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B-106-300NH
User Manual
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Emerson B-106-300NH User Manual

Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
World Class 3000
Oxygen Analyzer with IFT 3000 Intelligent Field Transmitter
http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and mainte-
nance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate In- struction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s per­formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.
If a Model 275 Universal HART® Communicator is used with this unit, the software within the Model 275 may require modification. If a software modification is required, please contact your local Fisher-Rosemount Service Group or National Response Center at 1-800-654-7768.
The information contained in this document is subject to change without notice.
Process Analytic Division
1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.c om
http://www.processanalytic.c om

HIGHLIGHTS OF CHANGES

Effective May, 1999 Rev. 4.0
Page Summary
Page P-6 Added new Quick Start Guide. Page 3-1 Added Section 3, Setup. Page 4-1 Removed calibration information from Operation section, and created
Section 4, Calibration. Page 6-2 Expanded explanations of IFT status codes. Section 6 Added new troubleshooting procedures.
Effective November, 2001 Rev. 4.1
Page Summary
Highlights Updated Highlights of Changes Appendix A page. Appendix A Replaced Appendix A, Rev. 3.6 with Rev. 3.7.
Effective July, 2002 Rev. 4.2
Page Summary
Highlights Updated Highlights of Changes Appendix A page. Page 4-1 Added reference to new Calibration Record sheet. Page 4-9 Added new Calibration Record sheet. Appendix A Replaced Appendix A, Rev. 3.7 with Rev. 3.8.
HIGHLIGHTS OF CHANGES
APPENDIX A
Effective May, 1996 Rev. 3
Page Summary
-- General. Updated appendix to reflect probe design changes. Page A-13 Added “Extended temperature by-pass arrangements” to Figure A-13
(Sheet 3 of 3)
Effective June, 1996 Rev. 3.1
Page Summary
Page A-13 Updated part ordering information.
Effective August, 1996 Rev. 3.2
Page Summary
Page A-25 Updated cell replacement kit part numbers for the probe.
Effective October, 1996 Rev. 3.3
Page Summary
Page A-6 Added NOTE to Figure A-7.
Effective January, 1997 Rev. 3.4
Page Summary
Page A-1 Added warning to read new safety instructions. Page A-12 Added protective covers and grounds warning. Page A-16 Added protective covers and grounds warning.
Effective February, 1998 Rev. 3.5
Page Summary
Page A-18 Changed screw torque in paragraph A-11h.
Effective July, 1998 Rev. 3.6
Page Summary
-- Changed test gas to calibration gas and reference gas to reference
air throughout the appendix.
HIGHLIGHTS OF CHANGES (CONTINUED)
Effective November, 2001 Rev. 3.7
Page Summary
A-8 Added new cup type diffusion assembly description, paragraph A-6.e.
and diffusion assembly illustrations, Figure A-13 and A-14. A-26 Added new cup type diffusion assembly part numbers 4851B89G04
and 4851B90G04 to replacement parts list. Deleted stainless steel
diffuser assembly from replacement parts list.
Effective July, 2002 Rev. 3.8
Page Summary
A-13 Added troubleshooting symptoms 5 and 6 to Table A-2.
HIGHLIGHTS OF CHANGES
APPENDIX B
Effective February, 1992 Rev. 2
Page Summary
Page B-1 Figure B-1. New HPS 3000 Optional Class 1, Division 1, Group B
(IP56) Explosion-Proof Enclosure added.
Page B-11 Figure and Index No. column added to Table B-2. Replacement Parts
for Heater Power Supply.
Effective January, 1995 Rev. 2.1
Page Summary
Page B-3 Updated Figure B-3, Heater Power Supply Block Diagram for IB
consistency.
Effective January, 1997 Rev. 2.2
Page Summary
Page B-1 Added warning to read new safety instructions.
Page B-3 Corrected Table B-1 specifications list.
Page B-4 Added protective covers and grounds warning.
Page B-8 Added protective covers and grounds warning.
Page B-11 Added expanded fuse description.
HIGHLIGHTS OF CHANGES
Effective June, 1994 Rev. 2
Page Summary
APPENDIX D
Page D-1 Page D-2
Page D-3
Page D-4
Page D-7
Page D-8
Page D-10
Page D-11
Page Summary
Page D-1 Updated Figure D-1, MPS 3000 to include hinge.
Page Summary
Page D-11 Updated replacement parts list to reflect new part numbers.
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 location of optional Z-Purge added as Figure D-4.
Power supply replacement procedures in paragraph D-7 changed to
reflect new design in the MPS. Solenoid valve replacement proce-
dures in paragraph D-8 changed to reflect new design in the MPS.
