Emerson 3000 manual

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 http:/ / ww w . raihome .com World Class 3000 Oxygen Analyzer with IFT 3000 Intelligent Field Transmitter[...]

Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 6565P Davis Industrial Parkway Solon, OH 44139 T (440) 914 1261 F (440) 914 1271 E gas.csc@emersonprocess.com http://www.raihome.com ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Rosemount Analytical designs, ma nufa ctures and tests its products to meet many [...]

HIGHLIGHTS OF CHANGES Effective May, 1999 Rev . 4.0 Page Summary Page P-6 Added new Quick Start Guide. Page 3-1 Added Section 3, Setup. Page 4-1 Removed calibration informati on from Operation se ction, and created Section 4, Calibration. Page 6-2 Expanded explanations of IFT status codes. Section 6 Added new troublesho oting p rocedures. Effective[...]

HIGHLIGHTS OF CHANGES (CONTINUED) Effective May, 2005 Rev . 4.3 Page Summary Highlights Updated Highlights of Change s Appendix A, B, D, E, J pages. --- Changed “Rosemount” to “R osemount Analytical”. P-8 Revised Figure 2. 1-1 Revised Figure 1-1. 1-6 Revised Figure 1-3. 2-5, 2-6 Revised Figure 2-1, sheets 1 and 2. 2-9 Revised Figure 2-4. 2-[...]

HIGHLIGHTS OF CHANGES APPENDIX A Effective May, 1996 Rev . 3 Page Summary --- General. Updated appendix to reflect p robe design changes. Page A-13 Added “Extended temperature by-p ass a rrangements” to Figure A-13 (Sheet 3 of 3) Effective June, 1996 Rev . 3.1 Page Summary Page A-13 Updated part ordering inform ation. Effective August, 1996 Rev[...]

HIGHLIGHTS OF CHANGES (CONTINUED) Effective November, 2001 Rev . 3.7 Page Summary A-8 Added new cup type diffusion assembly description, parag raph A-6.e. and diffusion assembly illustrations, Figure A-13 a nd A-14. A-26 Added new cup type diffusion assembly part num bers 4851B89G04 and 4851B90G04 to replacement part s list. Deleted stainless steel[...]

HIGHLIGHTS OF CHANGES APPENDIX B Effective February, 1992 Rev . 2 Page Summary Page B-1 Figu r e B- 1 . N e w H P S 3000 Optional Class 1, Division 1, Group B (IP56) Explosion-Proof Enclosure added. Page B-11 Figu r e a nd I n de x N o . c o l u mn added to Table B-2. Replacement Parts for Heater Power Supply. Effective January, 1995 Rev . 2.1 Page[...]

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HIGHLIGHTS OF CHANGES APPENDIX D Effective June, 1994 Rev . 2 Page Summary Page D-1 Page D-2 Page D-3 Page D-4 Page D-7 Page D-8 Page D-10 Page D-11 MPS outline drawing changed to show new MPS. MPS interior view replaced with new MPS in Figure D-2. "Optional" for check valve deleted in Figure D-3. Drawing showing lo cation of option al Z-[...]

HIGHLIGHTS OF CHANGES (CONTINUED) Effective July, 1998 Rev . 2.4 Page Summary --- Changed test gas to calibration g as a nd reference gas to reference air throughout the appendix. Effective May, 2005 Rev . 2.5 Page Summary --- Changed “Rosemount” to “Rosemount Analytical”. D- 3 Revised view of check valve in Figure D-3.[...]

HIGHLIGHTS OF CHANGES APPENDIX E Effective May, 1996 Rev . 4 Page Summary --- General. Updated text and illustrati ons to reflect new version of IFT. Page E-4 U pdated IFT display status codes and p laced in priority sequence. Effective June, 1996 Rev . 4.1 Page Summary Page E-2 U pdated specification table. Effective October, 1996 Rev . 4.2 Page S[...]

HIGHLIGHTS OF CHANGES (CONTINUED) Effective May, 2005 Rev . 4.6 Page Summary --- Changed “Rosemount” to “Rosemount Analytical”. Changed views o f IFT 3000 enclosure. Named GUI/LED displa y standard (not optional). E-2 Revised Electrical Noise specifications. E-8 t hr oug h E -1 6 Changed all service instructions to reflec t new IFT 3000 ass[...]

HIGHLIGHTS OF CHANGES APPENDIX J Effective April, 1995 Rev. 1 Page Summary Page J-13 A dded statement of reference to the return au thorization number. Effective June, 1995 Rev . 1.1 Page Summary --- Figure J-4. Updated figure to include “Status group” and “K3 eff” in calculations. Effective May, 2005 Rev . 1.2 Page Summary J-1 Revised Figu[...]

