION FOR METALWALL STACK OR DUCT

CONSTRUCTION

0.50 [13]

3.75 [95]

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

MTG HOLESSHOWN ROTATED45o OUT OFTRUE POSITION

WELD OR BOLT ADAPTORPLATE TO METAL WALLOF STACK OR DUCT. JOINT MUST BE AIR TIGHT.

0.50 [13]

4.50 [114]O.D. REF

PIPE 4.00 SCHED 40PIPE SLEEVE (NOTBY ROSEMOUNT)LENGTH BY CUSTOMER

MASONRYSTACK WALL

OUTSIDE WALLSURFACE

JOINT MUSTBE AIRTIGHT

MTG HOLESSHOWN ROTATED

45o

OUT OFTRUE POSITION

FIELD WELDPIPE TO

ADAPTOR PLATE

BOLT ADAPTORPLATE TO OUTSIDE

WALL SURFACE

NOTE: DIMENSIONS IN INCHES WITHMILLIMETERS IN PARENTHESES.

2.50 [63.5]

MIN DIA HOLEIN WALL

STACK OR DUCTMETAL WALL

WELD OR BOLT ADAPTORPLATE TO METAL WALL

OF STACK OR DUCT.JOINT MUST BE AIR TIGHT.

FIELD WELDPIPE TOADAPTOR PLATE

3.50 [89]O.D. REF

PIPE 3.00 SCHED 40PIPE SLEEVE (NOTBY ROSEMOUNT)LENGTH BY CUSTOMER

MASONRYSTACK WALLOUTSIDE WALL

SURFACE

JOINT MUSTBE AIRTIGHT

BOLT ADAPTORPLATE TO OUTSIDE

WALL SURFACE

624038


IB-106-300NH2-6

BRACE BARS(NOT BY ROSEMOUNT)

2.00(51)

NOTE: DIMENSIONS IN INCHES WITHMILLIMETERS IN PARETHESES.

VERTICAL BRACE CLAMP ASSY.

HORIZONTAL BRACE CLAMP ASSY.(BOTH BRACE CLAMP ASSEMBLIES ARE THE SAME.INSTALLATION AND LOCATION OF CLAMP ASSEMBLIESAND BRACE BARS TO BE DONE IN FIELD.)

BY ROSEMOUNT

2 HOLES - 0.625(16) DIA. FOR0.50 (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. 27270008


4. If using the optional ceramic diffusor element,the vee deflector must be correctly oriented.Before inserting the probe, check thedirection of flow of the gas in the duct. Orientthe vee deflector on the probe so that the apexpoints upstream toward the flow (Figure 2-2).This may be done by loosening the setscrews,and rotating the vee deflector to the desiredposition. Retighten the setscrews.

5. In horizontal installations, the probe junctionbox should be oriented so that the systemcable drops vertically from the probe junctionbox. In a vertical installation, the system cablecan be oriented in any direction.

6. If the system has an abrasive shield, check thedust seal packings. The joints in the twopackings must be staggered 180°. Also, makesure that the packings are in the hub grooves

as the probe slides into the 15° forcing conein the abrasive shield.

NOTE

If process temperatures will exceed 392°F(200°C), use anti-seize compound on studthreads to ease future removal of probe.

7. Insert probe through the opening in themounting flange and bolt the unit to theflange. When probe lengths selected are 9 or12 ft (2.74 or 3.66 m), special brackets aresupplied to provide additional support for theprobe inside the flue or stack. See Figure 2-1,sheet 5.

NOTE

Probe InstallationTo maintain CE compliance, ensure there isa good connection between the chassis of theprobe and earth.

IB-106-300NH2-7

VEEDEFLECTOR

VEEDEFLECTOR

DIFFUSIONELEMENT

SETSCREWFILTER

GAS FLOWDIRECTION

APEX

624017

Figure 2-2. Orienting the Optional Vee Deflector

c. Reference Air Package. After the oxygenanalyzing (probe) unit is installed, connect thereference air set to the probe junction box. Thereference air set should be installed in accordancewith Figure 2-3.

d. Service Required.

1. Power input: 100, 115 or 220 Vac singlephase, 50 to 60 Hz, 3 amp minimum. (Seelabel.)

2. Compressed air: 10 psig (68.95 kPa)minimum, 225 psig (1551.38 kPa) maximumat 2 scfh (56.6 L/hr) maximum; supplied byone of the following (less than 40 parts-per-million total hydrocarbons). Regulator outletpressure should be set at 5 psi (35 kPa).

(a) Instrument air - clean, dry.

TO PROBE HEAD

REF AIR SET263C152G01

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 WITHMILLIMETERS IN PARENTHESES.

12

3

4.81 (122.17)

FLOW SETPOINT KNOB

0.125-27 NPT FEMALEOUTLET CONNECTION

1.19(30.22)

10.0 REF(254)

DRAIN VALVE

3.12 (79.25) MAX

8.50 MAX(215.90)

2.0(50.80) 2 MOUNTING HOLES

3.19 (81.03) LGTHROUGH BODY FOR0.312 (7.92) DIA BOLTS

1.50(38.10)

2.250 (57.15)

SCHEMATIC HOOKUP FOR REFERENCE AIR SUPPLY ON OXYGEN ANALYZER PROBE HEAD.

OUTLET

0.25-18 NPT FEMALEINLET CONNECTION

COMPRESSED AIR SUPPLY10-225 PSIG MAX PRESSURE

27270003

0.250 OR 6 MM OD TUBING(SUPPLIED BY CUSTOMER)

0.250 OR 6 MM ODTUBE COMPRESSION

FITTING (SUPPLIED BY WECO)

Figure 2-3. Air Set, Plant Air Connection

IB-106-300NH2-8

(b) Bottled standard air with step-downregulator.

(c) Bottled compressed gas mixture(20.95% oxygen in nitrogen).

(d) Other equivalent clean, dry, oil-free airsupply.

2-2. INTELLIGENT FIELD TRANSMITTER (IFT) INSTALLATION.

a. Mechanical Installation. The outline drawing ofthe IFT module in Figure 2-4 shows mountingcenters and clearances. The NEMA 4X enclosureis designed to be mounted on a wall or bulkhead.The IFT should be installed no more than1200 feet (364 m) from the optional HPS or150 feet (45 m) from the probe if HPS is notinstalled in the system.

b. Electrical Connections.

To meet the Safety Requirements of IEC1010 (EC requirement), and ensure safeoperation of this equipment, connection tothe main electrical power supply must bemade through a circuit breaker (min 10A)which will disconnect all current carryingconductors during a fault situation. Thiscircuit breaker should also include amechanically operated isolating switch. Ifnot, then another external means ofdisconnecting the supply from the equipmentshould be located close by. Circuit breakersor switches must comply with a recognizedstandard such as IEC 947.

NOTE

Refer to Figure 2-7 for fuse locations andspecifications.

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 powersupply board. For 220 Vac usage, installjumpers JM6, JM5, JM2 (refer to Figures 2-5and 2-7).

2. For installations where the cable run is lessthan 150 feet (45 m), the IFT can beconfigured to connect directly to a probe. Anoptional HPS is available for cable runs over

5.76 (146.3)

9.00 (228.6)

1.25(31.75)

21190002

6.0(152.4)

DESIGN DIMENSIONS ARE IN INCHESWITH MILLIMETERS IN PARENTHESES.

NOTE:

8.00 (203.2)

11.24 (285.5)0.31(7.9)

13.24(336.3)

15.00(381.0)

16.00(406.4)

2.00(50.8)

1.62(41.1)

2.25(57.15) 0.867

(22.00)

11.5 (292.1) MINIMUM DOORSWING CLEARANCE

3.36(85.3)

Figure 2-4. Outline of Intelligent Field Transmitter

150 feet (45 m). The electrical connectionsfor a non-HPS equipped system should bemade as described in the electrical installationdiagram, Figure 2-8. Refer to Figure 2-14 forconnections for an HPS equipped system.

Do not install jumper JM6 on themicroprocessor board, or JM1 on theinterconnect board, if an HPS is installed inthe system. This will result in system failure.

3. The IFT must have JM6 on themicroprocessor board (Figures 2-9 and 2-10)and JM1 on the interconnect board (Figures2-11 and 2-12) installed if an HPS is notinstalled in the system.

IB-106-300NH2-9

4. If an MPS is not used in the system, wirejumper between CAL RET and NO GAS must be installed on the interconnect board.Remove wire jumper if MPS is installed in thesystem. Refer to Figure 2-8, note 6.

5. The power cable should comply with thesafety regulations in the user's country andshould not be smaller than 16 gauge, 3 amp.

6. Before supplying power to the IFT, verify thatthe jumpers have been properly set in the IFT(Figures 2-5, 2-9, and 2-11).

7. Terminal strip J5 on the power supply boardis used for supplying the IFT with power.Terminal strip J6 on the power supply boardis used to supply the probe heater with powerif an HPS is not used (Figure 2-7).

ALWAYS DISCONNECT LINE VOLTAGEFROM INTELLIGENT FIELD TRANSMITTERBEFORE CHANGING JUMPERS.

JUMPERCONFIGURATION

LINE VOLTAGESELECTION

JUMPER(INSTALL)

PROBE HEATERVOLTAGE SELECTION

JUMPER(INSTALL)

100 V.A.C.

120 V.A.C.

220 V.A.C.

240 V.A.C.

JM3, JM7, JM2

JM8, JM7, JM1

JM6, JM5, JM2

JM6, JM5, JM1

WORLD CLASS PROBE (44V)

WORLD CLASS "DIRECTREPLACEMENT" PROBE (115V)

218 PROBE (115V)

JM10

JM9

JM9

21190012

If incorrect heater voltage is selected, damage to the probe may occur. For HPS voltage selection jumper,refer to Figure 2-15. Always update the relevant labeling to reflect the set voltage.

Figure 2-5. Power Supply Board Jumper Configuration

NOTE

General Wiring RecommendationsTo maintain CE compliance and ensure proper EMC performance, all signal wires to the InterconnectBoard, with the exception of the probe cable, should be looped through the ferrite beads provided asshown in Figure 2-6 (P/N 1L04253H01). Signal wires may be grouped together and looped through beforeexiting the enclosure. Ferrite beads should be placed as close as possible to the exit point. Ferrite beadsare provided for European Common Market applications only.

Figure 2-6. Signal Wire Routing

IB-106-300NH2-10

Figure 2-7. IFT Power Supply Board Jumpers

IB-106-300NH2-11

BK

GN

WH

PU

SHIELD

SHIELD

CAL RET

NO GAS

LO GAS

HI GAS

IN GAS

SHIELD

SHIELD

STACK TC -

STACK TC +

PROBE MV +

PROBE MV -

PROBE TC +

PROBE TC -RD

YE

BL

OR

BL

OR

YE

RD

INTELLIGENT FIELDTRANSMITTER IFT 3000

WORLD CLASSPROBE

1 2 3 4 5 6 7 8

BL

PR

OB

EM

V-

PR

OB

EM

V+

PR

OB

ET

C+

PR

OB

ET

C-

OR

YE

RD

GN

E R H

WH

BK

GN

CE

LL

-VE

OR

CE

LL

+V

E

YE

CH

RO

ME

L

RD

AL

UM

EL

GN

BK

BKH

EA

TE

R

PROBE JUNCTIONBOX WIRING

STACK TC WIRING AS REQUIRED.

SPECIAL PROBE CABLE BETWEEN PROBEAND IFT BY ROSEMOUNT.

INSTALL JM1 ON INTERCONNECT BOARD.

INSTALL JM6 ON MICROPROCESSORBOARD.

IF STACK TEMPERATURE NOT USED.

IF MPS 3000 NOT USED.

1 RELAY PER PROBE AVAILABLE FORCALIBRATION STATUS INDICATION. (48 Vmax, 100 mA max)

CURRENT/VOLTAGE SELECTOR SWITCHMUST BE SELECTED TO CURRENT (I) FORHART COMMUNICATIONS APPLICATIONS.

JUMPER JM7 INFORMATION APPEARS INFIGURE 2-9.

NOTES:


LINEVOLTAGESECTION

JUMPER(INSTALL)

PROBE HEATERVOLTAGE SECTION

JUMPER(INSTALL)

120 V.A.C.

100 V.A.C.

220 V.A.C.

240 V.A.C.

J1

J5 J6

J1

JM1

JM7

JM6

J2J3

J4J5

J6J7

J8J9

3D39122G REV

POWER SUPPLY BOARD

3D39513G

MICROPROCESSOR

BOARD

3D39120G REV

INTERCONNECT BOARDJM8, JM7, JM1

JM3, JM7, JM2

JM6, JM5, JM2

JM6, JM5, JM1

WORLD CLASS PROBE

WORLD CLASS "DIRECTREPLACEMENT" PROBE

218 PROBE

JM10

JM9

JM9

JUMPER CONFIGURATION

5 CONDUCTOR SHIELDED CABLEPER PROBE #16 AWG BY CUSTOMER

ENL

LINEVOLTAGE

MPS TERMINATION BOARDMPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER (OPTIONAL)

ERH

L

E

N

LINEVOLTAGE

J13 J14 J15 J16 J17 J18

J12

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

LO

WG

AS

LO

WG

AS

LO

WG

AS

LO

WG

AS

NC C NO NC C NO NC C NO NC C NO

L

N

L

N

LINE OUT LINE IN

J10

J11

PROBE 1 PROBE 2 PROBE 3 PROBE 4


PR

OB

E1

SO

LE

NO

ID

PR

OB

E2

SO

LE

NO

ID

PR

OB

E3

SO

LE

NO

ID

PR

OB

E4

SO

LE

NO

ID

HIG

HG

AS

SO

LE

NO

ID

LO

WG

AS

SO

LEN

OID

PR

ES

SU

RE

SW

ITC

H

I

V

CURRENT/VOLTAGESELECTOR SWITCH

27270011

Figure 2-8. Wiring Layout for IFT 3000 System without HPS

IB-106-300NH2-12

OUTPUT JUMPER

HPSProbe (No HPS)

Remove JM6Install JM6

ANALOG OUTPUT(Condition duringmicrocontroller failure) JUMPER

Output = zero

Output = maximum

Install JM7

Remove JM7

(See Figure 2-10 for jumper locations.)

Figure 2-9. Microprocessor Board Jumper Configuration

c. Analog Output and Relay Output Connections.

1. The microprocessor board has a selector forvoltage or current operations. Figure 2-10shows switch orientation. In voltage mode,output is 0-10 V. In the current mode, theoutput can be configured from the SETUPmenu to be 0-20 mA or 4-20 mA.

2. The analog output and relay outputs areprogrammed by the user as needed. The

analog output is typically sent to recordingequipment such as chart recorders. Relayoutputs are typically sent to annunciators.

3. Relays K1 and K2 are user configurable fromthe probe SETUP sub-menu (Table 3-5).Typically these are used to indicate O2 valuesabove or below specified tolerances. OK relayis energized when unit is functioningproperly.

4. All wiring must conform to local and nationalcodes.

5. Connect the analog output and relay outputsas shown in Figure 2-12.

2-3. HEATER POWER SUPPLY INSTALLATION.

a. Mechanical Installation. The outline drawing ofthe heater power supply enclosure in Figure 2-13shows mounting centers and clearances. TheNEMA 4X enclosure is designed to be mounted ona wall or bulkhead. The heater power supplyshould be installed no further than 150 feet (45 m)from the probe. The heater power supply must belocated in a location free from significant ambienttemperature changes and electrical noise. Ambienttemperature must be between -20° and 140°F (-30°and 60°C).

IB-106-300NH2-13

Figure 2-10. IFT Microprocessor Board

IB-106-300NH2-14

OUTPUT JUMPER

HPSProbe (No HPS)

Remove JM1Install JM1

Figure 2-11. Interconnect Board Jumper Configuration

22

11

33

44

55

66

77

88

99

1010

1111

1212

1313

1414

1515

1616

1717

1818

1919

2020

2121

2222

2323

2424 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

(UNDERSHIELD)

NOTES:

DENOTES SHIELD CONNECTION.

OK RELAY IS ENERGIZED WHENUNIT IS FUNCTIONING PROPERLY.

16860010

Figure 2-12. IFT Interconnect Board Output Connections

IB-106-300NH2-15

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(177.8)

3.25(82.6)

3.63(92.2)

0.31(7.9)

NEMA 4X(NON-HAZARDOUS)

NOTE: DIMENSIONS IN INCHESWITH MILLIMETERS IN PARENTHESES.

10.39(264)

9.17(233)

9.96(253)

8.50(215.9)

6.18(156.9)4.72

(120)

8.50(215.9) 8.00

(203.2)

11.00(279.4)

6.75(171.5)

0.56 (14)DIA (2)MOUNTINGHOLES

1.00 (25.4) MINIMUM CLEARANCEFOR REMOVING COVER

4.38(111.3)

4.88(124)

0.38(9.7)

1.81(46)

6.00(152.4)

4.00(101.6)

#0.31686029

Figure 2-13. Outline of Heater Power Supply

b. Electrical Connections.

1. Electrical connections should be made asdescribed in the electrical installationdiagram, Figure 2-14. The wiring terminalsare divided into two layers; the bottom(FROM PROBE) terminals should beconnected first, the top (FROMELECTRONICS) terminals should beconnected last (Figure 2-15). Each terminalstrip has a protective cover which must beremoved when making connections. Toremove the terminal covers, remove twoslotted screws holding cover in place. Alwaysreinstall terminal covers after makingconnections. All wiring must conform to localand national codes.

NOTE


2. Power Input: 120, 220 or 240 Vac. For120 Vac usage, install jumpers JM4 and JM1.For 220 or 240 Vac usage, install jumper JM5(see label, Figure 2-16).

NOTE

For 100 Vac usage, the heater power supplyis factory-supplied with a different trans-former. When using the HPS with 100 Vactransformer, install jumpers JM1 and JM4.

3. The power cable should comply with safetyregulations in the user's country and shouldnot be smaller than 16 gauge, 3 amp.

IB-106-300NH2-16

Figure 2-14. Wiring Layout for Complete IFT 3000 System with HPS (Sheet 1 of 2)

IB-106-300NH2-17

JM7

I

V

MPS TERMINATION BOARDMPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER (OPTIONAL)

L

E

N

LINEVOLTAGE

J13 J14 J15 J16 J17 J18

J12

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

CA

LR

ET

HI

GA

S

INC

AL

NO

GA

S

LO

WG

AS

LO

WG

AS

LO

WG

AS

LO

WG

AS


L

N

L

N

LINE OUT LINE IN

J10

J11



PR

OB

E1

SO

LE

NO

ID

PR

OB

E2

SO

LE

NO

ID

PR

OB

E3

SO

LE

NO

ID

PR

OB

E4

SO

LE

NO

ID

HIG

HG

AS

SO

LE

NO

ID

LO

WG

AS

SO

LEN

OID

PR

ES

SU

RE

SW

ITC

H

SHIELD

SHIELD

RELAY –

RELAY +

TRIAC +

CAL RET

SHIELD

NO GAS

AD590 –

LO GAS

AD590 +

HI GAS

SHIELD

IN CAL

TRIAC –

SHIELD

SHIELD

STACK TC –

STACK TC +

PROBE MV –

PROBE MV +

PROBE TC +

PROBE TC –

INTELLIGENT FIELDTRANSMITTER IFT 3000


LINEVOLTAGESECTION

JUMPER(INSTALL)

PROBE HEATERVOLTAGE 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

J1

JM1

JM6

J2J3

J4J5

J6J7

J8J9

3D39122G REV

POWER SUPPLY BOARD

3D39513G

MICROPROCESSOR

BOARD

3D39120G REV

INTERCONNECT BOARD

JM3, JM7, JM2

JM8, JM7, JM1

JM6, JM5, JM2

JM4, JM5, JM2

JM6, JM5, JM1

NOT USED REMOVEJM9, JM10

JUMPER CONFIGURATION

ENL

LINEVOLTAGE

NOT USED

5 CONDUCTOR SHIELDED CABLEPER PROBE #16 AWG BY CUSTOMER

CURRENT/VOLTAGESELECTOR SWITCH

27270012

A

B

Figure 2-14. Wiring Layout for Complete IFT 3000 System with HPS (Sheet 2 of 2)

IB-106-300NH2-18

Figure 2-15. Heater Power Supply Wiring Connections

IB-106-300NH2-19

1

2

NOTES:

100 V.A.C. OPERATION REQUIRES TRANSFORMER PARTNUMBER 1M02961G02.

REFER TO TABLE 3-5 FOR PROPER SET POINT SELECTION.

1

20310122

Figure 2-16. Jumper Selection Label

NOTE

Before supplying power to the heater powersupply, verify that jumpers JM3, JM6 areremoved and JM7 is installed. If relay wire(Figure 2-14, note 1) is installed, JM2 mustbe removed from HPS Mother Board (Figure2-17).

4. Before supplying power to the heater powersupply, verify that the jumpers on the motherboard, Figure 2-17, are properly configured.Jumpers JM3 and JM6 should be removedand JM7 should be installed.

Additionally, make sure that the properjumper for your line voltage is installed,Figure 2-16. If relay wire (Figure 2-14, note1) is not installed, JM 2 should be installedon the HPS Mother Board (Figure 2-17).

NOTE

Refer to Figure 2-9 and 2-11 for proper IFTjumper configuration. IFT microprocessorand interconnect board jumper configura-tions must be set correctly in order for HPSto work properly.

3D3 080G

RE

V

219008

JM3

JM6

JM7

JM5

JM4

JM2

JM1

Figure 2-17. Jumpers on HPS Mother Board.

IB-106-300NH2-20

2-4. MULTIPROBE CALIBRATION GAS SEQUEN-CER INSTALLATION.

a. Mechanical Installation. The outline drawing ofthe MPS module in Figure 2-18 shows mountingcenters and clearances. The box is designed to bemounted on a wall or bulkhead. The MPS moduleshould be installed no further than 300 feet (91 m)piping distance from the probe, and no more than1000 feet (303 m) cabling distance from the IFT.Install the MPS module in a location where theambient temperature is between -20° and 160°F(-30° and 71°C).

b. Gas Connections. Figure 2-19 shows the bottomof 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 regulator valve is setat the factory to 20 psi (138 kPa). If thereference air pressure should need readjust-ment, turn the knob on the top of the valveuntil the desired pressure is obtained.

2. Connect the high O2 calibration gas to HIGHGAS. The calibration gas pressure should beset at 20 psi (138 kPa).

HIGH CALGAS IN

LOW CALGAS IN

CAL GASOUT

REF AIROUT

INSTRAIR

REF AIROUT

REF AIROUT

REF AIROUT

CAL GASOUT

CAL GASOUT

CAL GASOUT

PROBE 1 PROBE 2 PROBE 3 PROBE4

0.84 (21.34)

27270013

1.96 (49.78)

4.21 (106.93)

3.09 (78.49)

5.25 (133.35)

5.54 (140.72)

14.00 (355.60) REF

12.00(304.80)

12.00(304.80)

10.00(254.00)

NOTE: DIMENSIONS ARE IN INCHESWITH MILLIMETERS INPARENTHESES.