Old exploded view of MPS replaced with new MPS.
Paragraph D-11, Adding Probes to the new MPS, added.
Change part numbers for the power supply, solenoid valve, and test
gas flowmeter assembly. Add part numbers for reference gas flow-
meter assembly and all the parts in the probe adder kit.
Effective January, 1995 Rev. 2.1
Effective May, 1996 Rev. 2.2
Effective January, 1997 Rev. 2.3
Page Summary
Page D-1
Page D-2 Page D-5
Page D-7
Page D-11
Page Summary
--- Changed test gas to calibration gas and reference gas to reference
Added warning to read new safety instructions.
Corrected Table D-1 Specifications listing, 1
Added protective covers and grounds warning.
Added protective covers and grounds warning, corrected item num-
ber errors in paragraph D-6.
Added expanded fuse descriptions.
Effective July, 1998 Rev. 2.4
air throughout the appendix.
st
entry.
HIGHLIGHTS OF CHANGES
APPENDIX E
Effective May, 1996 Rev. 4
Page Summary
--- General. Updated text and illustrations to reflect new version of IFT.
Page E-4 Updated IFT display status codes and placed in priority sequence.
Effective June, 1996 Rev. 4.1
Page Summary
Page E-2 Updated specification table.
Effective October, 1996 Rev. 4.2
Page Summary
Page E-4 Added new status displays for password protection features.
Effective January, 1997 Rev. 4.3
Page Summary
Front matter Added "Safety instructions for the wiring and installation of this
apparatus.”
Page E-1 Added warning to read new safety instructions.
Page E-2 Deleted NOTE.
Page E-4 Added protective covers and grounds warning.
Page E-8 Added protective covers and grounds warning.
Page E-15 Added expanded fuse description.
Effective July, 1998 Rev. 4.4
Page Summary
--- Changed test gas to calibration gas throughout the appendix.
Effective June, 1999 Rev. 4.5
Page Summary
Page E-1 Changed “real time clock” to “timer”.
HIGHLIGHTS OF CHANGES
APPENDIX J
Effective April, 1995 Rev. 1
Page Summary
Page J-13 Added statement of reference to the return authorization number.
Effective June, 1995 Rev. 1.1
Page Summary
— Figure J-4. Updated figure to include “Status group” and “K3 eff” in
calculations.
World Class 3000
PREFACE........................................................................................................................P-1
Definitions........................................................................................................................P-1
Safety Instructions..........................................................................................................P-2
Glossary of Terms .........................................................................................................P-3
Quick Start Guide ..........................................................................................................P-6
1-0 DESCRIPTION AND SPECIFICATIONS...................................................................... 1-1
1-1 Component Checklist of Typical System (Package Contents).................................. 1-1
1-2 System Overview............................................................................................................ 1-2
2-0 INSTALLATION .............................................................................................................. 2-1
2-1 Oxygen Analyzer (Probe) Installation........................................................................... 2-1
2-2 Intelligent Field Transmitter (IFT) Installation.............................................................. 2-9
2-3 Heater Power Supply Installation ............................................................................... 2-14
2-4 Multiprobe Calibration Gas Sequencer Installation.................................................. 2-22
3-0 SETUP............................................................................................................................. 3-1
3-1 Overview.......................................................................................................................... 3-1
3-2 Configuring the Analog Output..................................................................................... 3-1
3-3 Setting Calibration Parameters....................................................................................... 3-1
3-4 Setting the O
3-5 Configuring Efficiency Calculations............................................................................... 3-2
3-6 Configuring the Relay Outputs ..................................................................................... 3-2
Instruction Manual
IB-106-300NH Rev. 4.2