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Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management i World Class 3000 TABLE OF CONTENTS PREFACE........................................................................................................................ P-1 Definitions ....................................................[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 ii Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 7-0 RETURN OF MATERI AL .............................................................................................. 7-1 8-0 APPE NDICE S .........................................................................[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management iii World Class 3000 LIST OF TABLES Table 4-1. Automatic Ca libration Para meters ......................................................................... 4-8 Table 5-1. Sample HELP Messages .........................................[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 iv Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Di vision of Emerson Process Management P-1 World Class 3000 NOTE ! Only one probe can be calibrated at a time. Probe calibrations must be scheduled appropriately in multip le probe applications. PREFACE The purpose of this manual is to provide a comprehen sive understand[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 P-2 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 IMPORTANT SAFETY INSTRUCTIONS FOR THE WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Di vision of Emerson Process Management P-3 World Class 3000 GLOSSARY OF TERMS Abrasive Shield An optional component that shields the probe fro m high velo city particulate entrained in the flue gas stream. Automatic Calibration An automatic calibration can only be perfor[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 P-4 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Reference Air Provides a known oxygen concentration to the referen ce side of the oxygen sensing cell. Semiautomatic Calibration Semiautomatic calibration is performed when the system does not include an MPS 3000[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Di vision of Emerson Process Management P-5 World Class 3000 WHAT YOU NEED TO KNOW BEFORE INSTALLING AND WIRI NG A ROSEMOUNT ANALYTICAL IFT 3000 INTELLIGENT FIELD TRANSMITTER WITH WORLD CLASS 3000 PROBE 1. What is the line voltage being supplied to the IFT 3000? Write the[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 P-6 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 QUICK START GUIDE Use this Quick Start Guide if ... 1. You are using a World Class 30 00 probe. 2. You are NOT using any optional com pone nts. Optional component s are shown in the shaded area in Figure 1. 3. Yo[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Di vision of Emerson Process Management P-7 World Class 3000 QUICK START GUIDE FOR IFT 3000 SYSTEMS Before using the Quick Start Guide, please read “WHAT YOU NEED TO KNOW BEFORE INSTALLING AND WIRING A ROSEMO UNT ANALYTICAL IFT 3000 INTELLIGENT FIELD TRANSMITTER WITH WO[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 P-8 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 BK GN WH PU SHIELD SHIELD SHIELD ST ACK TC - ST ACK TC + PROBE M V + PROBE MV - PROBE TC + PROBE TC - RD YE BL OR BL OR YE RD WORLD CLASS PROBE 123 456 78 BL PROBE MV - PROBE MV + PROBE TC + PROBE TC - OR YE RD G[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Di vision of Emerson Process Management P-9 World Class 3000 QUICK REFERENCE GUIDE IFT 3000 INTELLIGENT FIELD TRANSMITTER Performing a Manual (Semiautomatic) Calibration 1. Connect the high calibration gas to the probe fitting. 2. Press the CAL key. 3. Select the PERFORM [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 P-10 Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 HART COMMUNICATOR FAST KEY SEQUENCES Perform Calibration Analog Output Upper Range Value 2313 3 2 4 Trim Analog Output Analog Output Lower Range Value 24 325 Toggle Analog Output Tracking View O 2 Value 2312 1 1[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1 World Class 3000 1 3 4 5 6 7 8 9 2 37840019 o HART Communicator FISHER-ROSEMOUNT TM MAN 4275A00 English October 1994 SECTION 1 DESCRIPTION AND SPECIFICATIONS 1-1 COMPONENT CHECKLIST OF TYPICAL SYSTE[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 1-2 Description and Specifications Rosemount Analytic al Inc. A Division of Emerson Process Management World Class 3000 1-2 SYSTEM OVERVIEW a. Scope This Instruction Manual has be en designed to supply details needed to install, startup, operate, and maintain the Rosemount Ana- lytical World Class 3[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3 World Class 3000 c. System Configuration The equipment covered in this manual con- sists of three major comp one nts: the oxy- gen analyzer (probe), the intelligent field transmitter (IFT), and an o[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 1-4 Description and Specifications Rosemount Analytic al Inc. A Division of Emerson Process Management World Class 3000 9. An operator can set up, calibrate, or troubleshoot the IFT in one of two ways: (a) Optional General User Interface (GUI). The GUI is housed within the IFT el ectron ics enc losu[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5 World Class 3000 S TA N D A RD OP TI O N S DUC T ST A C K G ASES C ALIB R AT I O N G AS INST RU MENT AI R S UPP LY (R EF . AI R) PR ESS UR E R E GU LA T OR FL O WMETE R INTELLI G ENT FIEL D T R ANSM[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 1-6 Description and Specifications Rosemount Analytic al Inc. A Division of Emerson Process Management World Class 3000 HART Model 275/375 Handheld Communicator MPS 3000 CALIBRA TION GAS SEQUENCER HPS 3000 (OPTIONAL) (OPTIONAL) Explosion Proof Required only for Hazardous Area Applications, otherwise[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7 World Class 3000 After selecting the probe mounting location, provision should be made for a platform where the probe can be easily se rvice d. The intelligent field transmitter (IFT) can be located[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 1-8 Description and Specifications Rosemount Analytic al Inc. A Division of Emerson Process Management World Class 3000[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1 World Class 3000 SECTION 2 INSTALLATION 2-1 OXYGEN ANALYZER (PROBE) INSTALLATION Before starting to install this equip- ment, read the "Safety instructions for wiring and installation of this appara- tus" a[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-2 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 ROS EM OU NT C AL G AS R EF AI R FLAN G E D IA. H O LE D IA. ( 4 ) H O LES EQ S PO NB C ANSI 4 5 1 2C 1 7 H 0 1 6 . 00 ( 1 53) 7 . 28 ( 1 85) 6 .1 0 ( 1 55) 0 . 5 9 ( 1 5) 5 .1 2 ( 1 30) 0 . 75 (20)[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3 World Class 3000 SNUBBER DIFFUSION/ DUST SEAL ASSEMBL Y (P/N 4843B38G02) 7.00 (178) SEE T ABLE IV FOR FLANGE SIZES 3.6 (91.44) NOMINAL INSULA TE IF EXPOSED TO AMBIENT WEA THER CONDITIONS ELECTRICAL CONNECTOR REF AIR [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-4 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 22.5 o B C 8 THREADED HOLES E Q UALL Y SP ACED ON D DIA B.C. ABRASIVE SHIELD FLANGE O.D. A A T ABLE V . ADAPTOR PLA TE DIMENSIONS FOR PROBE T ABLE VI. ADAPTOR PLA TE DIMENSIONS FOR ABRASIVE SHIELD D[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5 World Class 3000 NOTE: ALL MASONR Y ST ACK WORK AND JOINTS EXCEPT ADAPTOR PLA TE NOT FURNISHED BY ROSEMOUNT ANAL YTICAL. INST ALLA TION FOR MASONRY W ALL ST ACK CONSTRUCTION INST ALLA TION FOR MET AL W ALL ST ACK OR [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-6 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 BRACE BARS (NOT BY ROSEMOUNT ANAL YTICAL) 2.00 (51) NOTE: DIMENSIONS IN INCHES WITH MILLIMETERS IN P ARETHESES. VERTICAL BRACE CLAMP ASSY . HORIZONT AL BRACE CLAMP ASSY . BY ROSEMOUNT ANAL YTICAL } [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7 World Class 3000 4. If using the optional ceramic diffusor element, the vee deflector must be cor- rectly oriented. Before inserting the probe, check the direction of flow of the gas in the duct. Orient the vee defle[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-8 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 c. Reference Air Packag e After the oxygen analyzing (probe) unit is installed, connect the reference air set to the probe junction box. The reference air set should be installed in accord ance with[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-9 World Class 3000 2-2 INTELLIGENT FIELD TRANSMITTER (IFT) INSTALLATION a. Mechanical Installation The outline drawing of the IFT module in Figure 2-4 shows mo unting centers and clearances. The NEMA 4X enclosure i s d[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-10 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 Do not install jumper JM6 on the mi- croprocessor board, or JM1 on the in- terconnect board, if an HPS is installed in the system. This w ill result in system failure. 3. The IFT must have JM6 on t[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-11 World Class 3000 FUSES FUSES NOTE: ALL FUSES (F1 THROUGH F5) ARE 5A @ 250 V AC, ANTI- SURGE, CASE SIZ E5X2 0M M , TYPE T T O IEC127, SCHURTER. Figure 2-6. IFT Power Supply Board Jumpers[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-12 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 BK GN WH PU SHIELD SHIELD CAL RET NO GAS LO GAS HI GAS IN CAL SHIELD SHIELD ST ACK TC - ST ACK TC + PROBE M V + PROBE MV - PROBE TC + PROBE TC - RD YE BL OR BL OR YE RD INTELLIGENT FIELD TRANSMITTE[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-13 World Class 3000 OUTPUT JUMPER HPS Remove JM6 Probe (No HPS) Install JM6 ANALOG OUTPUT (Condition during microcontroller failure) Switch SW3 Output = zero SW3 on Output = maximum SW3 off (See Figure 2-9 for jumper a[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-14 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 R10 R18 R29 C14 R2 TP10 D2 D1 TP9 TP20 U11 C2 R24 R20 C15 Q2 C6 D6 U10 TP36 TP7 J1 J2 J3 R28 C17 R129 G1 C42 D5 D7 D6 U2 TP19 TP51 TP36 TP29 TP8 R117 TP59 TP61 TP55 TP92 TP56 R97 JM6 C27 U15 R72 R4[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-15 World Class 3000 OUTPUT JUMPER HPS Remove JM1 Probe (No HPS) Install JM1 Figure 2-10. Interconnect Board Jumper Con figur ation 2 2 1 1 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-16 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 CLASS 1, DIVISION 1, GROUP B ENCLOSURE #10-32 UNF 2A THREADED INSERT (0.31 x 0.31 FROM CORNER OF PLA TE) 0.13" (3.3) THK U. L. APPROVED GASKET 7.00 (177.8) 3.25 (82.6) 3.63 (92.2) 0.31 (7.9) N[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-17 World Class 3000 + + + + + + + + + - - - - - - - - - BK WH J9 J8 J3 J2 J1 TRIAC RELA Y ST ACK TC ANALOG HEA TER PROBE MV PROBE MV PROBE TC PROBE TC AD590 (INTERNAL WIRING) WH BK OR CELL+ YE HTR TC + BL CELL - RD HTR[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-18 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 MPS TERMINA TION BOARD MPS 3000 MUL TIPROBE CALIBRA TION GAS SEQUENCER (OPTIONAL) L E N LINE VOL T AGE J13 J14 J15 J16 J17 J18 J12 CAL RET HI GAS IN CAL NO GAS CAL RET HI GAS IN CAL NO GAS CAL RET [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-19 World Class 3000 TRANSFORMER TRANSFORMER SCREW (2 PER CO VER) TERMINAL CO VERS FRONT SIDE TERMINAL STRIP (FROM ELECTRONICS) TERMINAL STRIP (FROM ELECTRONICS) 29850005 Figure 2-14. Heater Power Supply Wiring Connecti[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-20 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 AL WA YS DISCONNECT LINE VOL T AGE F ROM H EA TER POWER SUPPL Y AND ANALOG ELECTRONICS (I F USED) BE F ORE C H ANGING JUMPERS. JUMPER CON F IGURA TIONS LINE VOL T AGE SELECTION JUMPER (INST ALL) JU[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-21 World Class 3000 2-4 MULTIPROBE CALIBRATION GAS SEQUENCER INSTALLATION a. Mechanical Installation The outline drawing of the MPS module in Figure 2-17 shows mounting ce nters and clearances. The box is designe d to [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-22 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 3. Connect the low O 2 calibration gas to LOW GAS. The calibration gas pres- sure should be set at 20 psi (138 kPa ). 4. Connect the REF AIR OUT to the ref- erence air fitting on the probe junction[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-23 World Class 3000 MPS TERMINA TION BOARD L E N LINE VOL T AGE J13 J14 J15 J16 J17 J18 J12 CAL RET HI GAS IN CAL NO GAS CAL RET HI GAS IN CAL NO GAS CAL RET HI GAS IN CAL NO GAS CAL RET HI GAS IN CAL NO GAS LOW GAS LO[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 2-24 Installation Rosemount Analytical In c. A Division of Emerson Process Management World Class 3000 NOTE Upon completing installation, make sure that the prob e is turned on and operating prior to firing up the combustion process. Damage ca n result from having a cold probe exposed to the process[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Setup 3-1 World Class 3000 SECTION 3 SETUP 3-1 OVERVIEW This section provides information on configu ring the IFT 3000 Intelligent Field Transmitter. This section assumes that y ou are familiar with the operation of the IFT and the G[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 3-2 Setup Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 automatic calibrations, set the Auto Cal pa- rameter to Yes. f. The Output Tracks setting determines whether the analog output tracks the oxy- gen reading during a calibration. Setting Output Tracks to No l[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-1 World Class 3000 SECTION 4 CALIBRATION 4-1 ANALOG OUTPUT CALIBRA TIO N For the analog output to perform within the pub- lished specifications, it must be manually cali- brated. The only equipment needed to perfo rm th[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 4-2 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 2. Calibration Methods There are three calibration method s: manual (semiautomatic), manually ini- tiated automatic, and fully automatic. Manual (semiautomatic) calibration is done without an MPS unit[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-3 World Class 3000 255 Brimley Road Scarborough, Ontario, Canada 416/266-3161 SCOTT ENVIRONMENTAL TECHNOLOGY, INC. SCOTT SPECIALTY GASES 2600 Cajon Blvd. San Bernardino, CA 92411 714/887-2571 TWX: 910-390-1159 1290 Comb[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 4-4 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 PROBE (END VIEW) CALIBRA TION IN-PLACE FITTING CHECK VA LV E FLOW METER LEAK TIGHT V AL VES 37840014 NOTE: PROBE CALIBRA TION GAS FITTING HAS A SEAL CAP WHICH MUST BE IN PLACE A T ALL TIMES EXCEPT DUR[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-5 World Class 3000 37840018 CALIBRA TION GAS KIT #1 (P/N 6296A27G01) Analytical Figure 4-2. Portable Rosemount Analy tical Oxygen Calibration Gas Kit 2 Extra gas bottles are available at: Rosemount Analytical Inc. 6565 [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 4-6 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 0.4% O 2 8.0% O 2 37840013 CALIBRA TE IN PLACE CONNECTION CHECK VA LV E PUSHBUTTON REGULA TOR WITH CONTENTS GAGE - SET 5 SCFH REFERENCE AIR CONNECTION CALIBRA TION GAS HOSE CONNECTS TO CHECK VA LV E N[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-7 World Class 3000 PROBE (END VIEW) IFT CALIBRA TION GAS HPS OPTIONAL CHECK VA LV E PROBE SIGNAL CONNECTIONS MPS-IFT SIGNAL CONNECTIONS