Figure 2-18. MPS Module

IB-106-300NH2-21

3. Connect the low O2 calibration gas to LOWGAS. The calibration gas pressure should beset at 20 psi (138 kPa).

4. Connect the REF AIR OUT to the referenceair fitting on the probe junction box.

5. Connect the CAL GAS OUT to thecalibration gas fitting on the probe junctionbox.

6. If the MPS is configured for multiple probes(up to four), repeat steps 4 and 5 for eachadditional probe.

A check valve is required for each probeconnected to an MPS to preventcondensation of flue gas in the calibration gaslines. The check valve must be locatedbetween the calibration fitting and the gasline.

c. Electrical Connections. Electrical connectionsshould be made as described in the electricalinstallation diagram, Figure 2-20. All wiring mustconform to local and national codes. The electricalconnections will exist only between the electronicspackage and the MPS to enable automatic andsemiautomatic calibration. If more than one probe

system is being used, the additional probes andelectric packages would be wired similar to thefirst probe.

NOTE


1. Run the line voltage through the bulkheadfitting on the bottom of the MPS wheremarked LINE IN, Figure 2-19. Connect theline voltage as shown in Figure 2-20 to theLINE IN terminal on the MPS terminationboard located inside the unit. Tighten the cordgrips to provide strain relief.

2. The MPS can accommodate up to fourprobes. The terminal strips on the MPStermination board are marked PROBE 1,PROBE 2, PROBE 3, and PROBE 4. SelectPROBE 1 if this is the first probe andelectronic package installed on the MPS.

3. Make the connections from the MPS to theIFT as shown in Figure 2-20. Run wires fromthe MPS Termination Board inside the unitthrough the bulkhead fitting on the bottom ofthe unit where marked SIGNAL IN, Figure2-19. After the connections are made, tightenthe cord grips to provide strain relief.

HIGH CALGAS IN

LOW CALGAS IN

CAL GASOUT

REF AIROUT

INSTRAIR

REF AIROUT

REF AIROUT

REF AIROUT

CAL GASOUT

CAL GASOUT

CAL GASOUT

PROBE 1 PROBE 2 PROBE 3 PROBE4

LINE IN

SIGNAL IN

27270014DRAIN

Figure 2-19. MPS Gas Connections

IB-106-300NH2-22

MPS TERMINATION BOARD

L

E

N

LINEVOLTAGE

J13 J14 J15 J16 J17 J18

J12

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

CA

L R

ET

HI

GA

S

IN C

AL

NO

GA

S

LOW

GA

S

LOW

GA

S

LOW

GA

S

LOW

GA

S


L

N

L

N

LINE OUT LINE IN

J10

J11



J2J3

J4J5

J6J7

J8J9

J1MH1

MH2

MH4MH3

CAL RETNO GASLO GASHI GASIN CAL

IFTINTERCONNECT

BOARD

686032

Figure 2-20. MPS Probe Wiring

IB-106-300NH2-23/2-24

! NOTE

Upon completing installation, make sure that the probe is turned on andoperating prior to firing up the combustion process. Damage can result fromhaving a cold probe exposed to the process gases.

During outages, and if possible, leave all probes running to preventcondensation and premature aging from thermal cycling.

If the ducts will be washed down during outage, MAKE SURE to power downthe probes and remove them from the wash area.

IB-106-300NH3-1

SECTION III. GENERAL USER INTERFACE (GUI) OPERATION

3-1. OVERVIEW. Ensure that the oxygen analyzer, heaterpower supply, and intelligent field transmitter havebeen properly connected. It is important to check thatgrounding and screening of terminations are correctlymade to prevent the introduction of ground loops. TheIFT is equipped with noise suppression circuitry on thepower supply and signal input lines. Proper groundingat installation will ensure accuracy of function.

The following five languages are can be selected withinthe IFT:

English ItalianFrench SpanishGerman

NOTE

Support the keypad with the free hand toprevent bounce back of the IFT door.

a. Intelligent Field Transmitter (IFT). TheIntelligent Field Transmitter may be supplied witheither of two configurations. These are the blindversion and the deluxe version. The two versionsdiffer as follows:

1. Blind Version. The blind version has nodisplay and no keypad. With this version anexternal HART communications device isrequired.

2. Deluxe Version (GUI). The deluxe versionis also known as the General User Interface(GUI) version. This IFT contains an LEDdisplay, liquid crystal display panel, and aneight-key pad from which the probe andelectronics can be configured, calibrated andtroubleshooted.

b. HART Communicator Interface Devices. TheHART communications protocol can interface withany of the above IFT versions. To interface aHART communicator with an IFT, one of threeinterface devices is required. The interface devicesare as follows:

1. Rosemount Model 275 Handheld Commu-nicator. The handheld communicator requiresDevice Descriptor (DD) software specific tothe World Class 3000 product. The DDsoftware will be supplied with many model275 units, but can also be programmed intoexisting units at most Fisher-Rosemountservice offices.

2. Personal Computer (PC). The use of apersonal computer requires Cornerstonesoftware with Module Library (ModLib)specific to the World Class 3000 product.

3. Selected Distributed Control Systems. Theuse of distributed control systems requiresinput/output (I/O) hardware and softwarewhich permit HART communications.

This section of the manual deals with operator controlsand displays available with the GUI equipped IFT.Operating parameters are listed and instructions areincluded for viewing and changing them.

Any procedures not associated with normal operationare included in Section II, Installation, or Section V,Troubleshooting.

IB-106-300NH3-2

3-2. DELUXE VERSION IFT DISPLAYS AND CONTROLS. (Figure 3-1)

ENTER

ESC

DATA

CAL

SETUP

HELP

1

2

3

4

5

6

7

89

INTERNAL VIEW

CALTGHTGL

10

11

12

13

21190003EXTERNAL VIEW

IFT COVER DOORSHOWN FORREFERENCE.

NOTE:

Figure 3-1. Deluxe Version IFT Displays and Controls

Fig. 3-1Index No. Control/LED Description

1 LCD Display Top line displays system status, menu, and probe 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 todecrease a parameter value.

8 > The increase key is used to move the cursor (asterisk) when scrolling through lists or toincrease a parameter value.

9 ENTER The ENTER key is used to select a lower level menu, initiate calibration, or select aparameter to change.

10 LED Display Indicates current O2 or calibration gas value.

11 CAL Calibration in progress indicator light.

12 TGH High calibration gas indicator light. High calibration gas is being used in calibrationprocess.

13 TGL Low calibration gas indicator light. Low calibration gas is being used in calibrationprocess.

IB-106-300NH3-3

Table 3-1. Sample HELP Messages.

MENU, SUB-MENU, HELPOR PARAMETER NAME MESSAGE

PROBE DATA

CALIBRATE O2

SETUP

Press ENTER key to access DATA menu.

The CAL menu is used to start calibration and view calibration.

The SETUP menu is used to configure the IFT 3000.

3-3. HELP KEY. The HELP key will display explanatoryinformation about a menu, sub-menu, or parameter thatthe asterisk is next to when pressed. The HELP key isnot available during calibration routines. Refer to Table3-1 for sample HELP messages.

3-4. STATUS LINE. The top line of the LCD display (3,Figure 3-1) is a status line that always displays systemstatus, menu name, and O2 level. System status displayswill be displayed one at a time in priority sequence, asfollows:

a. Off - The probe has been turned off because theIFT cannot control the heater temperature.

b. PrbEr - The probe is disconnected, cold, or leadsare reversed.

c. HtrEr - Heater error.

d. InCAL - Calibration in progress.

e. LowO2 - O2 value is below the low alarm limit.

f. HiO2 - O2 value is above the high alarm limit.

g. NoGas - Calibration gas pressure is low.

h. CalEr - Calibration error.

i. ResHi - Resistance is above the high limit.

j. OK - System is functioning correctly.

3-5. QUICK REFERENCE CHART. The quickreference chart (Figure 3-2) is designed to help you getwhere you want to be in the menu system. The chartshows all the available menu and sub-menu options forthe IFT. Follow the lines to determine which menuchoices to make. Moving down a level on the chart isaccomplished by the use of the ENTER key. To moveup a level on the chart, press the ESCAPE key.

Table 3-2. MAIN Menu.

MENU SELECTION DESCRIPTION

PROBE DATA

CALIBRATE O2

SETUP

Refer to Table 3-3.

Refer to Table 3-4.

Refer to Table 3-5.

3-6. MAIN MENU. When power is first applied to theIFT, the MAIN menu (Table 3-2) is initially displayed.It is from the MAIN menu that the PROBE DATA(Table 3-3), CALIBRATE O2 (Table 3-4), and SETUP(Table 3-5) menus can be accessed.

IB-106-300NH3-4

3-7. PROBE DATA SUB-MENU. The PROBE DATAsub-menu is a list of all the parameters of the system asit is currently configured. To access the PROBE DATAsub-menu, press the DATA key at any time. Theincrease and decrease keys are used to scroll throughthe list. The PROBE DATA sub-menu can be

viewed but not changed. The operator must use theSETUP menu to change any of the parameters.

There are two selections available on the PROBEDATA sub-menu; Process Data and Diagnostic Data.Refer to Table 3-3 for contents of the sub-menu.

Table 3-3. PROBE DATA Sub-Menu.

SUB-MENUSELECTION PARAMETER DESCRIPTION

Process Data O2 __% O2Efficiency __%Stack Temp __DegC

O2 value for the probe.Efficiency display.Stack temperature.

Diagnostic DataTemperature

Voltages

Output Values

Cell __DegCStack __DegCCold Junct __DegC

Cell __mVCell T/C __mVStk T/C __mVCold Jnt __mV

Analog __% FSK1 State OFF/ONK2 State OFF/ON

Cell temperature of the probe.Stack temperature.Cold Junction temperature.

Cell voltage of the probe.Cell thermocouple voltage of the probe.Stack thermocouple voltage.Cold junction voltage.

Analog output voltage.Status of relay 1.Status of relay 2.

IB-106-300NH3-5

(CONTINUED ONSHEET 2) 686022

PROBE DATA DIAGNOSTICDATA

VOLTAGES

PROCESS DATA

TEMPERATURE

Cell

Stack

Cold Junct

Cell

Cell T/C

Stk T/C

Cold Jnt

OUTPUTVALUES

Analog

K1 State

K2 State

LATESTCALIBRATION

Slope

Constant

Resist

PREVIOUS CALSlope

Constant

Resist

Next Cal

Slope

Constant

Resist

CALIBRATIONSTATUS

CALIBRATE O2 VIEWCONSTANTS

PERFORMCALIBRATION

O2

Efficiency

Stack Temp

Figure 3-2. Quick Reference Chart (Sheet 1 of 5)

IB-106-300NH3-6

(CONTINUED ONSHEET 3)


(CONTINUED FROMSHEET 1)

See sheet 4

SLOPE

CONSTANT

SET POINT

RESET SLOPEAND CONST

34.5 mV/D-57.5 mV/D

-20.0 mV-20.0 mV

736 C843 C

o

o

0.1000% O2-25.00% O2

0.00% O2-25.00% O2

ENABLE CALC

K1 VALUEK2 VALUE

K3 VALUE

YesNo

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

EFFICIENCYCALC

RELAY OUTPUT

19860023


IB-106-300NH3-7


SETUP


ANALOGOUTPUTS

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


IB-106-300NH3-8


CALIBRATION

HIGH GAS

LOW GAS

AUTO CAL

OUTPUT TRACKS

CAL INTRVL

NEXT CAL

GAS TIME

PURGE TIME

RES ALARM

0.1000% O225.00% O2

0.1000% O225.00% O2

YesNo

YesNo

Off,

1H -

365 D OH

(1 hour to 365 daysand no hours)

(1 hour to 365 daysand no hours)

Disabled,

1H -

365 D OH

00:30 -20:00

00:30 -20:00

50 -10000

ΩΩ

16860025


IB-106-300NH3-9


RANGE SETUP

Log

LIN

Log

LIN

HIGH END

LOW END

0.000% O225.00% O2

0.000% O225.00% O2

0.000% O225.00% O2

0.000% O225.00% O2

0.000% O225.00% O2

0.000% O225.00% O2

0.000% O225.00% O2

Range Setup(Source not set to:

Dual Rng O2)

Range Setup(Source not set to:

Dual Rng O2)NORMAL RANGEVALUES

HIGH END

HIGH END

LOW END

LOW END

XFER FNCT

XFER FNCT

RANGE VALUES

DUAL RANGESETUP

MODE SETUP

HIGH RANGEVALUES

RANGE MODE

HIGH IN CAL

SWITCHES AT

NormalAutoHigh

YesNo

16860026


IB-106-300NH3-10

Table 3-4. CALIBRATE O2 Sub-Menu.

SUB-MENUSELECTION

SETUP SETTING(SEE TABLE 3-5) DISPLAY DESCRIPTION

PerformCalibration

Auto Cal in ProbeSetup is YES

Press ENTER to start Auto Calibration.

Starting Automatic Calibration

High Gas _____%O2Time Left 0:00

Cell mV ______mV

Low Gas _____%O2Time Left 0:00

Cell mV ______mV

Resistance CheckTime Left 0:00

Cell _____mV _____CCalibration CompletePurging 0:00

Cell _____mV _____C

Calibration Complete

MPS will start calibrating probe.

Value for high O2 calibration gas.Amount of time necessary to complete thecurrent testing phase in min:sec.

Cell voltage of the probe.

Value for low O2 calibration gas.Amount of time necessary to complete thecurrent testing phase in min:sec.

Cell voltage of the probe.

Resistance check in progress.

Cell voltage and probe temperature.

Gas lines are being purged of calibrationgas.

Cell voltage and probe temperature.

Auto Cal in ProbeSetup is NO.

Press ENTER to start Manual Calibration

Switch ON high calibration gas. PressENTER when ready.

High gas ______%O2

Press ENTER when O2 reading is stable.

Turn OFF high calibration gas and ON lowcalibration gas. Press ENTER when ready.

Low gas ______%O2

Press ENTER when O2 reading is stable.

Resistance Check

Turn off low calibration gas. Press ENTERwhen ready.

Press ENTER when probe has returned toprocess.

Manual calibration sequence will beginwhen ENTER is pressed.

High O2 calibration gas value.

Low O2 calibration gas value.

Resistance check in progress.

View Constants LatestCalibration

PreviousCalibration

Slope _____mV/DConstant _____mVResist _____ohms

Slope _____mV/DConstant _____mVResist _____ohms

Slope for probe from latest calibration.Latest calibration offset for probe.Latest calibration resistance of probe.

Slope for probe from previous calibration.Previous calibration offset for probe.Previous calibration resistance of probe.

Calibration Status N/A Next Cal XD XH

Slope _____Constant _____Resist _____

Time until next calibration in number ofdays and number of hours.

Status of the slope.Status of the offset.Status of the resistance.

IB-106-300NH3-11

Table 3-5. SETUP Sub-Menu.

SUB-MENUSELECTION PARAMETERS DESCRIPTION

Calibration High Gas ____%O2Low Gas ____%O2Auto Cal YES/NOOutput Tracks YES/NOCal Intrvl XD XH

Next Cal XH

Gas Time 0:30 - 20:00

Purge Time 0:30 - 20:00Res Alarm 50 W - 10 kW

Value of high O2 calibration gas (0.1000% - 25.00% O2).Value of low O2 calibration gas (0.1000% - 25.00% O2).MPS required for Auto Cal.NO, locks output during calibration.Select time between calibrations in number of days and hours(1 year max).Time until next calibration in number of hours(1 year max).Amount of time calibration gases will be turned on in numberof minutes and seconds; allow enough time for signal valuesto stabilize.Amount of time for gas lines to clear of calibration gas.Resistance alarm set from 50 to 10,000 ohms.

O2 Calculation Slope ____ mV/DConstant ____ mVSet 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 for218 probes.

Ensure the correct voltage is selectedwhen using HPS 3000 with either WorldClass 3000 probes or 218 probes. Referto Figure 2-15, Jumper Selection Labelfor proper voltage selections. Ifincorrect SET POINT is selected,damage to the probe may occur.

Reset slope and constants Press ENTER to reset slope and constants to values from thelatest successful calibration.

O2 Alarms Hi Alarm ____%O2

Lo Alarm ____%O2

Alarm DB ____%O2

Set value for high alarm limit (0.1000% - 25.00%).Set value for low alarm limit (0.1000% - 25.00%).Set value for alarm dead band (0.0000% - 25.00%).

Efficiency Calc. Enable Calc. YES/NOK1 Value _______K2 Value _______K3 Value _______

Select YES to enable, NO to disable.Set between 0.0000 and 1.000. Refer to Table 3-6.Set between 0.0000 and 1.000. Refer to Table 3-6.Set between 1.000 and 20.00. Refer to Table 3-6.

IB-106-300NH3-12

Table 3-5. SETUP Sub-Menu (Continued).


Relay Outputs

NOTE

K1 and K2 relay outputs can be configured for "OFF" or any one of the eightevents listed below. Up to three events can control each relay output. Events areselected in the SETUP sub-menu.

K1 Setup

K2 Setup

- OffEvent 1 1. In CalEvent 2 2. Hi O2

Event 3 3. Lo O2Event 1 4. Htr FailEvent 2 5. Cal FailEvent 3 6. TG Low

7. Cell Res8. High Range

No effect.Probe goes into calibration status.Output exceeds high end alarm limit.Output goes below low alarm limit.Probe heater fault occurs.Probe failed last calibration.Calibration gas pressure gets too low.Probe resistance exceeds high limit.High analog output range is selected.

Analog Output SOURCE O2

EfficiencyDual Rng O2

Select the measurement value to be represented on the analogoutput.

AOUT TYPEHART 4-20mA0-20mA0-10V

Select one of the listed options to define upper and lowerlimits of probe analog output. Only a selection that matchesthe position of the analog output selector switch on themicroprocessor board (Figure 2-9) will be accepted. Thedefined limits correspond to the upper-lower %O2 valuesdefined in the Range Setup menu.

RANGE SETUP(Source not set to Dual Rng O2)

Xfer Fnct LogLin

Select the transfer function used on the analog output.Selecting Log will not effect the output when Efficiency isselected as the Source.

Range Values

High End0.000% O2 - 25.00% O2

Low End0.000% O2 - 25.00% O2

Enter the upper and lower analog output range values. TheHigh End value defines the measured O2 valuecorresponding to the high analog output value, i.e, 20mA or10V, and the Low End value corresponds to the low analogoutput value, i.e., 0mA, 4mA, or 0V.

IB-106-300NH3-13

Table 3-5. SETUP Sub-Menu (Continued).


Analog Output(continued)

RANGE SETUP(Source set to Dual Rng O2)

Xfer Fnct LogLin

Select the transfer function used on the analog output.Selecting Log will not effect the output when Efficiency isselected as the Source.

Normal Range Values

High End0.000% O2 - 25.00% O2

Low End0.000% O2 - 25.00% O2

Enter the upper and lower analog output range values forNormal Operating Range. The High End value defines themeasured O2 value corresponding to the high analog outputvalue, i.e, 20mA or 10V, and the Low End value correspondsto the low analog output value, i.e., 0mA, 4mA, or 0V.

Dual Range Setup

Mode Setup

Range Mode Normal Forces the output to the Normal Range.

Auto Allows the IFT to select either the High Range or the NormalRange based on the present O2 value and the Mode SetupValues.

High Forces the output to the High Range.

High in Cal Yes/No Selecting Yes will cause the High Range to be used wheneverthe probe is being calibrated.

Switches at0.000% O2 - 25.00% O2

Enters the switching point between the High and NormalRanges. O2 values above this point will use the High Rangeand values below this point will use the Normal Range. TheO2 value must be below the switch point by 10% (of the"Switches at" value) to cause a switch from High to NormalRange.

High Range ValuesHigh End

0.000% O2 - 25.00% O2

Low End0.000% O2 - 25.00% O2

Enter the upper and lower analog output range values forHigh Operating Range. The High End value defines themeasured O2 value corresponding to the high analog outputvalue, i.e, 20mA or 10V, and the Low End value correspondsto the low analog output value, i.e., 0mA, 4mA, or 0V.

NOTE: Relay output can be initiated upon range change (See Table 3-5, page 3-11).

IB-106-300NH3-14

Table 3-6. Efficiency Constants.

CONSTANTUNITED STATES EUROPE

GAS OIL GAS OIL

K1K2K3

0.4070.05.12

0.4320.05.12

0.660.0082

12.28

0.690.00518.74

3-8. CALIBRATE O 2 SUB-MENU. The CALIBRATE O2 sub-menu (Table 3-4) is used to enter the calibrationmode. To access the CALIBRATE O2 sub-menu, pressthe CAL key at any time. The increase and decreasekeys are used to scroll through the list.

The CALIBRATE O2 sub-menu has three selectionsavailable: Perform Calibration, View Constants, andCalibration Status. Refer to Table 3-4 for contents ofthe sub-menus.

Perform Calibration has two options depending on howAuto Cal is selected in Probe Setup. Refer to SETUPSetting in Table 3-4.

3-9. SETUP SUB-MENU. The SETUP sub-menu is usedto enter all operator set variables into the system. Toaccess the SETUP sub-menu press the SETUP key atany time. To select the parameter to be changed, movethe cursor to the desired parameter using the arrowkeys. Press ENTER to select that parameter. To changethe value for that parameter, use the arrow keys toincrease or decrease the value. Press ENTER to savechanges.

There are six selections available on the SETUPsub-menu: Calibration, O2 Calculation, O2 Alarms,Efficiency Calc., Relay Outputs, and Analog Outputs.Refer to Table 3-5 for the contents of the SETUPsub-menu, or ESCAPE to abort changes.

3-10. ANALOG OUTPUT CALIBRATION. For theanalog output to perform within the publishedspecifications, it must be manually calibrated. The onlyequipment needed to perform the calibration is avoltage or current meter, depending on which mode ofoperation is to be calibrated. Prior to manualcalibration, remove the IFT from any control loops itmay be in.

Prior to manual calibration, the IFT shouldbe removed from any automatic controlloops. Failure to remove the IFT fromcontrol loops prior to calibration may resultin faulty equipment performance.

Once initiated from the Setup - Analog Outputs menu,the calibration procedure is self guiding.

3-11. SYSTEM CALIBRATION.

a. Overview. The primary purpose of an oxygenanalyzer is to give an accurate representation of thepercentage of O2 in the gas stream. The systemshould be calibrated periodically to maintain anaccuracy which may otherwise be reduced overtime due to cell aging.

A requirement for calibration is a set of twoaccurate calibration gases spanning the oxygenrange of most interest. For example, 0.4% and 8%for a 0-10% oxygen range.

Under normal conditions the probe should notneed frequent calibration. Because calibration isnecessary, the system can be equipped with theoptional MPS 3000 Multiprobe Calibration GasSequencer for fully automatic calibration at regularintervals. Without an MPS, the probes must becalibrated manually (semiautomatically).

b. Probe Calibration.

1. Previous Calibration Constants Func-tionality . There are three sets of registersused to store calibration constants. These are:Latest Calibration, Previous Calibration, and

IB-106-300NH3-15

Calculation. Only the values in theCalculation register are used to calculate theoxygen value for display and representationon the analog output signal. These values maybe changed in two ways.

(a) The operator may change the valuesthrough the SETUP menu. The operatormay adjust the slope and constantindividually, or reset both to the valuescalculated during the last goodcalibration. To reset the values, movethe cursor to RESET SLOPE & CONSTand push ENTER.

(b) The IFT will automatically change thevalues after each calibration as follows.

The values in the Latest Calibrationregisters are updated after everycomplete calibration, even if thecalibration is not successful. If thecalibration is successful, the values inthe Latest Calibration registers arecopied into the Previous Calibrationregisters. This is accomplished prior tothe update of the Latest Calibrationregisters. The new slope and constantare copied into the Calculation register.

If the calibration fails, the PreviousCalibration registers retain their existingvalues, while the Latest Calibrationregisters record the values of the failedcalibration. The Calculation register isnot updated when the calibration fails.

2. Calibration Methods. There are threecalibration methods: manual (semiautomatic),manually initiated automatic, and fully auto-matic. Manual (semiautomatic) calibration isdone without an MPS unit. Calibration gasesare switched on and off by the operator andthe IFT is sequenced through the calibrationprocedure by the operator with the front panelkeyboard. The IFT prompts the operator forthe correct action. Manually initiatedautomatic calibration is done with an MPS.The operator manually initiates the calibrationat the IFT or through a remote switch, and theIFT controls the operation of the MPS unitand the calibration sequencing. Fullyautomatic calibration requires no action fromthe operator. The setup is the same assemiautomatic except the IFT automaticallyinitiates the calibration at a fixed calibrationinterval. In this mode the operator can also

manually initiate calibrations between theintervals in the same manner as semiautomaticcalibrations.

c. Manual (Semiautomatic) Calibration.

1. Calibration Gases For Manual (Semi-automatic) Calibration. There are twooptions for supplying calibration gases to theprobe during semiautomatic calibration. Thefirst "A" uses refillable bottles and adjustable2-stage pressure regulators; the second, "B"uses disposable bottles and a fixed singlestage regulator to provide a mixed flow.Normally, the first (method "A") will have ahigher cost and not be portable. The second("B") is less costly, portable, and weighsabout 10 lbs (4.5 kg).

Test Method "A" Fixed Tanks and Manifolds.

(a) Required Equipment.

Do not use 100% nitrogen as a zero gas. It issuggested that gas for the zero be between0.4% and 2.0% O2. Do not use gases withhydrocarbon concentrations of more than 40parts per million. Failure to use proper gaseswill result in erroneous readings.

NOTE

Ambient air is not recommended for use ashigh calibration gas. An 8% O2 balance innitrogen is recommended for high calibra-tion gas.

1 Two tanks of precision calibrationgas mixtures. Recommended cali-bration gases are nominally 0.4%and 8.0% oxygen in nitrogen.

Two sources of calibrated gasmixtures are:

LIQUID CARBONIC GASCORP.SPECIALTY GASLABORATORIES

700 South Alameda StreetLos Angeles, California 90058213/585-2154

IB-106-300NH3-16

767 Industrial RoadSan Carlos, California 94070415/592-7303

9950 Chemical RoadPasadena, Texas 77507713/474-4141

12054 S.W. Doty AvenueChicago, Illinois 60628312/568-8840

603 Bergen StreetHarrison, New Jersey 07029201/485-1995

255 Brimley RoadScarborough, Ontario, Canada416/266-3161

SCOTT ENVIRONMENTALTECHNOLOGY, INC.SCOTT SPECIALTY GASES

2600 Cajon Blvd.San Bernardino, CA 92411714/887-2571TWX: 910-390-1159

1290 Combermere StreetTroy, MI 48084314/589-2950

Route 611Plumsteadville, PA 18949215/766-8861TWX: 510-665-9344

2616 South Loop, WestSuite 100Houston, TX 77054713/669-0469

2 If gas bottles will be permanentlyhooked up to the probe, a manualblock valve is required at the probe(between the calibration fitting andthe gas line) to prevent themigration of process gases down thecalibration gas line.

If an MPS 3000 Multiprobe GasSequencer is used, a check valve isrequired at the probe.

3 Two, 2-stage pressure regulatorswith stainless steel diaphragms fortanks. Maximum output required:20 psi (138 kPa).

4 One instrument air pressureregulator: 20 psi (138 kPa)maximum and a supply of clean, dryinstrument air.

5 Two zero-leakage shutoff valves.

6 Miscellaneous oil-free tubing andfittings.

(b) Calibration.

1 A typical calibration setup is shownin Figure 3-3. Care must be takenthat all fittings are tight and freefrom oil or other organiccontaminants. Small openings cancause back diffusion of oxygenfrom the atmosphere even thoughpositive pressures are maintained inthe lines.

NOTE

The probe calibration gas fitting has a sealcap which must be in place at all times exceptduring calibration.

In addition to the precisioncalibration gas mixtures, clean, dry,oil-free instrument air should beused for calibration.

For optimum accuracy, this calibrationshould be run with the process at normaltemperature and operating conditions.

When the calibration gas lineexceeds 6 ft (1.8 m) in length fromthe leak tight valves, a check valve,Rosemount P/N 6292A97H02,should be installed next to thecalibration gas connection on theprobe to prevent breathing of theline with the process gas andsubsequent gas condensation andcorrosion.

IB-106-300NH3-17

REFERENCE AIRCONNECTION

REFERENCEAIRSET

FLOW METER

INSTR.AIRIN

LEAK TIGHTVALVES

2 SCFH5 SCFH

PROBE(END VIEW)

CALIBRATEIN-PLACE

FITTING CHECKVALVE

REG

0.4%O2

8.0%O2

PROBE CALIBRATION GAS FITTING HAS A SEAL CAP WHICH MUSTBE IN PLACE AT ALL TIMES EXCEPT DURING CALIBRATION.

NOTE:

Figure 3-3. Typical Calibration Setup

NOTE

Only set the calibration gas flowmeter uponinitial installation and after changing thediffusion element. A slightly lower cali-bration gas flow rate may indicate aplugged diffusion element.

2 Set the calibration gas pressureregulators and the flow meter for aflow of 5 SCFH at 20 psi (138 kPa)for both gases. The reference airshould be flowing as in normaloperation.

3 Refer to paragraph d of this sectionfor Manual (Semiautomatic) Cali-bration setup and procedure usingthe IFT.

4 Calibration gases will be switchedon and off using the shutoff valves.

Test Method "B" Rosemount Oxygen Cali-bration Gas and Service Kit.

(a) Required Equipment


NOTE

Ambient air is not recommended for use ashigh calibration gas. An 8% O2 balance innitrogen is recommended for high cali-bration gas.

1 Portable Rosemount Oxygen Cali-bration Gas Kits (Figure 3-4),Rosemount P/N 6296A27G01,containing 8% and 0.4% gases in aportable carrying case withregulator, built-in valve, hose andconnecting adapter to the calibrationgas connection.

IB-106-300NH3-18

27270007

CALIBRATIONGAS KIT #1

(P/N 6296A27G01)

Figure 3-4. Portable Rosemount Oxygen CalibrationGas Kit

2 Extra gas bottles are available at:

Rosemount Analytical Inc.Box 901Orrville, Ohio 44667U.S.A.

Rosemount LimitedBurymead RoadHitchin, Herts. U.K.

Rosemount ItalyVIA Guido Cavalcanti 820127 Milan, Italy

Rosemount SpainSaturnino Calleja 628002 MadridSpain

Rosemount France165 Boulevard de Vallmy92706, Colombes, France

Rosemount P/N 3530B07G01 forprobe 0.4% oxygen in nitrogen indisposable bottle.

Rosemount P/N 3530B07G02 forprobe 8% oxygen in nitrogen indisposable bottle.

3 A check valve is required at theprobe (between the calibrationfitting and the gas line) to preventthe migration of process gases downthe calibration gas line.

(b) Calibration with a Portable RosemountOxygen Calibration Gases Kit.

1 A typical portable calibration setupis shown in Figure 3-5. For manual(semiautomatic) calibration, removecap plug from the calibrate in placefitting. The cap plug must beretained to seal this fitting aftercalibration is complete; failure to doso may render the probe useless ifthe system pressure is slightlynegative. The reference air shouldbe flowing as in normal operation.

2 Refer to paragraph d of this sectionfor Manual (Semiautomatic) Cali-bration setup and procedure usingthe IFT.

3 Screw the push button regulatorwith contents gage on to thecalibration gas of choice and injectthe calibration gas by opening thevalve. Gas is on continuously whenthe valve is opened.

0.4%O2

8.0%O2

27270005

CALIBRATEIN PLACE

CONNECTION CHECKVALVE

PUSHBUTTONREGULATOR

WITH CONTENTSGAGE - SET 5 SCFH

REFERENCE AIRCONNECTION

CALIBRATIONGAS HOSECONNECTSTO CHECKVALVE

NOTE: PROBE CALIBRATION GASFITTING HAS A SEAL CAPWHICH MUST BE IN PLACEEXCEPT DURING CALIBRATION.

Figure 3-5. Typical Portable Calibration Setup

IB-106-300NH3-19

d. Manual (Semiautomatic) Calibration Proce-dure. The following procedure relates to anoperator initiated calibration selected at the IFT bypressing the CAL key. The calibration is manuallyperformed by the operator upon data queues fromthe IFT. Any system without an MPS 3000Multiprobe Calibration Gas Sequencer must followthese steps.

1. Press SETUP to display the SETUP menu.Select PROBE CALIBRATION sub-menu.Ensure that Auto Cal is disabled. Set thecursor on Auto Cal. Press ENTER. Set AutoCal to NO if not already done.

2. Press the CAL key. Select PERFORMCALIBRATION sub-menu. "Press ENTERto start Manual Calibration" will appear onthe LCD display. Press ENTER to start.Follow the data queues. Refer to Table 3-4,CALIBRATE O2 Sub-menu.

e. Fully Automatic Calibration.

1. Calibration Gases For Fully Automatic Cali-bration. For fully automatic calibration, anMPS 3000 Multiprobe Calibration GasSequencer is required as well as the two typesof calibration gas.


NOTE

Ambient air is not recommended for use ashigh calibration gas. An 8% O2 balance innitrogen is recommended for high cali-bration gas.

Two tanks of precision calibration gasmixtures. Recommended calibration gases arenominally 0.4% and 8.0% oxygen in nitrogenset calibration gas pressure at 20 psi(138 kPa).

A typical automatic calibration system isshown in Figure 3-6.

2. Fully Automatic Calibration Setup. In orderfor the IFT system to calibrate automatically,the following parameters from theCALIBRATE sub-menu in the IFT have to beentered. Refer to Table 3-5. SETUPSub-Menu.

Auto Cal YES/NO

Output Tracks YES/NO

Cal Intvl XD XH

Next Cal. XD XH

Gas Time 0:00

Gas Time 0:00

Purge Time 0:00

Abort Time 0:00

Res Alarm ____

Set to YES

Set as desired to configureanalog output tracking.

Set the desired time betweencalibrations in number of daysand hours (1 year max).

Displays the time left to the startof the next calibration. Set thedesired time until the start of thenext calibration (1 year max). Ifnothing is entered here, the unitwill automatically enter the CalIntvl and count down from that.

Set the amount of time forcalibration gases to be turned onin minutes and seconds; allowenough time for signal value tostabilize.

Set the amount of time forcalibration gases to be turned onin minutes and seconds; allowenough time for signal value tostabilize.

Set the amount of time for thegas lines to clear in number ofminutes and seconds.

Set the amount of time allowedbetween key functions before thecalibration procedure is abortedin number of minutes andseconds.

Set the desired resistance alarmbetween 50 to 10000 ohms.

Once these parameters have been set, thesystem will initiate calibration withoutoperator intervention as set by the CALINTVL parameter.

IB-106-300NH3-20

3. Manually Initiated Fully Automatic Cali-bration Procedure. The following procedurerelates to an operator initiated calibration,either by a remote switch (CAL INIT oninterconnect board) or selected at the IFT bypressing the CAL key using an MPS 3000Multiprobe Gas Sequencer.

(a) Press SETUP to display the SETUPsub-menu. Select Calibration Ensure

that Auto Cal is enabled. Set the cursoron Auto Cal. Press ENTER. Set AutoCal to YES if not already done.

(b) Press the CAL key. Select PerformCalibration. "Press ENTER to startAutomatic Calibration" will appear onthe LCD display. Press ENTER to start.Refer to Table 3-5, CALIBRATE O2Sub-Menu.

PROBE(END VIEW)

IFT

CALIBRATION GASHPS

OPTIONALCHECKVALVE

PROBESIGNAL CONNECTIONS

MPS-IFTSIGNALCONNECTIONS

MPS

INSTRUMENTAIR IN

CALIBRATIONGAS 1

(HIGH )O2

CALIBRATIONGAS 2

(LOW O )2

27270006

NOTE: THE MPS CAN BE USED WITH UPTO FOUR PROBES. ONLY ONE PROBECAN BE CALIBRATED AT A TIME.PROBE CALIBRATIONS MUST BESCHEDULED IN MULTIPLE PROBEAPPLICATIONS.

NOTE: SHOWN WITH HPS OPTION.

REFERENCEAIR

Figure 3-6. Typical Automatic Calibration System.

IB-106-300NH4-1/4-2

SECTION IV. SYSTEM TROUBLESHOOTING

4-1. OVERVIEW. The system troubleshooting describeshow to identify and isolate faults which may develop inthe Oxygen Analyzer System. Refer to Probe, IFT,HPS, MPS, and HART Communicator appendices.

Install all protective equipment covers andsafety ground leads after troubleshooting.Failure to replace covers and ground leadscould result in serious injury or death.

4-2. SPECIAL TROUBLESHOOTING NOTES.

a. Grounding. It is essential that adequategrounding precautions are taken when the systemis being installed. A very thorough check must bemade at both the probe and electronics to ensurethat the grounding quality has not degraded duringfault finding. The system provides facilities for100% effective grounding and the total eliminationof ground loops.

b. Electrical Noise. The IFT has been designed tooperate in the type of environment normally foundin a boiler room or control room. Noisesuppression circuits are employed on all fieldterminations and main inputs. When fault finding,the electrical noise being generated in theimmediate circuitry of a faulty system should beevaluated. All cable shields must be connected toearth.

c. Loose Integrated Circuits. The IFT uses amicroprocessor and supporting integrated circuits.Should the electronics unit receive rough handlingduring installation in a location where it issubjected to severe vibration, an Integrated Circuit(IC) could work loose. The fault finding guides inparagraph 5-3.a. and Table 2-1 Appendix E, showthe resulting variety of failure modes. It isrecommended that all IC's be confirmed to be fullyseated before troubleshooting on the systembegins.

d. Electrostatic Discharge. Electrostatic dischargecan damage the IC's used in the electronics unit. Itis essential before removing or handling theprocessor board or the IC's used on it, that the userensure he/she is at ground potential.

4-3. SYSTEM TROUBLESHOOTING. The IFTprovides system failure information with two differenterror message formats. The error messages vary due tosystem configuration. Refer to Appendix E, Section II,IFT 3000 Troubleshooting.

a. GUI Equipped IFT. The status line of the GUIequipped IFT will display one of ten conditions.The system status displays will be displayed one ata time in priority sequence, as indicated in thefollowing list. Refer to Table 2-1, Appendix E foradditional troubleshooting information on the GUIequipped IFT.

1. Off - The probe has been turned off becausethe IFT cannot control the heater temperature.

2. Param - IFT has been unlocked using theuser’s password.

3. Serv - IFT has been unlocked using theservice password.

4. PrbEr - The probe is disconnected, cold, orleads are reversed.

5. HtrEr - If HtrEr is displayed, there is a faultwithin the heater system.

6. InCal - If InCal is displayed, the system iscurrently undergoing calibration.

7. LowO2 - If LowO2 is displayed, the O2 valueis below the low alarm limit.

8. HiO2 - If HiO2 is displayed, the O2 value isabove the high alarm limit.

9. NoGas - If NoGas is displayed, there is nocalibration gas pressure.

10. CalEr - If CalEr is displayed, an error wasdetected during the calibration process.

11. ResHi - If ResHi is displayed, the cellresistance is above the high limit.

12. OK - If OK is displayed, the system isoperating normally.

IB-106-300NH5-1/5-2

SECTION V. RETURNING EQUIPMENT TO THE FACTORY

5-1. If factory repair of defective equipment is required,proceed as follows:

a. Secure a return authorization number from aRosemount Analytical Sales Office orrepresentative before returning the equipment.Equipment must be returned with completeidentification in accordance with Rosemountinstructions or it will not be accepted.

In no event will Rosemount be responsible forequipment returned without proper authorizationand identification.

b. Carefully pack defective unit in a sturdy box withsufficient shock absorbing material to insure thatno additional damage will occur during shipping.

c. In a cover letter, describe completely:

1. The symptoms from which it was determinedthat the equipment is faulty.

2. The environment in which the equipment hasbeen operating (housing, weather, vibration,dust, etc.).

3. Site from which equipment was removed.

4. Whether warranty or nonwarranty service isrequested.

5. Complete shipping instructions for return ofequipment.

6. Reference the return authorization number.

d. Enclose a cover letter and purchase order and shipthe defective equipment according to instructionsprovided in Rosemount Return Authorization,prepaid, to:

American

Rosemount Analytical Inc.RMR Department1201 N. Main StreetOrrville, Ohio 44667

European

Rosemount IrelandEquipment Return Repair Dept.Site 7 Shannon Industrial EstateCo. ClareIreland

If warranty service is requested, the defective unitwill be carefully inspected and tested at the factory.If failure was due to conditions listed in thestandard Rosemount warranty, the defective unitwill be repaired or replaced at Rosemount's option,and an operating unit will be returned to thecustomer in accordance with shipping instructionsfurnished in the cover letter.

For equipment no longer under warranty, theequipment will be repaired at the factory andreturned as directed by the purchase order andshipping instructions.

IB-106-300NHI-1

INDEX

This index is an alphabetized listing of parts, terms, andprocedures related to the World Class 3000 Oxygen Analyzerwith IFT 3000 Intelligent Field Transmitter. Every item listedin the index refers to a location in the manual by page numberor numbers.

AAbrasive Shield, 2-6Absolute Temperature, 1-2Adapter Plate, 1-1, 2-1Air Pressure Regulator Valve, 2-20Analog Output, 2-12, 3-12, 3-13Annunciator, 2-12Arithmetic Constant, 1-2Automatic Calibration, 1-2, 2-21, 3-10, 3-19Auto Cal, 3-10

BBlind Version, 3-1

CCable Shields, 5-1CAL, 3-2Calibrate O2 Sub-menu, 3-9, 3-14Calibration, 3-14, 3-15Calibration Constants, 3-14Calibration Fitting, 1-4Calibration Gas, 3-16Calibration Gas Out, 2-21Cell Constant, 1-2Ceramic Filter, 2-1Chart Recorder, 2-12Check Valve, 1-4, 3-16

DDATA, 3-2Diagnostic Data, 3-4Dust seal packings, 2-6

EElectrical Noise, 5-1Electrostatic Discharge, 5-1

FField Replaceable Cell, 1-3Forcing Cone, 2-6Fully Automatic Calibration, 3-19Fuses

IFT Unit, 2-8, 2-10HPS Unit, 2-15, 2-19MPS Unit, 2-21, 2-22

GGas Kits, 3-17Gas Mixture, 2-8, 3-15, 3-19Gas Stratification, 2-1General User Interface, 1-3Grounding, 5-1GUI, 3-1, 5-1

HHART® Communications, 1-2, 3-1HART® Communicator, 1-1HART Interface, 1-3Heater Power Supply, 1-1, 1-2, 2-18, 2-19HELP Key, 3-2High Gas, 2-20

IInterconnect Board, 2-14Instrument Air, 1-4Instrument Air In, 2-20Intelligent Field Transmitter, 1-1, 1-2, 3-1

LLanguages, 1-3, 3-1Low Gas, 2-21

MMAIN Menu, 3-3Manual Calibration, 3-10Manual (Semiautomatic) Calibration, 3-15, 3-19Microprocessor Board, 2-13Mother Board, 2-19MPS Probe Wiring, 2-22Multiprobe Test Gas Sequencer, 1-1, 1-2

NNEMA 4X Enclosure, 2-8, 2-12

OOrsat Apparatus, 1-2Oxygen Analyzer, 1-1, 1-2

PPower Cable, 2-9Power Supply Board, 2-10Pressure Regulators, 3-16, 3-17PROBE DATA Sub-menu, 3-4Push Button Regulator, 3-18

IB-106-300NHI-2

QQuick Reference Chart, 3-3

RReference Air, 1-1, 2-7Ref Air Out, 2-21

SSemiautomatic Calibration, 2-21, 3-15Setup Sub-menu, 3-14Status Line, 3-3Stop Valve, 1-4

TTGH, 3-2TGL, 3-2Troubleshooting, 5-1

VVee Deflector, 2-6

WWiring Layout, 2-11, 2-16, 2-17

ZZ-purge, 1-4Zirconia Disc, 1-2

APPENDIX A, REV. 3.6WORLD CLASS 3000OXYGEN ANALYZER(PROBE)

Instruction Bulletin IB-106-300N SERIES

APPENDIX A



PAGE SUMMARY

-- General. Updated appendix to reflect probe design changes.

1-10 Added “Extended temperature by-pass arrangements” to Figure 1-13, Sheet 3 of 3.


PAGE SUMMARY

1-10 Updated part ordering information.

Effective August, 1996 Rev. 3.2

PAGE SUMMARY

4-1 Updated cell replacement kit part numbers for the probe.


PAGE SUMMARY

1-5 Added NOTE to Figure 1-7.


PAGE SUMMARY

1-1

2-1

3-1

Added warning to read new safety instructions.

Added protective covers and grounds warning.


Effective February, 1998 Rev. 3.5

PAGE SUMMARY

3-3 Changed screw torque in paragraph 3-3 h.