MPS INSTRUMENT AIR IN CALIBRA TION GAS 1 (HIGH ) O 2 CALIBRA TION GAS 2 (LOW O ) 2 [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 4-8 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table 4-1. Automatic Calibration Parameters Auto Cal YES/NO Set to YES Output Tracks YES/NO Set as desired to con- figure analog output tracking. Cal Intvl XD XH Set the desired time between calibrati[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Calibration 4-9 World Class 3000 Calibration Record For Rosemount Analytical In Situ O 2 Probe Probe Serial Number: Probe Tag Number: Probe Location: Date Placed Into Service: Date Slope Constant Impedance Response initial Response f[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 4-10 Calibration Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Divisi on of Emerson Process Management General User Interface (GUI) Op eration 5-1 World Class 3000 SECTION 5 GENERAL USER INTERFACE (GUI) OPERATION 5-1 OVERVIEW Ensure that the oxygen analyzer, heater power supply, and intelligent field transmitter have been properly co[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 5-2 General User Interface (GUI) Op eration Rosemount A nalytical Inc. A Divisi on of Emerson Process Management World Class 3000 5-2 DELUXE VERSION IFT DISPLAYS AND CONTROLS 37840022 E N T E R E S C D A TA C A L S E T U P H E L P EXTERNAL VIEW INTERNAL VIEW NOTE: ENCLOSURE COVER SHOWN FOR REFERENCE[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Divisi on of Emerson Process Management General User Interface (GUI) Op eration 5-3 World Class 3000 Table 5-1. Sample HELP Messages MENU, SUB-MENU, HELP OR PARAMETER NAME MESSAGE PROBE DATA Press ENTER key to access DATA menu. CALIBRATE O 2 The CAL menu is used to start [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 5-4 General User Interface (GUI) Op eration Rosemount A nalytical Inc. A Divisi on of Emerson Process Management World Class 3000 5-8 CALIBRATE O 2 SUB-MENU The CALIBRATE O 2 sub-menu (Table 5-4) i s used to enter the calibration mode. To access the CALIBRATE O 2 sub-menu, press the CAL key at any t[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Divisi on of Emerson Process Management General User Interface (GUI) Op eration 5-5 World Class 3000 (CONTINUED ON SHEET 2) 686022 PROBE DA T A DIAGNOSTIC DA T A VOL T AGES PROCESS DA T A TEMPERA TURE Cell Stack Cold Junct Cell Cell T/C Stk T/C Cold Jnt OUTPUT V ALUES Ana[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 5-6 General User Interface (GUI) Op eration Rosemount A nalytical Inc. A Divisi on of Emerson Process Management World Class 3000 (CONTINUED ON SHEET 3) (CONTINUED ON SHEET 3) (CONTINUED FROM SHEET 1) See sheet 4 SLOPE CONST ANT SET POINT RESET SLOPE AND CONST 34.5 mV/D- 57.5 mV/D -20.0 mV - 20.0 mV[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Divisi on of Emerson Process Management General User Interface (GUI) Op eration 5-7 World Class 3000 (CO NTIN U E D F RO M SHEET 2) SET UP (CO NTIN U E D F RO M SHEET 2) ANAL OG OU T PU TS S OURC E A OU TT Y P E R AN G E SET UP O2 E ff i c i ency Dua l Rng O2 HA R T4 - 20[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 5-8 General User Interface (GUI) Op eration Rosemount A nalytical Inc. A Divisi on of Emerson Process Management World Class 3000 (CONTINUED FROM SHEET 2) CALIBRA TION HIGH GAS LOW GAS AUTO CAL OUTPUT TRACKS CAL INTRVL NEXT CAL GAS TIME PURGE TIME RES ALARM 0.1000% O2 25.00% O2 0.1000% O2 25.00% O2 [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Divisi on of Emerson Process Management General User Interface (GUI) Op eration 5-9 World Class 3000 (CONTINUED FROM SHEET 3) RANGE SETUP Log LIN Log LIN HIGH END LOW END 0.000% O2 25.00% O2 0.000% O2 25.00% O2 0.000% O2 25.00% O2 0.000% O2 25.00% O2 0.000% O2 25.00% O2 0[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 5-10 General User Interface (GUI ) Operation Rosemount A nalytical Inc. A Divisi on of Emerson Process Management World Class 3000 Table 5-4. CALIBRATE O 2 Sub-Menu SUB-MENU SELECTION SETUP SETTING (SEE TABLE 3-5) DISPLAY DESCRIPTION Perform Calibration Auto Cal in Probe Setup is YES Press ENTER to [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Divisi on of Emerson Process Management General User Interface (GUI) Op eration 5-11 World Class 3000 Table 5-4. CALIBRATE O 2 Sub-Menu (continued) SUB-MENU SELECTION SETUP SETTING (SEE TABLE 3-5) DISPLAY DESCRIPTION View Constants Latest Calibration Slope _____mV/D Const[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 5-12 General User Interface (GUI ) Operation Rosemount A nalytical Inc. A Divisi on of Emerson Process Management World Class 3000 Table 5-5. SETUP Sub-Menu SUB-MENU SELECTION PARAMETERS DESCRIPTION Calibration High Gas ____% O 2 Value of high O 2 calibration gas (0.1 000% - 25. 00% O 2 ). Low Gas _[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Divisi on of Emerson Process Management General User Interface (GUI) Op eration 5-13 World Class 3000 Table 5-5. SETUP Sub-Menu (continued) SUB-MENU SELECTION PARAMETERS DESCRIPTION Relay Outputs NOTE K1 and K2 relay outputs can be con figured for "OFF" or any o[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 5-14 General User Interface (GUI ) Operation Rosemount A nalytical Inc. A Divisi on of Emerson Process Management World Class 3000 Table 5-5. SETUP Sub-Menu (continued) SUB-MENU SELECTION PARAMETERS DESCRIPTION Analog Output RANGE SETUP (continued) (Source set to Dual Rng O 2 ) Xfer Fnct Log Lin Sel[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-1 World Class 3000 SECTION 6 TROUBLESHOOTING 6-1 OVERVIEW The system troubleshooting de scribe s how to identify and isolate faults which may develop in the Oxygen Analyzer System. Refer to Probe, IFT, HPS, MPS, and[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 6-2 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table 6-1. IFT Status Codes Off Heater power has been turne d OFF by the electronics. The display shows 0% O 2 . Several con- ditions may cause the OFF status: 1. The cell heater tempe rature is b[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-3 World Class 3000 6-4 HEATER PROBLEM For all heater troubleshooting, allow at least 30 minutes for the operating temperature to stabi- lize. After the warmup pe riod, observe the sys- tem status and the voltages of[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 6-4 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table 6-2. Heater Troubleshooting (continued) Problem Cause Corrective Action Status is HtrEr or OFF. Cell TC > 28.4 mV. Cold Junction 273 to 330 mV (normal). O 2 Display = 0% 1. Triac failure.[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-5 World Class 3000 6-5 CELL PROBLEM For cell troubleshooting, as in heater probl ems, you should allow at least 30 minutes for operat- ing temperature to stabilize. After this warmup period, observe the system statu[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 6-6 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table 6-3. Cell Troubleshooting (continued) Problem Cause Corrective Action Status is ResHi or CalEr. Cell mV = -20 to 120 mV (normal) (continued). 1. Reference air contamination (oil/water). Clea[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-7 World Class 3000 6-6 IFT PROBLEM When an IFT problem is suspected, look at the LED on the microprocessor board. The LE D may be OFF, ON, or flashing. Refer to Table 6-4 to troubleshoot IFT related problems. Table [...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 6-8 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 6-7 MPS PROBLEM MPS problems can occur with a status of C Err, R Hi, TGLow. The O 2 reading can be 0% to 99%, and probe data will be in the normal ranges. Consider two conditions, A and B. Refer t[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 6-9 World Class 3000 6-8 PERFORMANCE PROBLEM (PROCESS RESPONSE IS SUSPECT) O 2 readings may not always agree with kno wn process condition s. Such a di screpancy can be the first sign of a problem either in the proces[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 6-10 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emers on Process Management Return of Material 7-1 World Class 3000 SECTION 7 RETURN OF MATERIAL 7-1 If factory repair of equipment is required, pro- ceed as follows: a. Secure a return authori zation number from a Rosemount Analytical Sales Office or rep- res[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 7-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 8-1 World Class 3000 SECTION 8 APPENDICES APPENDIX A. WORLD CLASS 3000 OXYGEN ANALYZER (PROBE) APPENDIX B. HPS 3000 HEATER POWER SUPPLY APPENDIX D. MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER APPENDIX E. IFT 3000 INTE LL[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-0 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 2 3 NOTE: NOT ALL P ARTS SHOWN ARE A V AILABLE FOR PURCHASE SEP ARA TEL Y . FOR LIST OF A V AILABLE P ARTS, SEE T ABLE A-3. 29 1 27 28 25 24 26 20 19 17 7 8 15 13 16 18 23 22 10 11 21 20 11 14 12 10 9 [...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-1 World Class 3000 APPENDIX A, REV. 3.9 WORLD CLASS 3000 OXYGEN ANALYZER (PROBE) DESCRIPTION Read the “Safety instructions for the wiring and installation of this appara- tus” at the front of this Instruction Bulleti[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table A-1. Specifications for Oxygen Analyzing Equipment. 1, 2 Probe lengths, nominal ..................................................................18 inches (457 mm), 3 feet (0.91 m), 6 feet (1.83[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-3 World Class 3000 A-2 PROBE ASSEMBLY EXTERIOR Primary probe exterior components in clude a flange-mounted zirconium oxide cell, mounted on a tube assembly and protected by a snubb er diffusion assembly. a. Cell and Flan[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 d. Cell - General The components whi ch make up the cell are machined to close tolerances and assembled with care to provide accu rate oxygen measurements. Any replacement requires attention to detail [...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-5 World Class 3000 C ALIB R AT I O N G AS FITTIN G PRO BE JU N C TI O NB O X CO VE R TE R MINAL ST R I P R EFE R EN C E AI R FITTIN G 272700 1 6 Figure A-6. Probe Junction Box A-4 PROBE JUNCTION BOX The probe junction bo[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 VIEW A VIEW B A B A B 15 o 2 .187 1 ON INSIDE BREAK FOR SMOOTH ROUNDED EDGE ON BOTH ENDS OF CHAMFER .187 6.00 125 .45 MIN 90 o 3.584 3.554 SKIN CUT F ACE FOR 90 o 22.5 o DIA ON A 7.50 DIA B.C. (REF) .7[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-7 World Class 3000 P0010 Fig ur e A- 8. Ceramic Diffus ion/Dust Seal Assembl y These modified diffusion and vee deflector assemblies are available in standard, Figu re A-8, and flame arrestor version, Figure A-9. b. Cera[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 d. Snubber Diffusion/Du st Seal Assembly The snubber diffusion/dust seal assembly, Figure A-12, is used in applications where an abrasive shield is to be used with a snubber type diffusion element. The[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-9 World Class 3000 06 G ASKET AN D HA RD WA R E 6 . 50 ( 1 65 .1 )R EF DR AIN A A ST D2 0 FT (6 .1 M )C ABLE 27 . 3 1 (6 9 3 . 67) C LEA R AN C E R E Q F OR PRO BE INSE R TI O N AN DR EM O V AL FLAN G E 06 0 1 02 03 0 4 [...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 NOTES: REFERENCE AIR SUPPL Y CONNECTION BITE TYPE FITTING (P ARKER CPI) FOR 0.250 O.D. TUBING. 2 SCFH A T 3 PSIG (20.69 kPa GAUGE) MAX. CLEAN DRY AIR REQUIRED. FITTING IS LOCA TED ON FAR SIDE. CALIBRA[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-11 World Class 3000 Extended Temperature By -Pass Arrangements (2400 ° F; 1300 ° C) PART NO. GROUP CODE DESCRIPTION 1U0571 G01 3’ By-pass Packa ge with ANSI bolt pattern. 1U0571 G02 6’ By-pass Packa ge with ANSI bo[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 PROBE TROUBLESHOOTING A-7 OVERVIEW The probe troubleshooting section describ es how to identify and isolate faults which may de- velop in the probe assembly. Install all protective equipment and safet[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-13 World Class 3000 Table A-2. Fault Finding (Continued) Symptom Check Fault Remedy 2. System responds to oxygen concentration changes but does not give correct indication Recorder or remote indicator Calibration error R[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-14 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Figure A-16. Flowchart of Probe Related Problems, #1[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-15 World Class 3000 Figure A-17. Flowchart of Probe Related Problems, #2[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-16 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 NOTE ! SERVICE AND NORMAL MAINTENANCE UPON COMPLETING INSTALL ATIO N, MA KE SURE THAT THE PROBE IS TURNED ON AND OPER ATING PRIOR TO FIRING UP THE COMBUSTION PROC ESS. DAMAGE CAN RESULT FROM HAVING A [...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-17 World Class 3000 C ELL EXTENSI O N WI R E (OR AN G E ) B O MB T AIL CO NNE C T OR IN CO NEL C ELL WI R E (C LEA R SLEEVIN G) HEA TE R WI R ES ( BLA C K SLEEVIN G) THE R M OCOUP LE - (R E D AL U MEL ) THE R M OCOUP LE [...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-18 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 OPTIONAL CERAMIC DIFFUSION ELEMENT VEE DEFLECTOR HUB PIN WRENCH SETSCREW RET AINER CEMENT PORT CEMENT FILLET 21240026 Figure A-19. Remov al of O pti o n al Di f fu s or and Vee Deflector PROBE TUBE (N[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-19 World Class 3000 Damage to the diffusion element may be- come apparent during cali bratio n. Compare probe response with previou s response. A broken diffusion element will cause a slower response to calibration gas. [...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-20 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 11. Wipe a heavy layer of anti-seize com- pound onto the threads and mating surfaces of the diffusion hub and retainer. 12. Assemble retainer and diffusion hub with two pin spanner wrenche s. Torque t[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-21 World Class 3000 d. Use a pencil to mark locations of spring clip on c e r am i c r od , Figure A-22. e. Pry or squeeze tabs on spring clips, and pull contact and thermocouple assembly out of probe assembly. Retain sp[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-22 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 lugs and the terminal strip co uld a ct as ad- ditional thermocouple junctions. This could produce a voltage that would affect the thermocouple output signal. Do not bend wires close r than 1/4 inch ([...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-23 World Class 3000 12 4 3 11 5 67 8 9 10 21240012 1. Snub ber Diffusion Element 2. Socket Hd Cap Scre w [0.25 in.-28 x 0.063 (16 mm)] 3. Cell a nd Flange Assembly 4. Corrugated Seal 5. Probe T ube Assembly 6. Gasket [4.[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-24 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Do not use sealant when installing the stainless steel tubes. Gas samples may become contaminated. 2. First install the stainless steel tu bing on the fitting at the bottom o f the probe junction box.[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices A-25 World Class 3000 REPLACEMENT PARTS Table A-3. Replacement Parts for Probe Figure and Index No. Part Number Description Figure A-22 Figure A-22 Figure A-22 Figure A-22 Figure A-22 Figure A-23, 2 Figure A-23, 2 Figure A[...]