PAGE SUMMARY

-- Changed test gas to calibration gas and reference gas to reference air throughout the appendix.

APPENDIX AIB-106-300N SERIES

i

TABLE OF CONTENTS

Section Page

I. DESCRIPTION .................................................................................................................................. 1-11-1. Oxygen Analyzer (Probe) - General ........................................................................................ 1-11-2. Probe Assembly Exterior ......................................................................................................... 1-11-3. Inner Probe Assembly .............................................................................................................. 1-31-4. Probe Junction Box .................................................................................................................. 1-41-5. Cable Assembly........................................................................................................................ 1-41-6. Probe Options........................................................................................................................... 1-4

II. PROBE TROUBLESHOOTING .................................................................................................... 2-12-1. Overview .................................................................................................................................. 2-12-2. Probe Troubleshooting............................................................................................................. 2-1

III. SERVICE AND NORMAL MAINTENANCE ........................................................................... 3-13-1. Overview .................................................................................................................................. 3-13-2. Probe Recalibration.................................................................................................................. 3-13-3. Cell Replacement ..................................................................................................................... 3-13-4. Optional Ceramic Diffusion Element Replacement................................................................. 3-33-5. Replacement of Contact and Thermocouple Assembly........................................................... 3-53-6. Replacement of Heater, V-Strut and Backplate Assembly...................................................... 3-63-7. Calibration Gas and Reference Air Lines

For High Temperature - Corrosive Environment Operation ................................................ 3-8

IV. REPLACEMENT PARTS ............................................................................................................... 4-1


Figure Page

1-1. Oxygen Analyzer (Probe) Exploded View .......................................................................................... 1-01-2. Main Probe Components...................................................................................................................... 1-11-3. Cell and Tube Assemblies.................................................................................................................... 1-21-4. Optional Ceramic Diffusor and Vee Deflector Assembly ................................................................... 1-21-5. Inner Probe Assembly .......................................................................................................................... 1-31-6. Probe Junction Box .............................................................................................................................. 1-41-7. Abrasive Shield Assembly ................................................................................................................... 1-51-8. Ceramic Diffusion/Dust Seal Assembly............................................................................................... 1-61-9. Flame Arrestor Diffusion/Dust Seal Assembly.................................................................................... 1-61-10. Ceramic Diffusion Assembly ............................................................................................................... 1-61-11. Flame Arrestor Diffusion Assembly .................................................................................................... 1-61-12. Snubber Diffusion/Dust Seal Assembly............................................................................................... 1-71-13. Bypass Probe Option............................................................................................................................ 1-82-1. Flowchart of Probe Related Problems, #1 ........................................................................................... 2-32-2. Flowchart of Probe Related Problems, #2 ........................................................................................... 2-43-1. Cell Wiring Connection ....................................................................................................................... 3-23-2. Removal of Optional Diffusor and Vee Deflector .............................................................................. 3-33-3. Cell Replacement Kit .......................................................................................................................... 3-33-4. Probe Junction Box Mechanical Connections ..................................................................................... 3-53-5. Inner Probe Replacement (Heater, V-Strut, and Backplate Assembly) ............................................. 3-53-6. Heater, Strut, and Backplate Assembly (Inner Probe Assembly) ....................................................... 3-63-7. Oxygen Analyzer (Probe), Cross-Sectional View .............................................................................. 3-73-8. High Temperature - Corrosive Environment Kit ................................................................................. 3-8


1-0

2

3

NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE FORPURCHASE SEPARATELY. FOR LIST OFAVAILABLE PARTS, SEE TABLE 4-1.

29

1

27

28

25

24

26

20

19 17

78

1513

16

18

23

2210

11

21

20

11

14

12

10

9

4

5

6

NOTE: ITEM , CALIBRATION GAS TUBE,

FITS INTO HOLES WHEN PROBE IS

ASSEMBLED.21240005

Figure 1-1. Oxygen Analyzer (Probe) Exploded View

1. Heater, Strut, and Backplate Assembly2. Diffusion Assembly3. Retainer Screw4. Cell and Flange Assembly5. Corrugated Seal6. Probe Tube Assembly7. Screw8. Washer9. Cover Chain Screw

10. Cover Chain11. Probe Junction Box Cover12. Cover Gasket13. Wiring Diagram14. O-Ring15. Terminal Block Screws16. Terminal Block17. Terminal Block Marker18. Terminal Block Mounting Plate

19. Probe Junction Box Screws20. Hose Clamp21. Hose22. Gas Connection23. Seal Cap24. Label25. Probe Junction Box26. Ground Wires27. Insulating Gasket28. Washer29. Screw


1-1


Read the “Safety instructions for the wiringand installation of this apparatus” at thefront of this Instruction Bulletin. Failure tofollow the safety instructions could result inserious injury or death.

1-1. OXYGEN ANALYZER (PROBE) - GENERAL.The Oxygen Analyzer (Probe), Figure 1-1, consists ofthree component groups: probe exterior, inner probe,and probe junction box, Figure 1-2.

1-2. PROBE ASSEMBLY EXTERIOR. Primary probeexterior components include a flange-mountedzirconium oxide cell, mounted on a tube assembly andprotected by a snubber diffusion assembly.

a. Cell and Flange Assembly. The primarycomponent in the cell and flange assembly,Figure 1-3, is a yttria-stabilized zirconium oxidecell. It creates an electrical signal when the oxygenlevel on one side is out of balance with the oxygenlevel on the other side. This signal is proportionalto the difference in oxygen levels.

b. Probe Tube Assembly. Four screws secure thecell and flange assembly, Figure 1-3, to the probetube assembly. When in place, the cell is inside thetube.

PROBEEXTERIOR(SENSING CELL INSTALLED)

PROBEINTERIOR

PROBEJUNCTION

BOX

21240006

Figure 1-2. Main Probe Components


1-2

Table 1-1. Specifications for Oxygen Analyzing Equipment.1, 2

Probe lengths, nominal ................................................................................................ 18 inches (457 mm), 3 feet (0.91 m), 6 feet(1.83 m), 9 feet (2.74 m), or 12 feet(3.66 m), depending on duct dimensions

Temperature limits in processmeasurement area.............................................................................................. 50° to 1300°F (10° to 704°C)

Standard/current output ................................................................................................ 4-20 mA dc signal (factory set)O2 indication (Digital display

and analog output)............................................................................................. 0.1% O2 or ±3% of reading, whichever is greater using Rosemount calibration gases

System speed of response............................................................................................. less than 3 seconds (amplifier output)Resolution sensitivity.................................................................................................... 0.01% O2 transmitted signalHPS 3000 housing ........................................................................................................ NEMA 4X (IP56)Probe reference air flow ............................................................................................... 2 scfh (56.6 L/hr) clean, dry, instrument

quality air (20.95% O2), regulated to 5 psi (34 kPa)

Calibration gas mixtures............................................................................................... Rosemount Hagan Calibration Gas Kit PartNo. 6296A27G01 contains 0.4% O2N2

Nominal and 8% O2N2 NominalCalibration gas flow...................................................................................................... 5 scfh (141.6 L/hr)HPS 3000 Power supply............................................................................................. 100/110/220 ±10% Vac at 50/60 HzHPS 3000 Power requirement .................................................................................... 200 VAHPS 3000 Ambient Operating Temperature.............................................................. 32° to 120°F (0° to 50°C)Ambient operating temperature (Probe Junction Box) ................................................ 300°F (150°C) maxApproximate shipping weights:

18 inch (457 mm) package................................................................................ 55 pounds (24.97 kg)3 foot (0.91 m) package .................................................................................... 60 pounds (27.24 kg)6 foot (1.83 m) package .................................................................................... 65 pounds (29.51 kg)9 foot (2.74 m) package .................................................................................... 72 pounds (32.66 kg)12 foot (3.66 m) package .................................................................................. 78 pounds (35.38 kg)

1 All static performance characteristics are with operating variables constant.2 Equipment ordered utilizing this document as reference will be supplied to the USA standard design. Customers requiring the EEC standard design should request the EEC documentation and utilize its ordering data. Temperatures over 1000°F (537°C) may affect the ease of field cell replaceability.

PROBE TUBE

CORRUGATEDSEAL

CELL ANDFLANGE

ASSEMBLY

21240007

Figure 1-3. Cell and Tube Assemblies

DIFFUSIONELEMENT

VEEDEFLECTOR

PINWRENCH

HUB

21240024

Figure 1-4. Optional Ceramic Diffusor andVee Deflector Assembly


1-3

The tube assembly includes a flange which mateswith a stack-mounted flange (shown attached to theprobe flange in Figure 1-2). Studs on the stackflange make installation easy. There is also a tubeto carry calibration gas from the probe junctionbox to the process side of the cell duringcalibration.

c. Snubber Diffusion Assembly. The snubberdiffusion assembly protects the cell from heavyparticles and isolates the cell from changes intemperature. The snubber diffusion assemblythreads onto the cell and flange assembly. Pinspanner wrenches (probe disassembly kit3535B42G01) are applied to holes in the snubberdiffusion element hub to remove or install thesnubber diffusion assembly.

An optional ceramic diffusor element and veedeflector, shown in Figure 1-4, is available. Theceramic diffusor assembly is also available in aflame arresting version to keep heat from the cellfrom igniting flue gases.

Systems that use an abrasive shield require aspecial snubber diffusion assembly with a hub thatis grooved to accept two dust seal gaskets. Thisspecial diffusor is available in both snubber andceramic versions. See Probe Options, section 1-6.

d. Cell - General. The components which make upthe cell are machined to close tolerances andassembled with care to provide accurate oxygenmeasurements. Any replacement requires attentionto detail and care in assembly to provide goodresults.

Failure to follow the instructions in thismanual could cause danger to personnel andequipment. Read and follow instructions inthis manual carefully.

The oxygen probe includes an inner electrode forthe cell assembly. It consists of a platinum pad anda platinum/inconel composite wire which producesthe cell constant offset voltage described in theNernst equation.

With this pad and wire, the constant will bebetween -10 and +15 mV. The cell constant isnoted in the calibration data sheet supplied witheach probe.

Every probe should be calibrated and checked afterrepair or replacement of cell, pad and wire, heater,and thermocouple, or after disassembly of theprobe.

1-3. INNER PROBE ASSEMBLY. The inner probeassembly, Figure 1-5, consists of six main parts:

a. Ceramic support rod with four holes runningthrough the length. The holes serve as insulatedpaths for the cell signal wire and thermocouplewires.

b. A heater that is helically wrapped on a quartzsupport cylinder and insulated.

c. A chromel-alumel thermocouple which acts as thesensing element for the temperature controller.(Not visible in Figure 1-5; located within ceramicsupport rod.)

d. A platinum screen pad which forms electricalcontact with the inner electrode of theelectrochemical cell. (Not visible in Figure 1-5;located at end of ceramic support rod.) The pad isattached to an inconel wire which carries the signalto the terminal strip.

e. A V-strut assembly to give support to the innerprobe assembly.

f. A tube to carry reference air to the cell.

Turn to Section III, Service and Normal Maintenance,for repair procedures for probe components.

HEATER

V-STRUT

CERAMICSUPPORT

ROD

INSULATINGGASKET

27270015

REFERENCEAIR TUBE

Figure 1-5. Inner Probe Assembly


1-4

CALIBRATIONGAS FITTING

PROBEJUNCTION BOX

COVERTERMINALSTRIP

REFERENCEAIR FITTING

27270016

Figure 1-6. Probe Junction Box

1-4. PROBE JUNCTION BOX. The probe junction box,Figure 1-6, is positioned at the external end of theprobe and contains a terminal strip for electricalconnections and fittings for reference air andcalibration gases. Fittings are for 0.250 inch stainlesssteel tubing on American units and 6 mm on Europeanunits. The calibration fitting has a seal cap which mustremain in place except during calibration. A tubingfitting is also supplied to be used with the calibrationgas supply during calibration.

If the calibration gas bottles will be permanentlyhooked up to the probe, a manual block valve isrequired at the probe (between the calibration fittingand the gas line) to prevent condensation of flue gasdown the calibration gas line.

During operation and calibration, reference air issupplied through the reference air fitting to thereference side of the cell. This gives the system aknown quantity of oxygen with which to compare theoxygen level in the process gas. Though ambient air

can be used for this purpose, accuracy can only beassured if a reference air set is used.

During calibration, two gases of different knownoxygen concentrations are injected one at a timethrough the calibration gas fitting. Stainless steel tubingdelivers this gas to the process side of the cell. In ahealthy cell, the difference in oxygen pressure from theprocess side to the reference side of the cell will cause amillivolt output proportional to the difference inoxygen levels. The electronics unit can use the twomillivolt outputs caused by the two calibration gases foreither automatic or semi-automatic calibration.

Do not attempt to remove a process gassample through either gas fitting. Hot gasesfrom the process would damage gas hoses inthe probe junction box.

1-5. CABLE ASSEMBLY. The system uses a7-conductor cable to connect the probe to theelectronics package. Standard length for this cable is 20feet (6 m), but lengths up to 150 feet (45 m) areavailable. The seven conductors include one shieldedpair of wires for the cell millivolt signal, one shieldedpair of type K wires for the thermocouple, and threeindividual 16-gauge wires for the heater and forground. The assembled conductors are wrapped by atype K TeflonTM jacket and braided stainless steelshield. The TeflonTM and stainless steel jacketing issuitable for high temperature use. All metal shields areisolated at the probe end and connect by drain wires toground at the electronics.

1-6. PROBE OPTIONS.

a. Abrasive Shield Assembly. The abrasive shieldassembly, Figure 1-7, is a stainless-steel tube thatsurrounds the probe assembly. The shield protectsthe probe against particle abrasion and corrosivecondensations, provides a guide for ease ofinsertion, and acts as a probe position support,especially for longer length probes. The abrasiveshield assembly uses a modified diffusor and veedeflector assembly, fitted with dual dust sealpacking.


1-5

VIEW A VIEW B

A

B

A

B

15o

2 .187 1

ON INSIDE BREAKFOR SMOOTHROUNDED EDGE ONBOTH ENDSOF CHAMFER

.187

6.00

125

.45 MIN

90o

3.5843.554

SKIN CUT FACE FOR 90o

22.5o

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 EXPANDINGCHILL BLOCK.

2 BEFORE WELDING, BUTT ITEM 2 OR 4 WITHITEM 1 AS SHOWN.

.187

16860033

Figure 1-7. Abrasive Shield Assembly

NOTEIn highly abrasive applications, rotate the shield 90 degrees at normal

service intervals to present a new wear surface to the abrasive flow stream.


1-6

P0010

Figure 1-8. Ceramic Diffusion/Dust Seal Assembly

These modified diffusion and vee deflectorassemblies are available in standard, Figure 1-8,and flame arrestor version, Figure 1-9.

b. Ceramic Diffusion Assembly. The ceramicdiffusion assembly, Figure 1-10, is the traditionaldesign for the probe. Used for over 25 years, theceramic diffusion assembly provides a greater filtersurface area for the probe.

P0011

Figure 1-9. Flame Arrestor Diffusion/DustSeal Assembly

19280010

Figure 1-10. Ceramic Diffusion Assembly

c. Flame Arrestor Diffusion Assembly. Where ahigh concentration of unburned fuel is present inthe exhaust gases, a flame arrestor diffusionassembly, Figures 1-9 and 1-11 is recommended.

The flame diffusion assembly includes a set ofbaffles between the cell and the stack gases. Thiskeeps 1500°F (816°C) cell temperatures fromigniting unburned fuel in the stack.

P0012

Figure 1-11. Flame Arrestor Diffusion Assembly


1-7

Figure 1-12. Snubber Diffusion/Dust Seal Assembly

d. Snubber Diffusion/Dust Seal Assembly. Thesnubber diffusion/dust seal assembly, Figure 1-12,is used in applications where an abrasive shield isto be used with a snubber type diffusion element.The dust seal consists of two rings of packing toprevent abrasive dust from collecting inside theabrasive shield.

e. Bypass Probe Options. For processes where theflue gas exceeds the maximum allowabletemperature of 1300°F (704°C) a bypass sensorpackage can be employed. The bypass system uses

an 18 inch (457 mm) or 3 foot (0.92 m) probemounted externally on the stack or duct. Theprocess or exhaust gases are directed out to theprobe through a passive sampling system usinginconel tubes. Flue gas flow induces the movementof gases into, through, and out of the bypass unit.The bypass arrangement does not require the useof aspiration air and the gas which flows past theprobe is returned to the stack or duct.

The bypass probe package is normally used forprocess temperatures of 1300°F (704°C) to 2000°F(1094°C). A higher temperature version of thebypass provides for operation at temperatures up to2500°F (1372°C). In this version the pick up tubesare made of a special high-temperature alloy.

Overall dimensions and mounting details of theAmerican and European bypass systems are shownin Figure 1-13.

f. Probe Mounting Jacket Options. A probemounting jacket option is available to allow theprobe to operate at temperatures of up to 2000°F(1095°C). A separate instruction bulletin isavailable for this option.


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1-10

Extended Temperature By-Pass Arrangements (2400°F; 1300°C)

PART NO. GROUPCODE DESCRIPTION

1U0571 G01 3’ By-pass Package with ANSI bolt pattern.



1U0571 G04 3’ By-pass Package with JIS bolt pattern.



1U0571 G07 3’ By-pass Package with DIN bolt pattern.





2-1

SECTION II. PROBE TROUBLESHOOTING

2-1. OVERVIEW. The probe troubleshooting sectiondescribes how to identify and isolate faults which maydevelop in the probe assembly.


2-2. PROBE TROUBLESHOOTING.

a. Probe Faults. Listed below are the four symptomsof probe failure.

1. The system does not respond to changes inthe oxygen concentration.

2. The system responds to oxygen changes butdoes not give the correct indication.

3. The system does not give an acceptableindication of the value of the oxygen calibra-tion gas being applied during calibration.

4. The system takes a long time to return to theflue gas value after the calibration gas isturned off.

b. Table 2-1 provides a guide to fault finding for theabove symptoms.

c. Figures 2-1 and 2-2 provide an alternate approachto finding probe related problems.

Table 2-1. Fault Finding.

SYMPTOM CHECK FAULT REMEDY

1. No response to oxygenconcentration changewhen:

Heater is cold and TCmV output is less thanset point

Heater is hot and T/C

mV output is at set

point ±0.2 mV

Thermocouple continuity

Heater cold resistance to be11 ohm to 14 ohm

Triac O/P to heater

Recorder chart

Cell mV input to electronicsand cell mV at probejunction box

Thermocouple failure

Heater failure

Failure of electronics

Recorder failure

No cell mV at probe whencalibration gas applied

Probe cell mV OK but noinput to electronics

Cell mV satisfactory both atprobe junction box and inputto electronics - failure ofelectronics

Replace thermocouple orreturn probe to Rosemount.

Replace heater or returnprobe to Rosemount.

Check HPS and electronicspackage.

See Recorder InstructionManual.

Replace cell or return probeto Rosemount.

Check out cable connection.

Check electronics package.


2-2

Table 2-1. Fault Finding (Continued).


2. System responds tooxygen concentrationchanges but does notgive correct indication

Good response, withincorrect indication

Recorder or remote indicator

System calibration

Probe mounting andcondition of duct

Cell mV input to electronics

Calibration error

Calibration error

Air ingress into duct

Failure of electronics

Recalibrate recorder orindicator. ReferenceRecorder InstructionManual.

Recalibrate system.

Stop air leaks or resite probe.

Check electronics package.

3. System does not giveaccurate indication ofapplied calibration gas

Calibration gas input port

Ceramic diffusion element

Blocked port

Diffusion element cracked,broken, or missing

Clean port. If the flue gas iscondensing in the calibrationgas line, insulate the back ofthe probe. Make sure that thecalibration gas line is cappedbetween calibrations, or acheck valve is installed.

Replace diffusion element.

4. System takes a longtime to return to fluegas value after calibra-tion gas is turned off

Diffusion element Plugged diffusion element Change diffusion element orsnubber diffusion element.


2-3

Figure 2-1. Flowchart of Probe Related Problems, #1


2-4

Figure 2-2. Flowchart of Probe Related Problems, #2


3-1

SECTION III. SERVICE AND NORMAL MAINTENANCE

NOTE

Upon completing installation, make sure that the probe is turned on andoperating prior to firing up the combustion process. Damage can result fromhaving a cold probe exposed to the process gases.

During outages, and if possible, leave all probes running to preventcondensation and premature aging from thermal cycling.

If the ducts will be washed down during outage, MAKE SURE to power downthe probes and remove them from the wash area.

3-1. OVERVIEW. This section describes routinemaintenance of the oxygen analyzer probe. Spare partsreferred to are available from Rosemount. Probedisassembly kit 3535B42G01 contains the requiredspanner and hex wrenches. Refer to Section IV of thisappendix for part numbers and ordering information.

Install all protective equipment covers andsafety ground leads after equipment repairor service. Failure to install covers andground leads could result in serious injury ordeath.

3-2. PROBE RECALIBRATION. The oxygen analyzersystem should be calibrated when commissioned.Under normal circumstances the probe will not requirefrequent calibration. When calibration is required,follow the procedure described in the InstructionBulletin applicable to your electronics package.

3-3. CELL REPLACEMENT. This paragraph coversoxygen sensing cell replacement. Do not attempt toreplace the cell until all other possibilities for poorperformance have been considered. If cell replacementis needed, order cell replacement kit, Table 4-1.

The cell replacement kit contains a cell and flangeassembly, corrugated seal, setscrews, socket head capscrews, and anti-seize compound. Items are carefully

packaged to preserve precise surface finishes. Do notremove items from packaging until they are ready to beused. Spanner wrenches and hex wrenches needed forthis procedure are part of an available special tools kit,Table 4-1.

Wear heat resistant gloves and clothing toremove probe from stack. Normal operatingtemperatures of diffusor and vee deflectorare approximately 600° to 800°F (316° to427°C). They could cause severe burns.

Disconnect and lock out power beforeworking on any electrical components.There is voltage up to 115 Vac.

Do not remove cell unless it is certain thatreplacement is needed. Removal may damagecell and platinum pad. Go through completetroubleshooting procedure to make sure cellneeds replacement before removing it.

a. Disconnect and lock out power to electronics. Shutoff and disconnect reference air and calibration gassupplies from probe junction box, Figure 3-1.Wearing heat resistant gloves and clothing, removeprobe assembly from stack carefully and allow tocool to room temperature. Do not attempt to workon unit until it has cooled to a comfortable workingtemperature.