Instruction Bulletin Appendix A Rev. 3.9 May 2005 A-26 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Table A-3. Replacement Parts for Probe (Continued) Figure and Index No. Part Number Description Figure A-9 Figure A-11 Figure A-4 Figure A-19 Figure A-25 Figure A-1, 2 Figure A-12 Figure A-14 Figure A[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-1 World Class 3000 APPENDIX B, REV . 2.3 HPS 3000 HEATER POWER SUPPLY DESCRIPTION Read the “Safety instructions for the wiring and installation of this appara- tus” at the front of this Instruction Bulletin. Failure [...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 B-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 TRANSFORMER TRANSFORMER TERMINAL CO VERS FRONT SIDE TERMINAL STRIP (FROM ELECTRONICS) TERMINAL STRIP (FROM PROBE) 35730002 Figure B-2. Heater Power Supply, Interior[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-3 World Class 3000 Table B-1. Specifications for Heater Power Supply Environmental Classificati on .................................................. NEMA 4X (IP56) Opti onal - Class 1, Division 1, Group B (IP56) Electri[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 B-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 In operation, when connected to the CRE 300 0 Control Room Electronics, line voltage passes through the relay (when on) and i s converted into 44 volts by the transformer. If the probe thermocouple ind[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-5 World Class 3000 HEA TER DOES NOT HEA T UP (DOES NOT INCREASE IN OUTPUT). SET METER* FOR 50 V AC. PLACE PROBES ON TERMINAL BLOCK J2, “FROM PROBE”, PROBE HEA TER. METER INDICA TES PULSA TING NOMINAL 44 V AC. DISCONN[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 B-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 HEA TER OVERHEA TS. NOTE: ON INITIAL ST ARTUP THE TEMPERA TURE OF THE PROBE MA Y OVERHEA T TO A NOMINAL TEMP OF 800°C. CHECK IF THE YELLOW WIRE IS CONNECTED TO POSITIVE AND THE RED T O NEGA TIVE ON BO[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-7 World Class 3000 PROBE HEA TER ST AR T TO HEA T UP AND THEN LOOSES TEMPERA TURE. (MODEL TC200 ONL Y) CHECK P ARAMETER 35 ON TC200. IF THE NUMBER IS NEGA TIVE THEN SOMEWHERE THE THERMOCOUPLE WIRES ARE REVERSED. SYMPTOM [...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 B-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 SERVICE AND NORMAL MAINTENANCE B-5 OVERVIEW This section describes service and routine maintenance of the HPS 3000 Heater Power Supply Field Module. Replacement parts referred to are available from Ros[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-9 World Class 3000 i. Making a note of the location and color of each wire, disconnect wires from termin al strip on mother board. j. Remove four screws (9) holding mother board to stand offs (10) on subplate (14). k. Re[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 B-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 35730006 NO TE: NOT ALL P ARTS SHO WN ARE A V AI LABLE FOR PURCHASE SEP ARA TEL Y . FOR LIST OF A V AI LABLE P ARTS SEE T ABLE B-2. Figure B-7. Heater Power Supply, Exploded View[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices B-11 World Class 3000 LEGEND FOR FIGURE B-7 1. Enclosure Cover 2. Screw 3. Lockwasher 4. Terminal Cover 5. Stand Off 6. Lockwasher 7. Daughter Board 8. Terminal Cover 9. Screw 10. Stand Off 11. Hex Nut 12. Mother Board 13.[...]

Instruction Bulletin Appendix B Rev. 2.3 May 2005 B-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-1 World Class 3000 APPENDIX D, REV 2.5 MPS 3000 MULTIPROBE CALIBRATION GAS SEQUENCER DESCRIPTION Read the “Safety instructions for the wiring and installation of this appara- tus” at the front of this Instruction Bul[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 D-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 PO WER SUPPL Y REGULA T OR TUBE SOLENOID MANIFOL D HOSE AD APTER CABLE GRIP TER MINATION BOARD FLO WMETER 27270024 Figure D-2. Multiprobe Calibration Gas Sequencer, Interior Table D-1. Specifications f[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-3 World Class 3000 PROBE (END VIEW) IFT CALIBRA TION GAS HPS OPTIONAL CHECK VA LV E PROBE SIGNAL CONNECTIONS MPS-IFT SIGNAL CONNECTIONS MPS INSTRUMENT AIR IN CALIBRA TION GAS 1 (HIGH ) O 2 CALIBRA TION GAS 2 (LOW O ) 2 3[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 D-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 REFERENCE PURGE Analytical NOTE: DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN P ARENTHESES. 3 "BEBCO" PURGE W ARNING NOTICE SUPPLIED WITH BEBCO UNIT AND TO BE INST ALLED ON MPS UNIT AS SHOWN.[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-5 World Class 3000 MPS 3000 TROUBLESHOOTING D-3 OVERVIEW This section describes tro ubleshooting for the Multiprobe Calibration Gas Sequen cer. Addi- tional troubleshooting information can be found in the Instruction Bul[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 D-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 YES YES NO NO SYMPTOM SOLENOID IS OPERA TING NORMALL Y . ENSURE THA T A SUFFICIENT SUPPL Y OF CALIBRA TION GAS IS A V AILABLE. CALL FOR F ACTOR Y ASSIST ANCE. SET METER* FOR 50 VDC. PLACE PROBES ON TER[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-7 World Class 3000 SERVICE AND NORMAL MAINTENANCE D-5 OVERVIEW This section describes service and routine maintenance of the MPS 3000 Multiprobe Cali- bration Gas Sequencer. Repla ceme nt part s re- ferred to are availab[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 D-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Analytical 37840017 49 49 50 53 53 41 31 54 14 34 54 1 17 16 18 15 26 27 42 48 46 42 40 30 30 22 35 36 37 21 32 4 33 58 57 59 60 56 21 44 45 19 20 42 51 43 52 47 62 61 55 2 3 38 39 25 24 23 28 29 5 63 [...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-9 World Class 3000 LEGEND FOR FIGURE D-6 1. Enclosure 2. Screw 3. Plug 4. Cable Grip 5. Fitting 6. Hose Adapter 7. Pressure Switch 8. Plug 9. Solenoid Valv e 10. Screw 11. Manifold 12. Washer 13. Screw 14. Gasket 15. Out[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 D-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 D-10 FLOWMETER ADJUSTMENTS There are two flowmeters per flowmeter assem- bly. The top flowmeter is factory set to 5 scfh. The bottom flowmeter is set to 2 scfh. Should the flow need to be changed or a[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices D-11 World Class 3000 REPLACEMENT PARTS Table D-3. Replacement Parts for the Multiprobe Test Gas Sequencer FIGURE and INDEX No. PART NUMBER DESCRIPTION Figure D-6, 58 1A97909H01* Power Supply Figure D-6, 9 3D39435G01** Sol[...]