3-2

CELL EXTENSIONWIRE (ORANGE)

BOMB TAILCONNECTOR

INCONELCELL WIRE

(CLEARSLEEVING)

HEATERWIRES(BLACK

SLEEVING)THERMOCOUPLE -

(RED ALUMEL)

THERMOCOUPLE +(YELLOW CHROMEL)

CALIBRATIONGAS FITTING

REFERENCEAIR FITTING

PROBE JUNCTIONBOX COVER

CABLE

27270019

Figure 3-1. Cell Wiring Connection

b. If the probe uses the standard diffusion element,use a spanner wrench to remove the diffusionelement.

c. If equipped with the optional ceramic diffusorassembly, remove and discard setscrews, Figure3-2, and remove vee deflector. Use spannerwrenches from probe disassembly kit, Table 4-1, toturn hub free from retainer. Inspect diffusionelement. If damaged, replace element.

d. Loosen four socket head cap screws from the celland flange assembly and remove the assemblyand the corrugated seal. The cell flange has a

notch which may be used to gently pry the flangeaway from the probe. Note that the contact padinside the probe will sometimes fuse to theoxygen sensing cell. If the cell is fused to thecontact pad, push the cell assembly back into theprobe (against spring pressure), and quickly twistthe cell assembly. The cell and contact padshould separate. If the contact pad stays fusedto the cell, a new contact/thermocouple assemblymust be installed. Disconnect the cell and thethermocouple wires at the probe junction box,and withdraw the cell with the wires still attached(see paragraph 3-5).


3-3

OPTIONAL CERAMICDIFFUSION ELEMENT

VEEDEFLECTOR

HUB

PINWRENCH

SETSCREW

RETAINER

CEMENTPORT

CEMENTFILLET

21240026

Figure 3-2. Removal of Optional Diffusorand Vee Deflector

PROBE TUBE(NOT INCLUDED

IN KIT)

SOCKET HEADCAP SCREWS

CORRUGATEDSEAL

CELL ANDFLANGE

ASSEMBLY

CALIBRATION GASPASSAGE

21240009

Figure 3-3. Cell Replacement Kit

e. If contact assembly is damaged, replace contactand thermocouple according to paragraph 3-5,Replacement of Contact and ThermocoupleAssembly.

f. Remove and discard corrugated seal. Clean matingfaces of probe tube and retainer. Remove burrs andraised surfaces with block of wood and crocuscloth. Clean threads on retainer and hub.

g. Rub a small amount of anti-seize on both sides ofnew corrugated seal.

h. Assemble cell and flange assembly, corrugatedseal, and probe tube. Make sure the calibrationtube lines up with the calibration gas passage ineach component. Apply a small amount ofanti-seize compound to screw threads and usescrews to secure assembly. Torque to 55 in-lbs(4 N•m).

i. Apply anti-seize compound to threads of cellassembly, hub, and setscrews. Reinstall hub on cellassembly. Using pin spanner wrenches, torque to10 ft-lbs (14 N•m). If applicable, reinstall veedeflector, orienting apex toward gas flow. Securewith setscrews and anti-seize compound. Torqueto 25 in-lbs (2.8 N•m).

j. On systems equipped with an abrasive shield,install dust seal gaskets, with joints 180o apart.

k. Reinstall probe and gasket on stack flange. If thereis an abrasive shield in the stack, make sure dustseal gaskets are in place as they enter 15o reducingcone.

l. Turn power on to electronics and monitorthermocouple output. It should stabilize at 29.3±0.2 mV. Set reference air flow at 2 scfh(56.6 L/hr). After probe stabilizes, calibrate probeper Instruction Bulletin applicable to yourelectronics package. If new components have beeninstalled, repeat calibration after 24 hours ofoperation.

3-4. OPTIONAL CERAMIC DIFFUSION ELEMENT REPLACEMENT.

a. General. The diffusion element protects the cellfrom particles in process gases. It does notnormally need to be replaced because the veedeflector protects it from particulate erosion. Insevere environments the filter may be broken orsubject to excessive erosion. Examine the diffusionelement whenever removing the probe for anypurpose. Replace if damaged.

Damage to the diffusion element may becomeapparent during calibration. Compare proberesponse with previous response. A brokendiffusion element will cause a slower response tocalibration gas.

Hex wrenches needed to remove setscrews andsocket head screws in the following procedure areavailable as part of a special tool kit, Table 4-1.


3-4

Wear heat resistant gloves and clothing toremove probe from stack. Normal operatingtemperatures of diffusor and vee deflectorare approximately 600° to 800°F (300° to425°C). They can cause severe burns.

Disconnect and lock out power beforeworking on any electrical component.There is voltage up to 115 Vac.

It is not necessary to remove the cell unless itis certain that replacement is necessary. Cellcannot be removed for inspection withoutdamaging it. Refer to paragraph 3-3, CellReplacement.

b. Replacement Procedure.

1. Shut off power to electronics. Disconnectcable conductors and remove cable, Figure3-1. Shut off and disconnect reference air andcalibration gas supplies from probe junctionbox. Wearing heat resistant gloves andclothing, carefully remove probe assemblyfrom stack and allow to cool to roomtemperature. Do not attempt to work on unituntil it has cooled to a comfortable workingtemperature.

2. Loosen setscrews, Figure 3-2, using hexwrench from special tools kit, Table 4-1, andremove vee deflector. Inspect setscrews. Ifdamaged, replace with M-6 x 6 stainlesssetscrews 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 4-1, to turn hub free from retainer.

5. Put hub in vise. Break out old diffusionelement with chisel along cement line and3/8 inch (9.5 mm) pin punch through cementport.

6. Break out remaining diffusion element bytapping lightly around hub with hammer.Clean grooves with pointed tool if necessary.

7. Replace diffusion element, using replacementkit listed in Table 4-1. This consists of adiffusion element, cement, setscrews,anti-seize compound and instructions.

8. Test fit replacement element to be sure seat isclean.

Do not get cement on diffusion elementexcept where it touches the hub. Any cementon ceramic element blocks airflow throughelement. Wiping wet cement off of ceramiconly forces cement into pores.

9. Thoroughly mix cement and insert tip ofsqueeze bottle into cement port. Tilt bottleand squeeze while simultaneously turningdiffusion element into seat. Do not get anycement on upper part of diffusion element.Ensure complete penetration of cementaround three grooves in hub. Cement shouldextrude from opposite hole. Wipe excessmaterial back into holes and wipe top fillet ofcement to form a uniform fillet. (A Q-Tip isuseful for this.) Clean any excess cement fromhub with water.

10. Allow filter to dry at room temperatureovernight or 1 to 2 hours at 200°F (93°C).

11. Wipe a heavy layer of anti-seize compoundonto the threads and mating surfaces of thediffusion hub and retainer.

12. Assemble retainer and diffusion hub withtwo pin spanner wrenches. Torque to 10 ft-lbs(14 N•m).

13. On systems equipped with abrasive shield,install dust seal gaskets with joints 180° apart.

14. Reinstall vee deflector, orienting apex towardgas flow. Apply anti-seize compound tosetscrews and tighten with hex wrench.


3-5

15. Reinstall probe on stack flange.

16. Turn power on to electronics and monitorthermocouple output. It should stabilize at29.3 ±0.2 mV. Calibrate probe per InstructionBulletin applicable to your electronicspackage.

3-5. REPLACEMENT OF CONTACT ANDTHERMOCOUPLE ASSEMBLY.

.

Use heat resistant gloves and clothing whenremoving probe junction box and innerprobe assembly. Do not attempt to work onthese components until they have cooled toroom temperature. Probe components canbe as hot as 800°F (427°C). This can causesevere burns.

Disconnect and lock out power beforeworking on any electrical components. Thereis voltage up to 115 Vac.

a. Disconnect and lock out power to electronics.Using heat resistant gloves and clothing, removeprobe junction box cover. Squeezing tabs on hoseclamps, remove hoses from probe junction box,Figure 3-4. Remove four screws in corners ofprobe junction box. Pull probe junction box andinner probe assembly free from probe tube. Set onbench and allow to cool to room temperature.

b. Disconnect cell extension wire (orange),thermocouple wire (red alumel), and thermocouplewire (yellow chromel) by cutting bomb tailconnections from the terminal strip, Figure 3-1.

c. Remove two screws, Figure 3-4, lockwashers, andflat washers that connect probe junction box toinner probe assembly. Pull heater, V-strut andbackplate assembly away from probe junction box.Inspect all O-rings and insulating gasket; replace ifworn or damaged.

d. Use a pencil to mark locations of spring clip onceramic rod, Figure 3-5.

e. Pry or squeeze tabs on spring clips, and pullcontact and thermocouple assembly out of probeassembly. Retain spring clips and spring; replace ifdamaged.

PROBE JUNCTION BOXINNER PROBE ASSEMBLYTO PROBE TUBE SCREWS

PROBE JUNCTION BOX TO HEATER,STRUT, AND BACKPLATE

ASSEMBLY SCREW

PROBEJUNCTION

BOX

HOSECLAMP

HOSE

21240027

Figure 3-4. Probe Junction Box Mechanical Connections

Be very careful when handling contact andthermocouple assembly. The ceramic rod inthis assembly is fragile.

f. While very carefully handling new contact andthermocouple assembly, lay old assembly next tonew one. Transfer pencil marks to new rod.

g. Note wire lengths of old assembly as an aid fortrimming new lengths in step (j). Trimming ofwires will not always be necessary. Throw awayold contact and thermocouple assembly.

21240010

MOUNTING SCREW(REAR VIEW)

CONTACT ANDTHERMOCOUPLER

ASSEMBLY

V-STRUT

HEATER SCREWS(NOT SHOWN)

HEATERCERAMIC ROD

SPRINGCLIP

INSULATINGGASKET

Figure 3-5. Inner Probe Replacement(Heater, V-Strut, and Backplate Assembly)


3-6

h. Carefully guide new contact and thermocoupleassembly through V-strut assembly leaf spring(4, Figure 3-6), spring (9), spring clip (10) (heldopen by squeezing tabs), and tube supports(11, 13) until spring clip reaches pencil mark.

i. Reinstall insulating gasket on backplate, replacetwo screws, O-rings, lockwashers and flatwashers connecting probe junction box to innerprobe assembly.

Do not trim new wiring shorter than existing(old) wiring. Excessive wire trim will preventconnections from being properly made andwill require a new replacement kit.

j. Trim wires, if necessary, as noted in step (g).

k. Connect color coded wires to proper terminals asshown in Figure 3-1. Rosemount recommendsconnecting the thermocouple wires directly to theterminal strip. This is because the junction ofdifferent metals at the wires and lugs and at thelugs and the terminal strip could act as additionalthermocouple junctions. This could produce avoltage that would affect the thermocoupleoutput signal.

Do not bend wires closer than 1/4 inch (6.4 mm)from end of ceramic rod. Dress wires so they donot touch sides of probe junction box.

l. Slide assembled probe junction box and innerprobe assembly into probe tube. To aligncalibration gas tube with corresponding hole inbackplate (A, B, Figure 1-1), insert scriberthrough hole in backplate and into calibration gastube. Secure with screws. Reinstall hoses andprobe junction box cover.

m. Power up system. Monitor thermocouple output.It should stabilize at set point mV ±0.2 mV.Recalibrate probe per Instruction Bulletinapplicable to your electronics package.

3-6. REPLACEMENT OF HEATER, V-STRUTAND BACKPLATE ASSEMBLY (Inner ProbeAssembly; Includes Contact and ThermocoupleAssembly).

Use heat resistant gloves and clothing whenremoving probe junction box and innerprobe assembly. Do not attempt to work onthese components until they have cooled toroom temperature. Probe components can beas hot as 800° (427°C). This can cause severeburns.


1 3 45

4

8

6

78

9101111213

12

1. Heater Ceramic Rod 5. Ring Lug 19. Spring2. Contact and Thermocouple Assembly 6. Butt Connector 10. Spring Clip Assembly3. Strut 7. Extension Wire 11. Common Tube Support

4. Leaf Spring 8. Backplate 12. Heater13. Short Tube Support

Figure 3-6. Heater, Strut, and Backplate Assembly

(Inner Probe Assembly)


3-7

NOTE

This replacement may be done withoutremoving the probe from the duct.

a. Disconnect and lock out power to electronics.Using heat resistant gloves and clothing, removeprobe cover. Squeezing tabs on hose clamps andremove hoses from probe junction box, Figure 3-4.Remove four screws and lockwashers (7, 10,Figure 3-7) that hold probe junction box and innerprobe assembly to probe tube. Pull probe junctionbox and inner probe assembly free from probetube. Set on bench and allow to cool to roomtemperature.

b. Disconnect cell extension wire (orange),thermocouple wire (red alumel), and thermocouplewire (yellow chromel) by cutting bomb tailconnections from the terminal strip, Figure 3-1.

c. Remove two screws, lockwashers, and flat washersthat connect probe junction box to inner probeassembly. Remove and discard inner probeassembly (heater, V-strut, and backplateassembly). Replace with new inner probe

assembly. Reinstall screws, lockwashers and flatwashers.

d. Connect color coded wires to proper terminals asshown in Figure 3-1. Rosemount recommendsconnecting the thermocouple wires directly to theterminal strip. This is because the junction ofdifferent metals at the wires and lugs and at thelugs and the terminal strip could act as additionalthermocouple junctions. This could produce avoltage that would affect the thermocouple outputsignal.

Do not bend wires closer than 1/4 inch (6.4 mm)from end of ceramic rod. Dress wires so they donot touch sides of probe junction box.

e. Slide assembled probe junction box and innerprobe assembly into probe tube. To aligncalibration gas tube with corresponding hole inbackplate (A, B, Figure 1-1), insert aligning tool(included in probe disassembly kit, P/N3535B42G01) through hole in backplate and intocalibration gas tube, while sliding the heater strutinto the probe tube. Secure with screws. Reinstallhoses and probe junction box cover.

1 2 4

3

11

5

6 7 8 9

1021240012

ITEM DESCRIPTIONSIZE-REFERENCEINFORMATION ITEM DESCRIPTION

SIZE-REFERENCEINFORMATION

1

2

3

45

Snubber DiffusionElementSocket HdCap ScrewCell and FlangeAssemblyCorrugated SealProbe TubeAssembly

0.25 in.-28x 0.63 (16 mm)

6

7

8

91011

Gasket

Fillister HdScrewCover HeadAssemblyHose ClampLockwasherHeater StrutAssembly

4.0 in. (102 mm) x 4.0 in. x0.12 in. (3 mm)8-32 x 0.5 in.(12.7 mm)

#8 Split

Figure 3-7. Oxygen Analyzer (Probe), Cross-Sectional View


3-8

f. Power up system. Monitor thermocouple output. Itshould stabilize at set point ±0.2 mV. Recalibrateprobe per Instruction Bulletin applicable to yourelectronics package.

3-7. CALIBRATION GAS AND REFERENCE AIRLINES FOR HIGH TEMPERATURE -CORROSIVE ENVIRONMENT OPERATION. Ahigh temperature, corrosive environment kit is availablewhen the probe is exposed to these types of operatingconditions. The kit includes stainless steel tubing andteflon fittings for inside the probe junction box. The kitpart number is 4843B93G01.

a. Installation Procedure.

Use heat resistant gloves and clothingwhen removing probe junction box andinner probe assembly. Do not attempt towork on these components until they havecooled to room temperature. Probecomponents can be as hot as 800°F (427°C).This can cause severe burns.


1. Disconnect and lock out power to digitalelectronics. Using heat resistant gloves andclothing, remove probe cover. Squeezing tabson hose clamps, remove hoses from probejunction box (Figure 3-4).

Do not use sealant when installing the stainless steel tubes. Gas samples maybecome contaminated

2. First install the stainless steel tubing on thefitting at the bottom of the probe junction box.Install the other end of the stainless steel tubeonto the tube going to the probe (Figure 3-8).

NOTE

If abrasive conditions of high ash content andhigh velocity exist, an abrasive shield isrecommended. To balance out the wear onthe shield, rotate the shield 90° every time theprobe is powered down for service.

STAINLESSSTEEL

TUBING

TEFLONSLEEVES

21240028

Figure 3-8. High Temperature - CorrosiveEnvironment Kit


4-1/4-2

SECTION IV. REPLACEMENT PARTS

Table 4-1. Replacement Parts for Probe.

FIGURE andINDEX No. PART NUMBER DESCRIPTION

3-53-53-53-53-53-6, 23-6, 23-6, 23-6, 23-6, 21-71-71-71-73-33-33-33-33-33-33-33-33-33-33-33-33-33-33-33-33-33-33-31-101-8

1-101-91-111-4

3-2

3-81-1,21-12

3D39441G061

3D39441G071

3D39441G081

3D39441G091

3D39441G101

3534B56G042

3534B56G052

3534B56G062

3534B56G072

3534B56G082

3D39003G013

3D39003G023

3D39003G073

3D39003G083

4847B61G014847B61G024847B61G034847B61G044847B61G054847B61G064847B61G074847B61G084847B61G094847B61G104847B61G114847B61G124847B61G134847B61G144847B61G154847B61G164847B61G174847B61G183535B42G013534B18G013535B60G01

4841B03G023535B63G013535B62G013534B48G01

6292A74G021537B70G03

4843B93G014843B37G014843B38G02

Heater, V-Strut, and Backplate Assembly, 18 in. (45.6 cm)Heater, V-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 Assembly, 12 ft (3.6 m)Abrasive Shield Assembly, 3 ft (0.9 m)Abrasive Shield Assembly, 6 ft (1.8 m)Abrasive Shield Assembly, 9 ft (2.7 m)Abrasive Shield Assembly, 12 ft (3.6 m)Cell Replacement Kit, ANSI, No Lead WireCell Replacement Kit, ANSI 18 in. (45.6 cm)Cell Replacement Kit, ANSI 3 ft (0.9 m)Cell Replacement Kit, ANSI 6 ft (1.8 m)Cell Replacement Kit, ANSI 9 ft (2.7 m)Cell Replacement Kit, ANSI 12 ft (3.6 m)Cell Replacement Kit, JIS, No Lead WireCell Replacement Kit, JIS 18 in. (45.6 cm)Cell Replacement Kit, JIS 3 ft (0.9 m)Cell Replacement Kit, JIS 6 ft (1.8 m)Cell Replacement Kit, JIS 9 ft (2.7 m)Cell Replacement Kit, JIS 12 ft (3.6 m)Cell Replacement Kit, DIN, No Lead WireCell Replacement Kit, DIN 18 in. (45.6 cm)Cell Replacement Kit, DIN 3 ft (0.9 m)Cell Replacement Kit, DIN 6 ft (1.8 m)Cell Replacement Kit, DIN 9 ft (2.7 m)Cell Replacement Kit, DIN 12 ft (3.6 m)Probe Disassembly KitDiffuser AssemblyDiffuser Dust Seal Hub Assembly (For use with Abrasive Shield)Stainless Steel Diffuser AssemblyFlame Arrestor Diffuser Dust SealFlame Arrestor DiffuserVee Deflector Assembly (For use with standard or dust seal type ceramic diffusers)Diffusion Element Replacement KitHorizontal and Vertical Brace Clamp Assembly, 9 and 12 foot (2.7 and 3.6 m) probeHigh Temperature - Corrosive Environment KitSnubber Diffusion AssemblyDust Seal/Snubber Diffusion Assembly

1Heater, V-strut, and backplate assembly includes contact and thermocouple assembly.2Contact and thermocouple assembly includes platinum pad and inconel wire.3Abrasive shield assembly includes accessories necessary for its use and a mounting plate and gasket.

APPENDIX B, REV. 2.2HPS 3000HEATER POWER SUPPLY

Instruction Bulletin IB-106-300N SERIESInstruction Bulletin IB-106-101N SERIES

APPENDIX B


Effective February, 1992 Rev. 2

PAGE SUMMARY

1-1

4-1

Figure 1-1. New HPS 3000 Optional Class 1, Division 1, Group B (IP56) Explosion-Proof Enclosureadded.

Figure and Index No. column added to Table 4-1. Replacement Parts for Heater Power Supply.


PAGE SUMMARY

1-3 Updated Figure 1-3, Heater Power Supply Block Diagram for IB consistency.


PAGE SUMMARY

1-1

1-3

2-1

3-1

4-1


Corrected Table 1-1 specifications list.



Added expanded fuse description.

APPENDIX BIB-106-300N SERIESIB-106-101N SERIES

i/ii

TABLE OF CONTENTS

Section Page

I. DESCRIPTION .................................................................................................................................. 1-11-1. Description............................................................................................................................... 1-11-2. Theory of Operation................................................................................................................. 1-3

II. HPS 3000 TROUBLESHOOTING................................................................................................ 2-12-1. Overview.................................................................................................................................. 2-12-2. HPS 3000 Troubleshooting ..................................................................................................... 2-1

III. SERVICE AND NORMAL MAINTENANCE ........................................................................... 3-13-1. Overview.................................................................................................................................. 3-13-2. Fuse Replacement .................................................................................................................... 3-13-3. Transformer Replacement........................................................................................................ 3-13-4. Mother Board Replacement..................................................................................................... 3-13-5. Daughter Board Replacement.................................................................................................. 3-2



Figure Page

1-1. HPS 3000 Heater Power Supply Field Module................................................................................... 1-11-2. Heater Power Supply, Interior ............................................................................................................. 1-21-3. Heater Power Supply Block Diagram.................................................................................................. 1-32-1. HPS Troubleshooting Flowchart, #1 ................................................................................................... 2-22-2. HPS Troubleshooting Flowchart, #2 ................................................................................................... 2-32-3. HPS Troubleshooting Flowchart, #3 ................................................................................................... 2-43-1. Heater Power Supply, Exploded View................................................................................................ 3-3


1-1



1-1. DESCRIPTION. The Rosemount HPS 3000 HeaterPower Supply Field Module acts as an interfacebetween probe and electronics, and supplies power tothe probe heater. The unit allows the use of probes witha number of different electronics packages.

The HPS is available in a NEMA 4X (IP56)non-hazardous enclosure or an optional Class 1,

Division 1, Group B (IP56) explosion-proof enclosure,Figure 1-1.

The heater power supply, Figure 1-2, consists of amother board, daughter board, and a transformer forsupplying correct voltage to the probe heater. Themother and daughter boards contain terminal strips forconnecting probe, electronics, and power supply.

The HPS is jumper configurable for 120, 220, or 240Vac. For 100 Vac usage, the HPS is factory-suppliedwith a special transformer. The 100 Vac transformercan also be easily field installed. Refer to paragraph3-3, Transformer Replacement for installationprocedure; refer to Table 4-1, for transformer partnumbers.

Figure 1-1. HPS 3000 Heater Power Supply Field Module


1-2

Figure 1-2. Heater Power Supply, Interior


1-3

Table 1-1. Specifications for Heater Power Supply.