Instruction Bulletin Appendix D Rev. 2.5 May 2005 D-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-1 World Class 3000 APPENDIX E, REV . 4.6 IFT 3000 INTELLIGENT FIELD TRANSMITTER DESCRIPTION Read the “Safety instructions for the wiring and installation of this appara- tus” at the front of this Instruction Bulletin[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 E-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 f. Z-Purge (optional) A Z-purge arrangement is available for ap- plications requiring hazardous area cl assifi- cation. See Application Data Bulletin AD 106-300B. E-2 THEORY OF OPERATION A functional b[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-3 World Class 3000 PROBE ZERO CROSSING DETECTOR TRIAC RELA Y TO HEA TER COLD JUNCTION TEMP . PROBE TC ST ACK TC CELL LINE RELA Y TRIAC AD590 PROBE TC ST ACK TC CELL MV HEA TER POWER SUPPL Y (OPTIONAL) IFT TRANSFORMER 378[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 E-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 IFT 3000 TROUBLESHOOTING E-3 OVERVIEW The IFT troubleshooting section describes how to identify and isolate faults which may develop in the IFT. Install all protective equipment cov ers and safety grou[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-5 World Class 3000 Figure E-3. IFT Troubleshooting Flowchart, #1[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 E-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 YES YES O XY G EN ANAL YZE R SYSTEM IS EQ U I PP E D WITH H P S 3000 . C HE C K JU M P E R S J M6 O N MI CROPROC ESS OR B O A RD AN DJ M1 O N INTE RCO NNE C T B O A RD A R E INST ALLE D . C HE C K JU M[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-7 World Class 3000 Table E-2. GUI Equipped IFT Fault Finding SYMPTOM COMPONENT FAILURE 1. Display is blank. Possible failure within IFT. Check LED on micropro ce ssor board. 2. CalEr is displayed. Repeat calibration sequ[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 E-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 37840025 14 8 9 4 3 11 10 12 5 13 6 1 2 1 7 1. Captive Scre w 2. Enclosure Cover 3. Fuseholder Cap 4. F use, 5 Amp 5. Electronics Chassis 6. Enclosure 7. Ribbon Cabl e 8. Ribbon Cabl e 9. Connector Plu[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-9 World Class 3000 SERVICE AND NORMAL MAINTENANCE E-5 OVERVIEW Use the instructions in this section of the ap- pendix to repair the Intelligent Field Transmitter. Disassemble the unit only as needed to repla ce damaged c[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 E-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 37840026 1 2 3 4 5 6 7 9 8 10 11 1. Screw 2. Plastic Washer 3. Microprocessor Board 4. Interconnect Board 5. Mounting Plate 6. Screw 7. Internal L ock Washer 8. Screw 9. Hex Nut 10. Fan 11. Connector [...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-11 World Class 3000 E-9 REPLACE MICR OPROCESSOR BOARD a. Remove four screws (1, Figure E-7) and washers (2). Pull very carefully on the microproc- essor board to ensure that none o f the mating connector pins are dam- ag[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 E-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 37840027 1 2 3 13 9 11 10 14 12 7 5 3 6 5 4 15 8 5 1. Screw 2. Protective Cover 3. Standoff 4. Po wer Supply Board 5. Screw 6. Plastic Washer 7. Internal L ock Washer 8. Electronics Chassis 9. Screw 1[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-13 World Class 3000 E-13 REPLACE TRANSFORMER a. Unplug tran sfo rmer connector pl ug s (not shown) from power supply board (4, Figure E-8). b. Remove four screws (9 ), flat washers (10), and internal lock washers (11). c[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 E-14 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 37840032 12 6 7 9 8 10 3 11 4 1 2 1 5 13 16. Captive Scre w 17. Enclosure Cover 18. Electronics Chassis 19. Enclosure 20. Ribbon Cabl e 21. Ribbon Cabl e 22. Connector Plug 23. Screw 24. Washer 25. Mi[...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices E-15 World Class 3000 37840028 7 6 4 3 2 1 5 E-16 REPLACE GUI ASSEMBLY OR RIBBON CABLE Use the following instruction s to repla ce the GUI assembly or the mating ribbon cable. a. Unplug rib bon cable (1, Figure E-10) from [...]