Environmental Classification ........................................................................ NEMA 4X (IP56) Optional - Class 1, Division 1, Group B (IP56

Electrical Classification ................................................................................ Category IIHumidity Range ............................................................................................ 95% Relative HumidityAmbient Temperature Range ....................................................................... -20° to 140°F (-30° to 60°C)Vibration ....................................................................................................... 5 m/sec2, 10 to 500 xyz planeCabling Distance Between HPS 3000 and Probe ......................................... Maximum 150 feet (45 m)Cabling Distance Between HPS 3000 and CRE 3000.................................. Maximum 1200 feet (364 m)Cabling Distance Between HPS 3000 and IFT 3000 ................................... Maximum 1200 feet (364 m)Approximate Shipping Weight...................................................................... 12 pounds (5.4 kg)

1-2. THEORY OF OPERATION. The HPS 3000Heater Power Supply may perform slightly differentfunctions, depending upon which electronics package itis used with. Figure 1-3 shows a functional blockdiagram of the unit. The HPS contains a transformer forconverting line voltage to 44 volts needed to power theprobe heater. The relay, Figure 1-3, can be used toremotely turn the probe on or off manually. A triacmodule is used to turn the heater on or off, dependingon probe temperature.

When used with the CRE 3000 Control RoomElectronics or IFT 3000 Intelligent Field Transmitter,the HPS uses a cold junction temperature compensationfeature. This allows for the use of a less expensive

cable between the HPS and CRE or HPS and IFT. TheHPS and electronics package can be located up to 1200feet (364 m) apart.

The standard cable, between probe and HPS, isthermocouple compensated. This prevents theadditional junctions between thermocouple and cablefrom producing a voltage which would affect thethermocouple output signal. A temperature sensor inthe HPS monitors the temperature at the junction andsends a voltage signal to the CRE and IFT. The CREand IFT uses this signal to compensate the probethermocouple reading for the temperature at thejunction between the compensated and uncompensatedcables.

TO HEATER

PROBE TC

STACK TC

CELL

LINE

RELAY

TRIAC

AD590

PROBE TC

STACK TC

CELL MV

FROMIFT

TOPROBE

686015

Figure 1-3. Heater Power Supply Block Diagram


1-4

In operation, when connected to the CRE 3000 ControlRoom Electronics, line voltage passes through the relay(when on) and is converted into 44 volts by thetransformer. If the probe thermocouple indicates thatthe probe has dropped below operating temperature, asignal from the CRE triggers the triac. The triac thensupplies voltage to the probe heater, warming the cell.Conversely, if the probe thermocouple indicates thatthe probe heater has reached the upper limit ofoperating temperature, the CRE deactivates the triac,shutting off power to the heater.

NOTE

When using the HPS 3000 with an existingelectronics package, such as Models 218,218A, 225, or TC200, the electronics will nothave the input/output capacity to support allof the functions mentioned in this section.Refer to Instruction Bulletin IB-106-300NE.


2-1

SECTION II. HPS 3000 TROUBLESHOOTING

2-1. OVERVIEW. The HPS 3000 troubleshooting sectiondescribes how to identify and isolate faults which maydevelop in the HPS 3000 assembly.


2-2. HPS 3000 TROUBLESHOOTING. The HPS 3000troubleshooting may overlap with the probe in use in thesystem. Faults in either system may cause an error to bedisplayed in the electronics package. Figures 3-1, 3-2, and 3-3provide troubleshooting information.


2-2

Figure 2-1. HPS Troubleshooting Flowchart, #1


2-3



2-4



3-1


3-1. OVERVIEW. This section describes service androutine maintenance of the HPS 3000 Heater PowerSupply Field Module. Replacement parts referred to areavailable from Rosemount. Refer to Section IV of thismanual for part numbers and ordering information.

Install all protective equipment covers andsafety ground leads after equipment repair orservice. Failure to install covers and groundleads could result in serious injury or death.

3-2. FUSE REPLACEMENT. The heater power supplymother board (12, Figure 3-1) contains four identical 5amp fuses. Refer to Table 4-1 for replacement fusespecifications. To check or replace a fuse, simplyunscrew the top of the fuseholder with a flat headscrewdriver and remove fuse. After checking orreplacing a fuse, reinstall fuseholder top.

3-3. TRANSFORMER REPLACEMENT.


a. Turn off power to system.

b. Loosen captive screws retaining HPS cover.Remove cover.

c. Remove hex nut (25, Figure 3-1) from top oftransformer assembly. Remove retaining plate (24)and gasket (22).

d. Disconnect transformer harness plug from motherboard.

e. Remove old transformer. Place new transformer inposition and reconnect harness plug as noted instep d.

f. Place gasket and retaining plate on transformer.

g. Tighten hex nut only enough to firmly holdtransformer in place.

h. Reinstall HPS cover.

3-4. MOTHER BOARD REPLACEMENT.




c. Remove hex nut (25, Figure 3-1) from top oftransformer assembly. Remove retaining plate (24)and gasket (22).

d. Disconnect transformer harness plug from motherboard.

e. Remove screws on either side of terminal stripcovers (2). Remove terminal strip covers (4 and 8).

f. Unplug ribbon cable from the receptacle on thedaughter board (7).

g. Unscrew stand offs on either side of the daughterboard. Remove daughter board (7).

h. Unscrew four stand offs that supported the daughterboard.

i. Making a note of the location and color of eachwire, disconnect wires from terminal strip onmother board.

j. Remove four screws (9) holding mother board tostand offs (10) on subplate (14).

k. Remove mother board (12).


3-2

l. Position new mother board on stand offs andreinstall screws removed in step j.

m. Reconnect wires to terminal strip in positions notedin step i.

n. Reinstall four stand offs removed in step h. Positiondaughter board on stand offs and reinstall stand offsremoved in step g.

o. Plug ribbon cable back into receptacle on daughterboard. Reinstall terminal covers.

p. Reinstall transformer, tightening hex nut onlyenough to hold transformer firmly in position.Reconnect transformer harness plug to motherboard.

q. Reinstall HPS cover.

3-5. DAUGHTER BOARD REPLACEMENT .

When turning power off at the HPS, also turnoff the respective probe at associatedelectronics. When service on the HPS iscompleted, restore power at the HPS and theassociated electronics.



c. Remove screws on either side of terminal stripcovers (2, Figure 3-1). Remove terminal stripcovers (4 and 8).

d. Making a note of the location and color of eachwire, disconnect wires from the terminal strip on thedaughter board (7).

e. Unplug ribbon cable from receptacle on daughterboard.

f. Unscrew two stand offs from daughter board.Remove daughter board (7).

g. Position new daughter board on four stand offs onmother board. Reinstall the stand offs removed instep f.

h. Plug ribbon cable into receptacle on daughterboard.

i. Reconnect wires to terminal strip in positions notedin step d. Reinstall terminal covers.

j. Reinstall HPS cover.

LEGEND FOR FIGURE 3-1.

1.2.3.4.5.6.7.8.9.

10.11.12.13.

Enclosure CoverScrewLockwasherTerminal CoverStand OffLockwasherDaughter BoardTerminal CoverScrewStand OffHex NutMother BoardFuse

14.15.16.17.18.19.20.21.22.23.24.25.

SubplateEnclosure BoxLockwasherStand OffScrewLockwasherMounting PlateScrewGasketTransformerRetaining PlateHex Nut


3-3/3-4

Figure 3-1. Heater Power Supply, Exploded View


4-1/4-2


Table 4-1. Replacement Parts for Heater Power Supply.

FIGURE and INDEX NO. PART NUMBER DESCRIPTION

1-11-11-11-11-11-13-1, 13

3-1, 123-1, 73-1, 233-1, 23

3D39129G013D39129G023D39129G031U05667G011U05667G021U05667G031L01293H02

3D39080G023D39078G011M02961G011M02961G02

Non-Hazardous HPS (120 Vac)Non-Hazardous HPS (100 Vac)Non-Hazardous HPS (220, 240 Vac)Explosion-Proof HPS (120 Vac)Explosion-Proof HPS (100 Vac)Explosion-Proof HPS (220, 240 Vac)Fuse, 5A @ 250 Vac, anti-surge, casesize; 5 x 20 mm, type T to IEC127,SchurterMother BoardDaughter BoardTransformer (120, 220, 240 Vac)Transformer (100 Vac)

APPENDIX D, REV. 2.4MPS 3000MULTIPROBE CALIBRATIONGAS SEQUENCER

Instruction Bulletin IB-106-300N SERIESInstruction Bulletin IB-106-101N SERIESInstruction Bulletin IB-106-107 SERIES

APPENDIX D


Effective June, 1994 Rev. 2

PAGE SUMMARY

i

1-1

1-2

1-3

1-4

3-1

3-2

3-4

4-1

Add title for paragraph 3-7, Adding Probes to the MPS, to Section III. Add title for Figure 1-4, MPSwith Z-Purge, to List of Illustrations.

MPS outline drawing changed to show new MPS.

MPS interior view replaced with new MPS in Figure 1-2.

"Optional" for check valve deleted in Figure 1-3.

Drawing showing location of optional Z-Purge added as Figure 1-4.

Power supply replacement procedures in paragraph 3-3 changed to reflect new design in the MPS.Solenoid valve replacement procedures in paragraph 3-4 changed to reflect new design in the MPS.

Old exploded view of MPS replaced with new MPS.

Paragraph 3-7, Adding Probes to the new MPS, added.

Change part numbers for the power supply, solenoid valve, and test gas flowmeter assembly. Add partnumbers for reference gas flowmeter assembly and all the parts in the probe adder kit.


PAGE SUMMARY

1-1 Updated Figure 1-1, MPS 3000 to include hinge.

Effective May, 1996 Rev. 2.2

PAGE SUMMARY

4-1/4-2 Updated replacement parts list to reflect new part numbers.


PAGE SUMMARY

Front matter

1-1

1-2

2-1

3-1

4-1

Added “Safety instructions for the wiring and installation of this apparatus”.


Corrected Table 1-1 Specifications listing, 1st entry.


Added protective covers and grounds warning, corrected item number errors in paragraph 3-2.

Added expanded fuse descriptions.


PAGE SUMMARY

--- Changed test gas to calibration gas and reference gas to reference air throughout the appendix.

APPENDIX DIB-106-300N SERIESIB-106-101N SERIESIB-106-107 SERIES

i/ii

TABLE OF CONTENTSSection Page

I DESCRIPTION .................................................................................................................................. 1-11-1. Description............................................................................................................................... 1-11-2. Theory of Operation................................................................................................................. 1-1

II MPS 3000 TROUBLESHOOTING ............................................................................................... 2-12-1. Overview.................................................................................................................................. 2-12-2. Troubleshooting ....................................................................................................................... 2-1

III SERVICE AND NORMAL MAINTENANCE ........................................................................... 3-13-1. Overview.................................................................................................................................. 3-13-2. Fuse Replacement .................................................................................................................... 3-13-3. Power Supply Replacement ..................................................................................................... 3-13-4. Solenoid Valve Replacement................................................................................................... 3-13-5. Pressure Regulator Maintenance .............................................................................................3-33-6. Flowmeter Adjustments ........................................................................................................... 3-43-7. Adding Probes to the MPS ...................................................................................................... 3-4

IV REPLACEMENT PARTS ............................................................................................................... 4-1


Figure Page

1-1 MPS 3000 Multiprobe Calibration Gas Sequencer............................................................................. 1-11-2 Multiprobe Calibration Gas Sequencer, Interior ................................................................................. 1-21-3 Typical Automatic Calibration System................................................................................................ 1-31-4 MPS with Z-Purge ............................................................................................................................... 1-42-1 MPS Troubleshooting Flowchart......................................................................................................... 2-23-1 Multiprobe Calibration Gas Sequencer, Exploded View.................................................................... 3-2


1-1



1-1. DESCRIPTION. The Rosemount MPS 3000Multiprobe Calibration Gas Sequencer providesautomatic calibration gas sequencing for up to fourprobes. The MPS routes calibration gas to the selectedprobe under control of the CRE, IFT, or digitalelectronics package. The electronics package can bepreprogrammed by the user for automatic periodicrecalibration, or manually initiated calibration throughthe keypad on the front of the electronics package. Thecalibration parameters held in the electronics packagecan be selected to automatically update after eachcalibration.

The MPS is housed in a NEMA 4X (IP56)non-hazardous enclosure, Figure 1-1.

NOTE

A single multichannel MPS cannot be sharedamong a number of CRE electronics.

The MPS, Figure 1-2, consists of: an air pressureregulator, a terminal board, a flowmeter assembly (onefor 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 forhazardous area classification. See Application DataBulletin AD 106-300B.

Figure 1-1. MPS 3000Multiprobe Calibration Gas Sequencer

1-2. THEORY OF OPERATION. A typical automaticcalibration setup is shown in Figure 1-3. The MPS3000 Multiprobe Calibration Gas Sequencer operatesunder the control of the CRE, IFT, or digital electronicspackage. When the electronics package initializesautomatic calibration, the solenoid controlling theselected probe is energized. Next, the solenoidcontrolling calibration gas 1 (high O2) energizesallowing calibration gas 1 to flow to that probe. Afterthe probe measures the oxygen concentration ofcalibration gas 1, the gas solenoid is deenergized. Anoperator selected time delay allows the gas to clear thesystem. Next, the solenoid controlling calibration gas 2(low O2) energizes and allows calibration gas 2 to flowto the probe. After the probe measures the oxygenconcentration of calibration gas 2, the gas and probesolenoids deenergize. The automatic calibration is nowcomplete for the probe selected.


1-2

POWERSUPPLY

REGULATOR

TUBE

SOLENOID MANIFOLD HOSEADAPTER

CABLEGRIP

TERMINATIONBOARD

FLOWMETER

Figure 1-2. Multiprobe Calibration Gas Sequencer, Interior

Table 1-1. Specifications for Multiprobe Calibration Gas Sequencer.

Environmental Classification...................................................................... NEMA 4X (IP56)Humidity Range .......................................................................................... 95% Relative HumidityAmbient Temperature Range...................................................................... -20° to 160°F (-30° to 71°C)Vibration...................................................................................................... 5 m/sec2, 10 to 500 xyz planeExternal Electrical Noise ............................................................................ Minimum InterferencePiping Distance Between MPS 3000 and Probe ........................................ Maximum 300 feet (91 m)Cabling Distance Between MPS 3000 and Electronics Package ............... Maximum 1000 feet (303 m)In Calibration Status Relay ......................................................................... 48V max, 100 mA maxCabling Distance Between MPS 3000 and Status Relay Indicator ............ Maximum 1000 feet (303 m)Approximate Shipping Weight ................................................................... 35 pounds (16 kg)


1-3

CALIBRATIONGAS 1

(HIGH O )2

CALIBRATIONGAS 2

(LOW O )2

PROBE(END VIEW)

ELECTRONICPACKAGE

CALIBRATION GAS

CHECKVALVE

PROBESIGNAL CONNECTIONS

MPS ELECTRONICSPACKAGE SIGNALCONNECTIONS

NOTE: THE MPS CAN BE USED WITH UPTO FOUR PROBES AND FOURELECTRONIC PACKAGES. ONLYONE PROBE CAN BE CALIBRATEDAT A TIME. PROBE CALIBRATIONSMUST BE SCHEDULED IN MULTIPLEPROBE APPLICATIONS.

MPS

INSTRUMENTAIR IN

REFERENCEAIR

27270022

Figure 1-3. Typical Automatic Calibration System


1-4

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Figure 1-4. MPS with Z-Purge


2-1

SECTION II. MPS 3000 TROUBLESHOOTING

2-1. OVERVIEW. This section describes troubleshootingfor the Multiprobe Calibration Gas Sequencer.Additional troubleshooting information can be found inthe Instruction Bulletin for the electronics package.


2-2. TROUBLESHOOTING. Table 2-1 provides a guideto fault finding failures within the MPS. The flowchartin Figure 2-1 provides an alternate approach to faultfinding MPS related problems.

Table 2-1. Fault Finding.


1. Power to solenoid,calibration gas notreleased to probe.

Calibration gas

Solenoid

Insufficient calibrationgas

Solenoid failure

Install new calibration gastanks.

Replace solenoid.

2. No power tosolenoid.

Power supply output

Fuses in power supply

Main power source

Power supply failure

Fuse blown

Main power off

Replace power supply.

Replace fuse.

Reestablish power.


2-2

YES YES

NO NO

SYMPTOM

SOLENOID ISOPERATING NORMALLY.

ENSURE THAT ASUFFICIENT SUPPLY OFCALIBRATION GAS ISAVAILABLE.

CALL FOR FACTORYASSISTANCE.

SET METER* FOR 50 VDC.PLACE PROBES ONTERMINAL BLOCK J2, CALRET, AND J1 HI GAS.

INSTALL NEW CALIBRATIONGAS BOTTLES.

SOLENOID IS RECEIVING24 VDC.

YESREPLACE SOLENOID.

NO

PLACE PROBES FROMMETER ON J11.

METER INDICATES24 VDC.

YES REPLACE TERMINALBOARD.

NO

FUSES BLOWN IN MPS.NO

PLACE PROBES FROMMETER ON J1, LINE 1,AND LINE 2. SET METERFOR 200 VAC.

YES

REPLACE BLOWN FUSES.METER INDICATES 110VAC AT J1.

YESREPLACE POWER SUPPLY.

NO

CHECK MAIN POWERSOURCE.

*SIMPSON MODEL 260 OREQUIVALENT MULTIMETER. 27270023

Figure 2-1. MPS Troubleshooting Flowchart


3-1


3-1. OVERVIEW. This section describes service androutine maintenance of the MPS 3000 MultiprobeCalibration Gas Sequencer. Replacement partsreferred to are available from Rosemount. Refer toTable 4-1 for part numbers and ordering information.

Install all protective equipment covers andsafety ground leads after equipment repairor service. Failure to install covers andground leads could result in serious injuryor death.

3-2. FUSE REPLACEMENT. Power supply (58,Figure 3-1) contains two identical 1 amp fuses (3).Perform the following procedure to check or replacea fuse.

Disconnect and lock out power beforeworking on any electrical components.

a. Turn off power to the system.

b. Unscrew top of fuseholder (40) and remove thefuse. Refer to Table 4-1 for replacement fusespecifications. After checking or replacing afuse, reinstall top of fuseholder.

3-3. POWER SUPPLY REPLACEMENT.



b. Loosen two captive screws holding the MPScover (15, Figure 3-1). Open the MPS cover.

c. Loosen two captive screws holding the innercover (16). Lower the inner cover.

d. Disconnect the 24V connector from J11 on thetermination board (34).

e. Remove two screws (39) and washers (38)holding the terminal cover (37). Remove theterminal cover.

f. Tag and remove wires from terminals 1 and 4 or5 of the transformer in the power supply (58).

g. Remove two nuts (60) and washers (59) from thescrews holding the power supply (58). Removethe power supply.

h. Mount the new power supply onto the screwswith two nuts (60) and washers (59). Make surethe ground wires are connected to the uppermounting screw.

i. Reconnect the wires removed in step f.

j. Install the terminal cover (37) with two screws(38) and washers (39).

k. Connect the 24V connector to J11 on thetermination board (34).

l. Close and secure the inner cover (16) with twocaptive screws. Close and secure the outer cover(15) with two captive screws.

3-4. SOLENOID VALVE REPLACEMENT. AnMPS 3000 will always have a HI GAS solenoid (63,Figure 3-1) and a LOW GAS solenoid (64) mountedto the manifold (11). Each probe will also have asolenoid valve (9) mounted on the manifold.



b. Loosen two captive screws holding the MPScover (15, Figure 3-1). Open the MPS cover.

c. Loosen two captive screws holding the innercover (16). Lower the inner cover.

d. Disconnect the HI GAS (J17), LOW GAS (J18),or Probe (J13-J16) plug from its receptacle onthe termination board (34).


3-2

49

49

50

53

5341

31

54

14

34

54

1

17

16

18

15

26

2742

48 46

42

40

30

30

22

35

36

37

21

32

4

33

5857

5960

56

21

44

45

19

20

42

51

43

52

47

62

61

55

2

3

3839

2524

23

28

29

5

63

64

67

98

1312

11

10

Figure 3-1. Multiprobe Calibration Gas Sequencer, Exploded View


3-3

LEGEND FOR FIGURE 3-1

ITEM DESCRIPTION1 Enclosure2 Screw3 Plug4 Cable Grip5 Fitting6 Hose Adapter7 Pressure Switch8 Plug9 Solenoid Valve

10 Screw11 Manifold12 Washer13 Screw14 Gasket15 Outer Cover16 Inner Cover17 Flowmeter, 10 SCFH18 Flowmeter, 2.0 SCFH19 Bracket20 Screw21 Hose Adapter22 1/8 in. Hose

ITEM DESCRIPTION23 Nut24 Lockwasher25 Washer26 Washer27 Screw28 Nut29 Washer30 Washer31 Cover Stop Slide32 Screw33 Washer34 Termination Board35 Standoff36 Mounting Bracket37 Cover Plate38 Washer39 Screw40 Fuseholder41 Plastic Nut42 Bushing43 Pressure Gauge44 Bolt

ITEM DESCRIPTION45 Washer46 Drain Valve47 1/8 in. Impolene Tubing48 Connector49 Elbow50 Pressure Regulator51 Hose Adapter52 1/4 in. Tube53 Screw54 Washer55 Inner Enclosure56 Washer57 Screw58 Power Supply59 Washer60 Nut61 Screw62 Washer63 Solenoid64 Solenoid

e. Loosen the retaining ring in the middle of thesolenoid and remove the top part.

f. With a spanner wrench or padded pliers, removethe remaining part of the solenoid from themanifold (11).

g. Separate the new solenoid and screw the smallerpart into the manifold.

h. Place the top part of the solenoid into position andtighten the retaining ring.

i. Connect the plug to the proper receptacle on thetermination board (34).

j. Close and secure the inner cover (16) with twocaptive screws. Close and secure the outer cover(15) with two captive screws.

3-5. PRESSURE REGULATOR MAINTENANCE.

a. Pressure Adjustments. Pressure regulator (50,Figure 3-1) is factory set to 20 psi (138 kPa).Should the pressure need to be changed oradjusted, use the knob on top of the pressureregulator.

b. Condensation Drain. To drain excess moisturefrom the internal gas circuit of the MPS,periodically loosen drain valve (46) on the bottomof pressure regulator (50). The moisture will flowthrough vinyl tubing drain (47) on the bottom ofpressure regulator (50) and exit the bottom of MPSenclosure (1).


3-4

3-6. FLOWMETER ADJUSTMENTS. There are twoflowmeters per flowmeter assembly. The top flowmeteris factory set to 5 scfh. The bottom flowmeter is set to2 scfh. Should the flow need to be changed or adjusted,use knob on the bottom of the respective flowmeter.