Instruction Bulletin Appendix E Rev. 4.6 May 2005 E-16 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 REPLACEMENT PARTS Table E-3. Replacement Parts fo r the Intelligent Field Transmitter. FIGURE and INDEX No PART NUMBER DESCRIPTION Figure E-8, 13 1N0494 6G0 1 Transformer Figure E-7, 4 3D39120G01 Inte[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-1 World Class 3000 APPENDIX J, REV 1.2 HART COMMUNICATOR MODEL 275/375 IFT 3000 APPLICATIONS DESCRIPTION J-1 COMPONENT CHECKLIST OF TYPICAL HART ® COMMUNI CATOR PACKAGE A typical Model 275D9E HART ® Communicator packag[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 J-2 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 b. Device Description The HART (Highway Addressable Remote Transducer) Communi cator is a hand-held communications interface devi ce. It provide s a common communications link to all microproc- essor-b[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-3 World Class 3000 INSTALLATION J-4 HART COMMUNICATOR SIGN AL LINE CONNECTIONS The HART Communicato r ca n connect to the IFT analog output signal line at any wiring ter- mination point in the 4-20 mA current loop. There[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 J-4 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Explosions can result in death or seri- ous injury. Do not make connections to the HART Communicator's serial port or NiCad recharger jack in an ex- plosive atmosphere. 1. Program IFT analog outpu[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-5 World Class 3000 INTELLIGENT FIELD TRANSMITTER IFT 3000 J1 JM1 J2 J3 J4 J5 J6 J7 J8 J9 250 OHM LOAD RESISTOR (SEE NOTE) THE SIGNAL LOOP MUST BE BROKEN TO INSER T THE OPTIONAL 250 OHM LOAD RESISTOR . NO TE: LOOP CONNECT[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 J-6 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 OPERATION J-6 OFF-LINE AND ON-LINE OPER ATIO NS The HART Communicato r can be operated both off-line and on-line. Off-line operations a re those in which the communicator is not conne cted to the IFT s[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-7 World Class 3000 Oxygen Efficiency Stack O cell CJtemp 2 VIEW FLD DEV V ARS PV is PV PV % mge PV AO PROCESS V ARIABLES DIAG/SERVICE VIEW PV -Aout VIEW OUTPUT V ARS VIEW SV SV is SV SV % mge O cell Cell TC Stack TC CJmV[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 J-8 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 DEVICE SETUP PV PV AO PV LRV PV URV (CONTINUED ON SHEET 3) Ta g ASSIGN P V&S V SELECT O RANGE 2 Set O Xfer fn 2 DEVICE INFORMA TION Manufacturer Distributor Model Dev id Ta g Descriptor Message Dat[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-9 World Class 3000 DEVICE SETUP PV PV AO PV LRV PV URV (CONTINUED FROM SHEET 2) Manufacturer Distributor Model Dev id Ta g Descriptor Message Date Final asmbly num Snsr s/n Fld dev rev Hardware rev Software rev Universal[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 J-10 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 TROUBLESHOOTING J-8 OVERVIEW If the HART Communicato r fails to function properly, verify that the unit's battery pack and memory module are correctly assembled to the communicator. C heck the co[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-11 World Class 3000 DOES HART UNIT HA VE POWER ? DOES HART UNIT INDICA TE BA TTERY POWER GOOD ? IS HART UNIT BEING USED "ON-LINE" ? IS HART UNIT CONFIGURED FOR IFT? IS IFT POWERED ? IS IFT EXPERIENCING F AUL TS[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 J-12 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Figure J-5. Model 275D9E, Troubleshooting Flo wchart (Sheet 2 of 2)[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices J-13 World Class 3000 RETURNING EQUIPMENT TO THE FACTORY J-10 If factory repair of equipment is required, pro- ceed as follows: a. Secure a return authori zation number from a Rosemount Analytical Sales Office or Represent[...]