3-7. ADDING PROBES TO THE MPS. Thisprocedure is used to add a probe to the MPS.



b. Loosen the two captive screws holding the MPScover (15). Lift the cover.

c. Loosen the two captive screws that hold the innercover (16) and lower the cover.

d. From the backside of the inner cover, locate theflowmeter positions next to the existing unit(s).Insert a hacksaw blade into the slots surroundingthe positions for two flowmeters, and saw out theknockout tabs.

e. From the front of the inner cover, install aflowmeter (P/N 771B635H01) into the top holeand a flowmeter (P/N 771B635H02) into thebottom hole. From the backside secure withbrackets provided.

f. Remove four brass screw plugs (CAL GAS IN,CAL GAS OUT, REF AIR IN, and REF AIROUT) for the next probe position in the manifold.

g. Install 1/8" hose adapters (P/N 1A97553H01) intothe empty holes using a suitable pipe dope. Attachthe tubing.

h. Remove a brass screw plug (P/N 1A97900H01)and install a solenoid (P/N 3D39435G01). Makesure the O-ring seals properly.

i. Attach the hoses to the flowmeter using theexisting installation as a guide. Support theflowmeter while attaching the hose.

j. Install the solenoid wire connector into the properposition (J14-J16) on the termination board (34).

k. Close and secure the inner cover (16) with twocaptive screws. Close and secure the outer cover(15) with two captive screws.


4-1/4-2


Table 4-1. Replacement Parts for the Multiprobe Test Gas Sequencer.


3-1, 13-1, 93-1, 40

3-1, 40

3-1, 73-1, 7

3-1, 17

1-3

1A97909H01*3D39435G01**138799-004

138799-014

771B635H01**771B635H02**1A986311A97953H01**4847B46H01**4847B46H02**4847B46H03**4847B46H04**7307A56G02

Power SupplySolenoid ValveFuse, fast acting, 1A @ 250 Vac, size: 1/4" Dia. x 1-1/4” Lg., glass

body, non time delay, Bussman part no. BK/AGC-1Fuse, 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-1/2Flowmeter Assembly - Calibration GasFlowmeter Assembly - Reference AirProbe Adder KitHose AdapterTubing LengthTubing LengthTubing LengthTubing LengthCheck Valve

* Specify line voltage and probe type when ordering.** These items are included in the probe adder kit.

APPENDIX E, REV. 4.4IFT 3000INTELLIGENT FIELDTRANSMITTER

Instruction Bulletin IB-106-300N SERIESInstruction Bulletin IB-106-101N SERIES

APPENDIX EIB-106-300N SERIESIB-106-101N SERIES



PAGE SUMMARY

--- General. Updated text and illustrations to reflect new version of IFT.

2-1 Updated IFT display status codes and placed in priority sequence.


PAGE SUMMARY

1-2 Updated specification table.


PAGE SUMMARY

2-1 Added new status displays for password protection features.


PAGE SUMMARY

Front matter

1-1

1-2

2-1

3-1

4-1

Added "Safety instructions for the wiring and installation of this apparatus"

Added warning to read new safety instructions

Deleted NOTE

Added protective covers and grounds warning

Added protective covers and grounds warning

Added expanded fuse description


PAGE SUMMARY

--- Changed test gas to calibration gas throughout the appendix.


i/ii

TABLE OF CONTENTS

Section Page

I. DESCRIPTION .................................................................................................................................. 1-11-1. Description............................................................................................................................... 1-11-2. Theory of Operation................................................................................................................. 1-2

II. IFT 3000 TROUBLESHOOTING ................................................................................................. 2-12-1. Overview.................................................................................................................................. 2-12-2. IFT Troubleshooting................................................................................................................ 2-1

III. SERVICE AND NORMAL MAINTENANCE ........................................................................... 3-13-1. Overview.................................................................................................................................. 3-13-2. Fuse Replacement .................................................................................................................... 3-13-3. Transformer Replacement........................................................................................................ 3-23-4. Power Supply Board Replacement .......................................................................................... 3-23-5. Microprocessor Board Replacement ....................................................................................... 3-33-6. Interconnect Board Replacement.............................................................................................3-43-7. GUI Assembly Replacement.................................................................................................... 3-43-8. Heater/Fan/Thermostat Replacement ...................................................................................... 3-5



Figure Page

1-1 IFT 3000 Intelligent Field Transmitter ................................................................................................ 1-11-2 System Block Diagram ........................................................................................................................ 1-32-1 IFT Troubleshooting Flowchart, #1..................................................................................................... 2-22-2 IFT Troubleshooting Flowchart, #2..................................................................................................... 2-32-3 IFT Troubleshooting Flowchart, #3..................................................................................................... 2-33-1 Intelligent Field Transmitter, Exploded View..................................................................................... 3-13-2 Replacing the GUI Assembly .............................................................................................................. 3-43-3 IFT with Heater Option........................................................................................................................ 3-7


1-1



1-1. DESCRIPTION. The Rosemount IFT 3000Intelligent Field Transmitter (IFT), Figure 1-1,provides all necessary intelligence for controlling aprobe and the optional Multiprobe Calibration GasSequencer. The IFT provides a user-friendly,menu-driven operator interface with context-sensitive,on-line help. The IFT may also be used without anHPS.

The IFT is based on a modular design. There is amaximum total of four PC boards within the IFT. EveryIFT contains a microprocessor board, a power supplyboard, and an interconnect board. In addition to theseboards, deluxe version IFTs also contain a GeneralUser Interface/LED display board.

IFTs with no displays are known as "blind" units. BlindIFTs also lack a General User Interface (GUI) and mustbe controlled with an external HART communicationsdevice.

a. Microprocessor Board. The microprocessorboard contains, EEPROM, RAM, and a real-timeclock. The microprocessor board also controls theprobe heater. The IFT can be used in conjunctionwith or without an optional HPS 3000 HeaterPower Supply providing power to the heaterdepending upon the user's application.

Figure 1-1. IFT 3000 Intelligent Field Transmitter

b. Interconnect Board. The interconnect board isused for all communications from the IFT to theother components within the system. These othercomponents may include an optional HPS 3000Heater Power Supply, optional MPS MultiprobeCalibration Gas Sequencer, World Class 3000Probe (non-HPS equipped system), analog output,and relay outputs.

c. Power Supply Board. The power supply board isuser configurable for five different line voltages toinclude 100, 120, 220, and 240 Vac. In addition,the output voltage for a probe heater is alsoconfigurable if used in a non-HPS equippedsystem.

d. GUI/LED Display Board (Optional) . TheGUI/LED display board, which is part of the GUIassembly, has a 4-line by 20-character liquidcrystal display and eight membrane keys. Theboard also contains an LED display whichindicates the current O2 value. The LED displayhas indicator LEDs for calibration gas high(TGH), calibration gas low (TGL) and calibrating(CAL).

e. Heater (optional). A heater is available forambient conditions below 32°F (0°C).

f. Z-Purge (optional). A Z-purge arrangement isavailable for applications requiring hazardous areaclassification. See Application Data Bulletin AD106-300B.


1-2

1-2. THEORY OF OPERATION. A functional blockdiagram of the IFT, connected to the HPS and probe, isshown in Figure 1-2. In operation, the IFT monitors thetemperature of the cell by means of the probethermocouple. The IFT controls the temperature of thecell. If the temperature of the cell becomes too high, theIFT will disable the HPS.

A cold junction temperature compensation featureensures an accurate probe thermocouple reading. Atemperature sensor in the heater power supply monitors

the temperature at the junction between thecompensated cable running to the probe and theuncompensated cable running to the IFT. The voltagefrom this sensor is used by the IFT to compensate theprobe thermocouple readings for the temperature at thejunction.

The cell signal is a voltage proportional to the oxygenconcentration difference between the two sides of thecell. The IFT receives this signal and translates it into auser-specified form for display and/or output.

Table 1-1. Specifications for Intelligent Field Transmitter.

Environmental Classification................................ NEMA 4X (IP56)Humidity Range .................................................... 95% Relative HumidityAmbient Temperature Range................................ -20° to 122°F (-30° to 50°C)Vibration................................................................ 5 m/sec2, 10 to 500 xyz planeElectrical Noise Immunity Standard..................... EN 50 082-1Electrical Noise Radiated Emission Standard ...... EN 55 011Installation Category ............................................. Overvoltage Category II (IEC 664)HART Communications ...................................... Modulated on a 4-20 mA analog output, onlyAnalog Outputs ..................................................... isolated, 0-20 mA, 4-20 mA, 0-10 V, 20-0 mA, 20-4 mA, or 10-0 V outputO2 Accuracy (analog output)................................. 0.1% O2 or ±3% of reading, whichever is greater using Hagan calibration

gasesO2 Range ............................................................... Field Selectable 0-40% (linear or logarithmic)Power Supply ........................................................ 100/120/220/240 ±10% Vac at 50/60 Hz.Power Requirements ............................................. (w/HPS 3000): 30 Watts (VA); (w/Model 218 Probe): 275 VA

(w/WC 3000 Probe): 275 Watts (VA)Output Resolution ................................................. 11 bits (1 bit = 0.05% of output F.S.)System Speed of Response (amplifier output)...... less than 3 secondsResolution Sensitivity - Transmitted Signal ......... 0.01% O2

Deadman Contact Output...................................... Form-C, 48 Volt max, 100 mA maxProgrammable Contact Outputs............................ 2 available, Form-C, 48 V max, 100 mA maxGUI/LED Display Board (optional) ..................... 1, with 0.8 in. (20 mm) high, 3-character, alphanumeric LED display

4-line by 20-character backlight LCD alpha-numeric display; 8-keygeneral purpose keyboard, or HART device

Approximate Shipping Weight ............................. 25 lbs (11 kg)


1-3/1-4

PROBE

ZEROCROSSINGDETECTOR

TRIACRELAYTO HEATER

COLDJUNCTION

TEMP.PROBE TC

STACK TC

CELL

LINE

RELAY

TRIAC

AD590

PROBE TC

STACK TC

CELL MV

HEATER POWER SUPPLY(OPTIONAL)

IFT

TRANSFORMER

19280014

Figure 1-2. System Block Diagram


2-1

SECTION II. IFT 3000 TROUBLESHOOTING

2-1. OVERVIEW. The IFT troubleshooting sectiondescribes how to identify and isolate faults which maydevelop in the IFT.

Install all protective equipment covers andsafety ground leads after troubleshooting. Failure to replace covers and ground leadscould result in serious injury or death.

2-2. IFT TROUBLESHOOTING. IFT troubleshooting isachieved by determining the functional status of themicroprocessor board and interpreting status displayson the front panel.

a. Microprocessor Status LED. The microprocessorboard includes an LED to aid in isolatingequipment faults. LED indications are as follows:

1. LED OFF. IFT failure, or power is removed;refer to Troubleshooting Flowchart #1 (Figure2-1).

2. LED ON - STEADY. Heater system failure;refer to Troubleshooting Flowchart #2 (Figure2-2).

3. LED ON - FLASHING. Microprocessornormal.

b. Equipment Status (LCD) Displays. The statusline of the GUI equipped IFT will display onesystem status display (one at a time) in prioritysequence, as indicated in the following list. Totroubleshoot an equipment fault, refer toCOMPONENT FAILURE indications applicableto the display message (SYMPTOM) in Table 2-1.

1. Off - The probe has been turned off becausethe IFT cannot control the heater temperature.

2. Param - IFT has been unlocked using theuser’s password.

3. Serv - IFT has been unlocked using theservice password.

4. PrbEr - The probe is disconnected, cold, orleads are reversed.

5. HtrEr - If HtrEr is displayed, there is a faultwithin the heater system.

6. InCal - If InCal is displayed, the system iscurrently undergoing calibration.

7. LowO2 - If LowO2 is displayed, the O2 valueis below the low alarm limit.

8. HiO2 - If HiO2 is displayed, the O2 value isabove the high alarm limit.

9. NoGas - If NoGas is displayed, there is nocalibration gas pressure.

10. CalEr - If CalEr is displayed, an error wasdetected during the calibration process.

11. ResHi - If ResHi is displayed, the cellresistance is above the high limit.

12. OK - If OK is displayed, the system isoperating normally.


2-2

Figure 2-1. IFT Troubleshooting Flowchart, #1


2-3

YES

YES

OXYGEN ANALYZERSYSTEM IS EQUIPPEDWITH HPS 3000.

CHECK JUMPERS JM6 ONMICROPROCESSOR BOARDAND JM1 ON INTERCONNECTBOARD ARE INSTALLED.CHECK JUMPERS 9OR 10 ON POWERSUPPLY BOARD FOR COR-RECT CONFIGURATIONS.

REFER TO PROBETROUBLESHOOTING,APPENDIX A, SECTION 2.

CHECK THAT JUMPERSJM6 ON MICROPROCESSORBOARD AND JM1 ONINTERCONNECT BOARDARE REMOVED.

REFER TO APPENDIX B,SECTION 2, FORJUMPER LOCATIONS.

DISCONNECT POWERAND INSTALL JUMPERSCORRECTLY. REFER TOFIGURE 2-5 OF MAIN IBSECTION.

NO

NO

SYMPTOM - MICROPROCESSOR BOARD LED IS STEADY ON

27270021


END OF FLOWCHART #2

SYMPTOM - GENERAL USER INTERFACE ORLED DISPLAY PANEL DOES NOT FUNCTION

REPLACE GUI BOARD.

STILL NOT FUNCTIONING.CALL FACTORY FORASSISTANCE.

27270020



2-4

Table 2-1. GUI Equipped IFT Fault Finding.

SYMPTOM COMPONENT FAILURE

1. Display is blank.

2. CalEr is displayed.

3. HtrEr is displayed.

4. NoGas is displayed.

*5. HiO2 is displayed.

*6. LowO2 is displayed.

7. ResHi is displayed.

8. Off

9. PrbEr

Possible failure within IFT. Check LED on microprocessor board.

Repeat calibration sequence. If error persists, troubleshoot major components.

Ensure jumpers are set correctly on IFT. If system is equipped with HPS refer toAppendix B, Section II, for additional troubleshooting procedures.

Possible failure within the MPS. Refer to Appendix D, Section II, for additionaltroubleshooting procedures.

Possible failure within the probe. Ensure the high alarm level has been enteredcorrectly. Refer to Appendix A, Section II, for additional troubleshootingprocedures.

Possible failure within the probe. Ensure the low alarm parameter has been enteredcorrectly. Refer to Appendix A, Section II, for additional troubleshootingprocedures.

Cell resistance has exceeded upper limit. Ensure resistance value has been enteredcorrectly. Refer to Appendix A, Section II, for additional troubleshootingprocedures.

The probe has been turned OFF because the IFT cannot control the heatertemperature.

The probe is disconnected, cold, or leads are reversed.

*HiO2 and LowO2 can occur in the system without system failure.


3-1


3-1. OVERVIEW. This section describes service androutine maintenance of the Intelligent FieldTransmitter. Replacement parts referred to are availablefrom Rosemount. Refer to Section IV for part numbersand ordering information.

Install all protective equipment covers andsafety ground leads after equipment repairor service. Failure to install covers andground leads could result in serious injury ordeath.

3-2. FUSE REPLACEMENT. Power supply board (4,Figure 3-1) contains four identical 5 amp fuses.

Perform the following procedure to check or replace afuse. In addition, 2 additional 5 amp fuses (F1 and F2)are included if the IFT unit has an internal heaterinstalled.

Disconnect and lock out power beforeworking on any electrical components. Thereis voltage up to 240 Vac, and could causepersonal injury.


b. Open cover door (16) of the IFT by removingscrews (17).

1

2

3 4

6

5

7

11

10

9 8

219

12

2

3

1415

18

1316

17

21

20

NOTE 1: NOT ALL PARTS SHOWN ARE AVAILABLE FOR PURCHASESEPARATELY. FOR A LIST OF AVAILABLE PARTS, SEE SECTION IV.

NOTE 2: NYLON WASHER (19) IS USED IN FIVE PLACES ONMICROPROCESSOR BOARD (11). LOCKWASHER (3) IS USED INFOUR PLACES ON BOARD (12) AND IN FIVE PLACES ON BOARD (4).

21240003

Figure 3-1. Intelligent Field Transmitter, Exploded View

1. Cable2. Machine Screw, M3 x 8 mm3. Lockwasher, 3 mm (Note 2)4. Power Supply Board5. Fuses, 5 Amp6. Enclosure7. Plug8. Machine Screw, M5 x 8 mm9. Transformer

10. Mounting Plate11. Microprocessor Board12. Interconnect Board13. Protective Cover14. Screw, M415. Washer16. Cover Door17. Screw, M418. Pin19. Nylon Washer (Note 2)20. O-Ring21. Nylon Washer


3-2

c. Remove protective cover (13) by removing screws(14) and washers (15).

d. Unscrew fuseholder top and remove the fuse (5).After checking or replacing a fuse, reinstall thefuseholder top.

e. Replace protective cover (13) and secure withwashers (15) and screws (14).

f. Close cover door (16) and secure with screws (17).

3-3. TRANSFORMER REPLACEMENT.




c. Remove protective cover (13) by removing screws(14) and washers (15).

d. Disconnect cable (1) from the receptacle onmicroprocessor board (11). Disconnect GUIassembly cable from receptacles onmicroprocessor board if IFT is equipped with GUI.

e. Carefully tagging wires, remove the wires fromterminal strip on interconnect board (12).

f. If unit is equipped with heater option, removethermoswitch assembly (18, 19, Figure 3-3) byremoving screws (13) and washers (14).

g. Remove mounting plate (10) by removing thenecessary screws.

h. Disconnect transformer cable plugs from thereceptacles on power supply board (4).

i. Remove transformer (9) from enclosure (6) byremoving four screws (8).

j. Attach new transformer to enclosure (6) with fourscrews (8).

k. Connect the transformer cable plugs fromtransformer (9) to the receptacles on power supplyboard (4).

l. Reinstall mounting plate (10) to enclosure (6) withthe necessary screws and washers.

m. If removed, replace thermoswitch assembly(18, 19, Figure 3-3) and secure with screws (13)and washers (14).

n. Reinstall the wires to the terminal strip oninterconnect board (12) as was noted in step e.

o. Connect cable (1) to the receptacle onmicroprocessor board (11). Reconnect GUIassembly cable to receptacles on microprocessorboard if IFT is equipped with GUI.

p. Replace protective cover (13) and secure withwashers (15) and screws (14).

q. Close cover door (16) and secure with screws(17).

3-4. POWER SUPPLY BOARD REPLACEMENT.




c. Remove protective cover (13) by removingscrews (14) and washers (15).


e. Carefully tagging wires, remove the wires fromterminal strip on interconnect board (12).

f. If unit is equipped with heater option, removethermoswitch assembly (18, 19, Figure 3-3) byremoving screws (13) and washers (14).


3-3

g. Remove mounting plate (10) by removing thenecessary screws.

h. If unit is equipped with heater option, disconnectplug from J2 on power supply board (4, Figure3-1) by squeezing tabs in and pulling connector up.

i. If unit is equipped with heater option, remove fanassembly (7, 10, Figure 3-3) by removing screws(5) and washers (6).

j. Disconnect the transformer cable plugs from thereceptacles on power supply board (4, Figure 3-1).

k. Carefully tagging wires, remove the wires fromterminal strips J5 and J6 on power supply board(4, Figure 3-1).

l. Remove power supply board (4) from enclosure(6) by removing screws (2) and washers (3).

m. Attach new power supply board (4) to enclosure(6) with screws (2) and washers (3).

n. Reconnect the wires as noted in step e.

o. Connect the transformer cable plugs fromtransformer (9) to the receptacles on power supplyboard (4).

p. If removed, install fan assembly(7, 10, Figure 3-3) and secure with screws (5)and washers (6).

q. If disconnected, reconnect plug to J2 on powersupply board (4, Figure 3-1).

r. If removed, replace thermoswitch assembly (18,19, Figure 3-3) and secure with screws (13) andwashers (14).

s. Reinstall mounting plate (10) to enclosure (6)using the necessary screws.

t. Reconnect the wires to interconnect board (12) asnoted in step e.

u. Connect cable (1) to the receptacle onmicroprocessor board (11). Reconnect GUIassembly cable to receptacles on microprocessorboard if IFT is equipped with GUI.

v. Replace protective cover (13) and secure withwashers (15) and screws (14).

w. Close cover door (16) and secure with screws (17).

3-5. MICROPROCESSOR BOARDREPLACEMENT.






e. Remove microprocessor board (11) by removingscrews (2) and nylon washers (19).

Pull up very carefully on the microprocessorboard to ensure that none of the pins in theconnection between the microprocessorboard and interconnect board are damaged.

f. Connect the new microprocessor board (11) to theinterconnect board (12) by carefully lining up thepins on the plug.

h. Attach microprocessor board (11) to mountingplate (10) with screws (2) and nylon washers (19).

i. Reconnect cable (1) to receptacle onmicroprocessor board. Reconnect GUI assemblycable to receptacles on microprocessor board ifIFT is equipped with GUI.

j. Replace protective cover (13) and secure withwashers (15) and screws (14).

k. Close cover door (16) and secure with screws (17).


3-4

3-6. INTERCONNECT BOARD REPLACEMENT.





d. Carefully tagging wires, remove the wires fromterminal strip on interconnect board (12).

e. Remove interconnect board (20) by removingscrews (2) and washers (3).

Pull down very carefully on the interconnectboard to ensure that none of the pins in theconnection between the microprocessorboard and interconnect board are damaged.

f. Connect new interconnect board (12) to themicroprocessor board by carefully lining up thepins on the plug.

g. Attach interconnect board (12) to mounting plate(10) with screws (2) and washers (3).

h. Reconnect wires to the terminal strip as noted instep d.

i. Replace protective cover (13) and secure withwashers (15) and screws (14).

j. Close cover door (16) and secure with screws (17).

3-7. GUI ASSEMBLY REPLACEMENT . Thesereplacement instructions are provided for GUIequipped systems. Refer to Figure 3-2.

ENTER

ESC

DATA

CAL

SETUP

HELP

NOTES:

1.

2.

GUI MOUNT AREA IS PART OF COVER DOOR.

GUI FACES INSIDE OF IFT ENCLOSURE WHENCOVER DOOR IS CLOSED.

3. NOT ALL PARTS SHOWN ARE AVAILABLE FORPURCHASE SEPARATELY. FOR A LIST OFAVAILABLE PARTS, SEE SECTION IV.

(SEENOTE 1)

12

3

4

56

21240001

1. Screw2. Washer3. GUI Assembly4. Cover Door5. Screw, M46. O-Ring

Figure 3-2. Replacing the GUI Assembly



b. Open cover door (43, Figure 3-2) of the IFT byremoving screws (5).

c. Disconnect GUI assembly cables frommicroprocessor board (11, Figure 3-1).

e. Remove GUI assembly (3, Figure 3-2) byremoving screws (1) and washers (2).

f. Attach new GUI assembly to inside of cover door(4) with washers (2) and screws (1).

g. Reconnect GUI assembly cables to microprocessorboard (11, Figure 3-1).

h. Close cover door (4, Figure 3-2) and secure withscrews (5).


3-5

3-8. HEATER / FAN / THERMOSWITCHREPLACEMENT. These replacement instructionsare provided for heater/fan/thermoswitch equippedsystems.

a. Heater Replacement.


1. Turn off power to the system.

2. Open cover door (1, Figure 3-3) of the IFT byremoving screws (5, Figure 3-2).

3. Remove protective cover (4) by removingscrews (2) and washers (3).

4. Disconnect cable (1, Figure 3-1) frommicroprocessor board (11, Figure 3-1).

5. Partially remove mounting plate assembly(15) from enclosure (23) by removingnecessary screws.

6. Remove screws (11) and washers (12) to freeheater mounting plate (20) from mountingplate (15).

7. Cut wires to old heater (21) close to theheater; then remove old heater from heatermounting plate (20).

8. Splice heater wire to new heater (21) andattach new heater to heater mounting plate(20).

9. Attach heater assembly (20, 21) to mountingplate (15) using screws (11) and washers (12).

10. Reconnect all cables removed in step 3.

11. Position mounting plate (15) onto enclosure(23) and secure with the necessary screws.

12. Reinstall protective cover (15) using screws(2) and washers (3).

13. Close door cover (1) and secure with screws(5, Figure 3-2).

b. Thermoswitch Replacement.





4. Disconnect cable (1, Figure 3-1) frommicroprocessor board (11, Figure 3-1).

5. Partially remove mounting plate assembly(15) from enclosure (23) by removingnecessary screws.

6. Remove screws (13) and washers (14), andremove thermoswitch mounting plate (18)from mounting plate (15).

7. Pull wires free of thermoswitch tabs.

8. Remove old thermoswitch (19) fromthermoswitch mounting plate (18) byremoving screws (16) and washers (17).

9. Install new thermoswitch (19) tothermoswitch mounting plate (18) usingscrews (16) and washers (17).

10. Connect wires to thermoswitch tabs.

11. Attach thermoswitch assembly (18, 19) tomounting plate (15) using screws (13) andwashers (14).

12. Reconnect cable removed in step 4.

13. Position mounting plate (15) onto enclosure(23) and secure with the necessary screws.

14. Reinstall protective cover (4) using screws (2)and washers (3).



3-6

c. Fan Replacement.





4. Remove fan mounting bracket (7) frommounting plate (15) by removing screws (5)and washers (6).

5. Remove fan (10) from fan mounting plate (7)by removing screws (9) and washers (8).

7. Cut wires close to old fan (10).

8. Splice wires to new fan (10).

9. Mount new fan (10) to fan mounting bracket(7) using screws (8) and washers (9).

10. Mount fan assembly (7, 10) to mounting plate(15) using screws (5) and washers (6).

11. Reinstall protective cover (4) using screws (2)and washers (3).



3-7/3-8

1

23

4

56

7

10A

1112

8

9

1314

19

18

17

16

15

A

B

B

20

21

22

23

NOTES: 1.

2.

LETTERS INDICATE WIRECONTINUITY; A TO A AND B TO B.

NOT ALL PARTS SHOWN ARE AVAILABLEFOR PURCHASE SEPARATELY. FOR A LISTOF AVAILABLE PARTS, SEE SECTION IV.

24

21240004

Figure 3-3. IFT with Heater Option

1. Cover Door2. Screw3. Washer4. Protective Cover5. Screw6. Washer7. Fan Mounting Bracket8. Washer9. Screw

10. Fan11. Screw12. Washer

13. Screw14. Washer15. Mounting Plate16. Screw17. Washer18. Thermoswitch Mounting Plate19. Thermoswitch20. Heater Mounting Plate21. Heater22. Electrical Plug23. Enclosure24. Nylon Washer


4-1/4-2


Table 4-1. Replacement Parts for the Intelligent Field Transmitter.


3-1, 113-1, 203-1, 43-1, 223-2, 53-1, 5

3-3, 413-3, 413-3, 113-3, 113-3, 9

1N04946G013D39120G013D39122G01*3D39513G021L04279H011L01293H02

1A97964H011A97964H021M03255G011M03255G021M03256G01

TransformerInterconnect BoardPower Supply BoardMicroprocessor BoardGUI AssemblyFuse, 5A @ 250 Vac, anti-surge, case size; 5 x 20 mm, type T to

IEC127, SchurterHeater, 120VHeater, 240VFan, 120VFan, 240VThermoswitch

*Specify line voltage and probe type when ordering.

APPENDIX J, REV. 1.1HART COMMUNICATORMODEL 275D9EIFT 3000 APPLICATIONS

Instruction Bulletin IB-106-300N SERIES

APPENDIX J


Effective April, 1995 Rev. 1

PAGE SUMMARY

5-1 Added statement of reference to the return authorization number.

Effective June, 1995 Rev 1.1

PAGE SUMMARY

— Figure 3-1. Updated figure to include "Status group" and "K3 eff" in calculations.

APPENDIX J

IB-106-300N SERIESi/ii

TABLE OF CONTENTS

Section Page

I DESCRIPTION1-1. Component Checklist of Typical HART Communicator Package..................................... 1-11-2. Unit Overview ................................................................................................................... 1-11-3. Specifications .................................................................................................................... 1-2

II INSTALLATION2-1. HART Communicator Signal Line Connections................................................................ 2-12-2. HART Communicator PC Connections............................................................................. 2-2

III OPERATION3-1. Off-Line and On-Line Operations...................................................................................... 3-13-2. Menu Tree for HART Communicator/World Class 3000 IFT Applications ..................... 3-1

IV TROUBLESHOOTING4-1. Overview ........................................................................................................................... 4-14-2. Troubleshooting Flowchart................................................................................................ 4-1

V RETURNING EQUIPMENT TO THE FACTORY ................................................................ 5-1


Figure Page

1-1 Typical HART Communicator Package, Model 275D9E............................................................. 1-12-1 Signal Line Connections, > 250 Ohms Load Resistance............................................................... 2-12-2 Signal Line Connections, < 250 Ohms Load Resistance............................................................... 2-33-1 Menu Tree for IFT 3000 Applications.......................................................................................... 3-24-1 Model Number 275D9E, Troubleshooting Flowchart................................................................... 4-2

APPENDIX JIB-106-300N SERIES

1-1


1-1. COMPONENT CHECKLIST OF TYPICALHART ® COMMUNICATOR PACKAGE. Atypical Model 275D9E HART® Communicatorpackage should contain the items shown in Figure1-1, with the possible exception of options. If arechargeable NiCad battery pack has been selected, atleast one spare battery pack (per HARTCommunicator) is recommended.

1-2. UNIT OVERVIEW.

a. Scope. This Instruction Bulletin supplies detailsneeded to install and operate the HART®

Communicator in relation to the World Class3000 Intelligent Field Transmitter. Informationon troubleshooting the communicator is alsoincluded.

12

3

4

56

7

o

8

9

10

686001

ITEM DESCRIPTION1 Lead Set (with Connectors)2 Carrying Case3 Communicator4 AA Alkaline Battery Pack, or

Rechargeable NiCad Battery Pack (Option)5 Memory Module

ITEM DESCRIPTION6 Belt Clip (with screws)7 Hanger (mounts on belt clip, Option)8 Pocket-sized Instruction Manual9 PC Interface Adaptor (Option)

10 Load Resistor, 250 W (Option)

Figure 1-1. Typical HART® Communicator Package, Model 275D9E


1-2

b. Device Description. The HART (HighwayAddressable Remote Transducer) Communicator isa hand-held communications interface device. Itprovides a common communications link to allmicroprocessor-based instruments which areHART compatible. The hand-held communicatorcontains an 8 x 21 character liquid crystal displayand 25 keys. A pocket-sized manual, included withthe HART Communicator, details the specificfunctions of all keys.

To interface with the IFT 3000, the HARTCommunicator requires a termination point alongthe 4-20 mA current loop, and a minimum loadresistance of 250 ohms between the communicatorand the power supply. The HART Communicatoraccomplishes its task by use of a frequency shiftkeying (FSK) technique. With the use of FSK,high-frequency digital communication signals are

superimposed on the 4-20 mA transmitter currentloop. The communicator does not disturb the 4-20mA signal, since no net energy is added to theloop.

The HART Communicator may be interfaced witha personal computer, providing special softwarehas been installed. To connect the HARTCommunicator to a PC, an interface adaptor isrequired. Refer to the proper HARTCommunicator documentation in regard to the PCinterface option.

1-3. SPECIFICATIONS. HART CommunicatorSpecifications, Table 1-1, contains physical, functional,and environmental information about thecommunicator. Use Table 1-1 to ensure the unit isoperated in suitable environments, and that the properbattery charging options are used.

Table 1-1. HART Communicator Specifications.

Physical SpecificationsDisplay.................................................. 8-line liquid crystal display with a line width of 21 characters (128 x 64 pixels)Keypad.................................................. Membrane design with tactile feedback. 25 keys include:

6 action keys4 software-defined function keys

12 alphanumeric keys3 shift keys

Weight...................................................≈ 3 lbs (1.4 kg) including batteries

Functional SpecificationsMemory................................................. Nonvolatile memory. Retains memory when the communicator is not powered.Program (and Device) Descriptions ..... 1.25 MBTransmitter Data ................................... 2 KPower Supply........................................ Five AA 1.5 volt batteries. A rechargeable Nickel-Cadmium battery pack is optional.Battery Charger Options....................... 110/120 Vac, 50/60 Hz, U.S. plug

220/230 Vac, 50 Hz, European plug220/230 Vac, 50 Hz, UK plug

Microprocessors ................................... 32-bit Motorola type 683318-bit Motorola type 68HC05

Connections .......................................... Lead set: Two 4 mm banana plugsBattery charger: 2.5 mm jackSerial port: PC connection through optional adaptorMemory Module: 26 pin, 0.1 inch Berg connector

Environmental SpecificationsOperating Limits................................... 32° to 122°F (0° to 50°C)Storage Limits....................................... -4° to 158°F (-20° to 70°C)Humidity ............................................... 0 to 95% relative humidity under non-condensing conditions below 104°F (40°C)

without errorHazardous Locations ............................ CENELEC - Intrinsic Safety CertificationCertifications......................................... Factory Mutual (FM) - Intrinsic Safety Approval

Canadian Standards Association (CSA) - Intrinsic Safety Approval


2-1

SECTION II. INSTALLATION

2-1. HART COMMUNICATOR SIGNAL LINECONNECTIONS. The HART Communicator canconnect to the IFT analog output signal line at anywiring termination point in the 4-20 mA current loop.There are two methods of connecting the HARTCommunicator to the signal line. For applications inwhich the signal line has a load resistance of 250 ohmsor more, refer to method 1. For applications in which

the signal line load resistance is less than 250 ohms,refer to method 2.

a. Method 1, For Load Resistance > 250 Ohms.Refer to Figure 2-1 and the following steps toconnect the HART Communicator to a signal linewith 250 ohms or more of load resistance.

RL 250 >_ Ω

LOOP CONNECTORSUSE INTERFACE00275 0013 ONLY

SERIAL PORT & BATTERY

CHARGER MUST

NOT BE USED IN

HAZARDOUS AREAS

SERIAL PORT

INTELLIGENT FIELD TRANSMITTER IFT 3000

MICROPROCESSORBOARD

CURRENT/VOLTAGE SELECTION SWITCHTO "CURRENT" POSITION

INTERCONNECT BOARD

ANALOG OUTPUT

4-20mA SIGNAL LINE

ANALOG OUTPUT DEVICE

LEAD SET

HARTCOMMUNICATOR

HART COMMUNICATORREAR PANEL

LOOP CONNECTORS

686002

Figure 2-1. Signal Line Connections, > 250 Ohms Load Resistance


2-2

Explosions can result in death or seriousinjury. Do not make connections to theHART Communicator's serial port or NiCadrecharger jack in an explosive atmosphere.

1. Program IFT analog output to 4-20 mA.Select the current mode using thecurrent/voltage selector switch on themicroprocessor board in the IFT.

2. Using the supplied lead set, connect theHART Communicator in parallel to the IFT3000. Use any wiring termination points inthe analog output 4-20 mA signal line.

b. Method 2, For Load Resistance < 250 Ohms.Refer to Figure 2-2 and the following steps toconnect the HART Communicator to a signal linewith less than 250 ohms load resistance.

Explosions can result in death or seriousinjury. Do not make connections to theHART Communicator's serial port or NiCadrecharger jack in an explosive atmosphere.

1. Program IFT analog output to 4-20 mA.Select the current mode using thecurrent/voltage selector switch on themicroprocessor board in the IFT.

2. At a convenient point, break the analog output4-20 mA signal line and install the optional250 ohm load resistor.

3. Plug the load resistor into the loop connectors(located on the rear panel of the HARTCommunicator).

2-2. HART COMMUNICATOR PCCONNECTIONS. There is an option to interface theHART Communicator with a personal computer. Loadthe designated Cornerstone® software into the PC.Then, link the HART Communicator to the PC usingthe interface PC adaptor which connects to the serialport (on the communicator rear panel).

Refer to the proper HART Communicatordocumentation in regard to the PC interface option.


2-3/2-4

RL < 250 Ω

INTELLIGENT FIELD TRANSMITTER IFT 3000

LOOP CONNECTORS USE INTERFACE00275 0013 ONLY

SERIAL PORT & BATTERY

CHARGER MUST

NOT BE USED IN

HAZARDOUS AREAS

SERIAL PORT

NOTE: THE SIGNAL LOOP MUST BE BROKENTO INSERT THE OPTIONAL 250 OHMLOAD RESISTOR

MICROPROCESSORBOARD

CURRENT/VOLTAGE SELECTION SWITCHTO "CURRENT" POSITION

INTERCONNECT BOARD

ANALOG OUTPUT

4-20mA SIGNAL LINE

ANALOG OUTPUT DEVICE

250 OHMLOADRESISTOR(NOTE 1)

HARTCOMMUNICATOR

HART COMMUNICATORREAR PANEL

LOOP CONNECTORS

686003

Figure 2-2. Signal Line Connections, < 250 Ohms Load Resistance


3-1

SECTION III. OPERATION

3-1. OFF-LINE AND ON-LINE OPERATIONS. TheHART Communicator can be operated both off-lineand on-line. Off-line operations are those in which thecommunicator is not connected to the IFT system. Off-line operations can include interfacing the HARTCommunicator with a PC (refer to applicable HARTDocumentation regarding HART/PC applications).

In the on-line mode, the communicator is connected tothe 4-20 mA analog output signal line. Thecommunicator is connected in parallel to the IFT, or inparallel to the 250 ohm load resistor.

The opening menu (displayed on the LCD) is differentfor on-line and off-line operations. When powering upa disconnected (off-line) communicator, the LCD willdisplay the Main Menu. When powering up aconnected (on-line) communicator, the LCD willdisplay the On-line Menu. Refer to the HARTCommunicator manual for detailed menu information.

3-2. MENU TREE FOR HART COMMUNICATOR/WORLD CLASS 3000 IFT APPLICATIONS.This section consists of a menu tree for the HARTCommunicator. This menu is specific to IFT 3000applications.


3-2

OxygenEfficiencyStackO cellCJtemp

2

VIEW FLDDEV VARS

PV isPVPV % mgePV AO

PROCESSVARIABLES

DIAG/SERVICE

VIEW PV-Aout

VIEW OUTPUTVARS

VIEW SVSV isSVSV % mge

O cellCell TCStack TCCJmV

2

VIEW FLDDEV mV

Not ApplicableVIEW STATUS

SELF TEST Not Applicable

LOOP TEST Loop testmethod...

Cal ModeOptrak TG?PERFORM OCALCalState

2

PERFORM OCAL

2O CALIBRATE2

CalStateTimeRemainPresent TGPresent O2

O CALSTATUS

2

Cal slopeCal constCellRes

LASTCALCONSTANTS

ResetCalConstantsmethod...

RESETCALCONSTANTS

D/A trim methodD/A TRIM

O Cal method...2

DEVICE SETUPPVPV AOPV LRVPV URV


21240020

Figure 3-1. Menu Tree for IFT 3000 Application (Sheet 1 of 3)


3-3



TagASSIGNPV & SV

SELECT ORANGE

2

Set O Xfer fn2

DEVICEINFORMATION

ManufacturerDistributorModelDev idTagDescriptorMessageDateFinal asmbly numSnsr s/nFld dev revSoftware revUniversal rev

OefficiencyStackTempO cellTempColdJuncTempO cell mVO cellTCmVStackTCmVCold Junc mV

2

2

2

2

PV URVPV LRVXfer fnctnPV % mge

ANALOGOUTPUT

HART OUTPUT

RELAYOUTPUTS

O2

EFFICIENCY

HighTGLowTGCal ModeOPtrak TG?Cal IntrvlNxtCalTimeTGtimePurgeTimeResAirSP

HiAlarmSPLoAlarmSPDeadband

SENSORS

SIGNALCONDITION

OUTPUTCONDITION

CALCULATIONS

OCALIBRATION

2

O ALARMS2


BASIC SETUP

DETAILEDSETUP

PV AOAO Alrm typ

LOOP TEST

D/A TRIM

Poll addrNum req preams

K1

K2

SlopeConstantHeaterSP

Eff.enabled?K1 efficncyK2 efficncyK3 efficncy

Loop testmethod...

D/A trim method...

K1 stateK1 input1K1 input2K1 input3

K2 stateK2 input1K2 input2K2 input3

PV isSV is

O RngeModeHiRnginCal?RngeSwtSPNormal URVNormal LRVHi.mg.URVHi.mg.LRV

2

21240021

Figure 3-1. Menu Tree for IFT 3000 Applications (Sheet 2 of 3)


3-4



ManufacturerDistributorModelDev idTagDescriptorMessageDateFinal asmbly numSnsr s/nFld dev revHardware revSoftware revUniversal rev

Cal modeOptrak TG?Cal IntrvlTgtimePurgeTimeResAirSPLowTGHighTGCal slopeCal constCellRes

HeaterSPSlopeConstantEff.enabled?K1 efficncyK2 efficncyK3 efficncy

Normal URVNormal LRVHi.mg.URVHi.mg.LRVO RngeModeHiRnginCal?RngeSwtSPHiAlarmSPLoAlarmSPDeadbandK1 input1K1 input2K1 input3K2 input1K2 input2K2 input3Poll addrNum req preams

2

DEVICEINFORMATION

CAL INFO

DEVICE CONFIG

OUTPUTSCONFIG

REVIEW

21240022

Figure 3-1. Menu Tree for IFT 3000 Applications (Sheet 3 of 3)


4-1

SECTION IV. TROUBLESHOOTING

4-1. OVERVIEW. If the HART Communicator fails tofunction properly, verify that the unit's battery pack andmemory module are correctly assembled to thecommunicator. Check the communicator's modelnumber. For IFT applications, HART Communicatormodel number 275D9E must be used. If the HARTCommunicator model number is correct, and if it is

properly assembled, the troubleshooting flowchart,Figure 4-1, may be useful to find and correct problems.

4-2. TROUBLESHOOTING FLOWCHART.Refer to Figure 4-1.


4-2

DOES HART UNIT

HAVEPOWER

?

DOES HART UNITINDICATEBATTERYPOWERGOOD

?

ISHART UNIT

BEING USED"ON-LINE"

?

ISHART UNIT

CONFIGUREDFOR IFT?

IS IFTPOWERED

?

IS IFTEXPERIENCING

FAULTS?

DOESIFT HAVE

MICROPROCESSORBOARDREV.#

3039513G?

CLEAR IFT OF ALL FAULT CONDITIONS.

YES

YES

YES

YES

YES

YES

YES

(GO TOSHEET 2 OF 2)

REPLACE BATTERIES. IFAPPLICABLE, RECHARGE NiCad BATTERIES.

VERIFY HART IS CONFIGURED FOR IFT.REFERENCE OFF-LINECONFIGURATION (HARTPOCKET-SIZED MANUAL).

RECONFIGURE HART UNITFOR IFT.

CONTACT SERVICEREPRESENTATIVE.

SUPPLY POWER TO IFT.

NO

NONO

NO

NO

NO

NO

686004

Figure 4-1. Model Number 275D9E, Troubleshooting Flowchart (Sheet 1 of 2)


4-3/4-4

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

>

ISLOAD

RESISTANCE250 OHMS

?

(CONTINUED FROMSHEET 1 OF 2)

CONNECT THE HART UNITTO THE 4-20 mA SIGNALLOOP. REFER TO SECTION2. IF LOAD RESISTANCE IS<250 OHMS, THE 250 OHMLOAD RESISTOR MUST BEUSED.

686005

Figure 4-1. Model Number 275D9E, Troubleshooting Flowchart (Sheet 2 of 2)


5-1/5-2

SECTION V. RETURNING EQUIPMENT TO THE FACTORY

5-1. If factory repair of defective equipment is required,proceed as follows:

a. Secure a return authorization number from aRosemount Analytical Sales Office orRepresentative before returning the equipment.Equipment must be returned with completeidentification in accordance with Rosemountinstructions or it will not be accepted.

In no event will Rosemount be responsible forequipment without proper authorization andidentification.

b. Carefully pack defective unit in a sturdy box withsufficient shock absorbing material to insure thatno additional damage will occur during shipping.

c. In a cover letter, describe completely:

1. The symptoms from which it was determinedthat the equipment is faulty.

2. The environment in which the equipment hasbeen operating (housing, weather, vibration,dust, etc.).

3. Site from which equipment was removed.

4. Whether warranty service or non-warrantyservice is requested.

5. Complete shipping instructions for return ofequipment.

6. Reference the return authorization number.

d. Enclose a cover letter and purchase order and shipthe defective equipment according to instructionsprovided in Rosemount Return Authorization,prepaid, to:

American

Rosemount Analytical Inc.RMR Department1201 N. Main StreetOrrville, Ohio 44667

European

Rosemount IrelandEquipment Return Repair Dept.Site 7 Shannon Industrial EstateCo. ClareIreland

If warranty service is requested, the defective unitwill be carefully inspected and tested at the factory.If failure was due to conditions listed in thestandard Rosemount warranty, the defective unitwill be repaired or replaced at Rosemount's option,and an operating unit will be returned to thecustomer in accordance with shipping instructionsfurnished in the cover letter.

For equipment no longer under warranty, theequipment will be repaired at the factory andreturned as directed by the purchase order andshipping instructions.

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