Instruction Bulletin Appendix J Rev. 1.2 May 2005 J-14 Appendices Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 Rosemount Analytical Inc. A Division of Emerson Process Management Appendices 9-1 World Class 3000 SECTION 9 INDEX This index is an alphabetized listing of part s, terms, and procedures for the Worl d Class 3000 Instruction Manua l. Each item listed in this index refers to a location in the manual b[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 9-2 Index Rosemount Analytical Inc. A Division of Emerson Process Management World Class 3000 Q Quick Reference Chart, 5-3 R Reference Air, 1-1, 2-8, 2-21 S Semiautomatic Calibration, 2-22, 4-2, 4-6 SETUP Sub-Menu, 5-4 Status Line, 5-3 Stop Valve, 1-7 T TGH, 5-2 TGL, 5-2 Troubleshooting, 6-1 V Vee D[...]

365 6 3784/5-05 ROSEMOUNT ANALYTICAL WARRANTY Rosemount Analytical warrant s that the equip ment manufactured and sold by it will, upon ship- ment, be free of defects in workmanship or materi al. Should any failure to conform to this war- ranty become apparent during a peri od of one year after the date of shipment, Rosemount Ana- lytical shall, up[...]

Instruction Manual IB-106-300NH Rev. 4.3 May 2005 © Rosemount Analytical Inc. 2005 WORLD HEADQUARTERS Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 6565P Davis Industrial Parkway Solon, OH 44139 T 440 914 1261 T 800 433 6076 gas.csc@emersonprocess.com ASI A – P AC I FI C Emerson Process Management Asia Pacific Pr[...]