TABLE OF CONTENTS

Alarm Setpoints.................................................................................... 3-2
2
July 2002
4-0 CALIBRATION................................................................................................................ 4-1
4-1 Analog Output Calibration ............................................................................................. 4-1
4-2 System Calibration ......................................................................................................... 4-1
5-0 GENERAL USER INTERFACE (GUI) OPERATION.................................................. 5-1
5-1 Overview.......................................................................................................................... 5-1
5-2 Deluxe Version IFT Displays and Controls................................................................. 5-2
5-3 Help Key......................................................................................................................... 5-3
5-4 Status Line...................................................................................................................... 5-3
5-5 Quick Reference Chart.................................................................................................. 5-3
5-6 Main Menu......................................................................................................................5-3
5-7 Probe Data Sub-Menu................................................................................................... 5-3
5-8 Calibrate O
5-9 Setup Sub-Menu............................................................................................................. 5-4
6-0 TROUBLESHOOTING.................................................................................................... 6-1
6-1 Overview.......................................................................................................................... 6-1
6-2 Special Troubleshooting Notes...................................................................................... 6-1
6-3 System Troubleshooting................................................................................................. 6-1
6-4 Heater Problem ..............................................................................................................6-3
6-5 Cell Problem................................................................................................................... 6-5
6-6 IFT Problem....................................................................................................................6-7
6-7 MPS Problem .................................................................................................................6-8
6-8 Performance Problem (Process Response is Suspect)............................................. 6-9
Sub-Menu.................................................................................................. 5-4
2
Rosemount Analytical Inc. A Division of Emerson Process Management i
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
7-0 RETURN OF MATERIAL.............................................................................................. 7-1
8-0 APPENDICES ................................................................................................................. 8-1
Appendix A .....................................................................................................................A-1
Appendix B .....................................................................................................................B-1
Appendix D.....................................................................................................................D-1
Appendix E .....................................................................................................................E-1
Appendix J.......................................................................................................................J-1
9-0 INDEX.............................................................................................................................. 9-1
Figure 1. Complete World Class 3000 System.....................................................................P-5
Figure 2. Wiring Layout for World Class 3000 System without HPS or MPS.......................P-8
Figure 1-1. Typical System Package ....................................................................................... 1-1
Figure 1-2. Typical System Installation .................................................................................... 1-5
Figure 1-3. World Class 3000 Typical Application with Intelligent Field Transmitters ............. 1-6
Figure 2-1. Probe Installation................................................................................................... 2-2
Figure 2-2. Orienting the Optional Vee Deflector..................................................................... 2-7
Figure 2-3. Air Set, Plant Air Connection................................................................................. 2-8
Figure 2-4. Outline of Intelligent Field Transmitter................................................................... 2-9
Figure 2-5. Power Supply Board Jumper Configuration ........................................................ 2-10
Figure 2-6. Signal Wire Routing............................................................................................. 2-11
Figure 2-7. IFT Power Supply Board Jumpers....................................................................... 2-12
Figure 2-8. Wiring Layout for IFT Systems without HPS ....................................................... 2-13
Figure 2-9. Microprocessor Board Jumper Configuration..................................................... 2-14
Figure 2-10. IFT Microprocessor Board ................................................................................... 2-15
Figure 2-11. Interconnect Board Jumper Configuration........................................................... 2-16
Figure 2-12. IFT Interconnect Board Output Connections....................................................... 2-16
Figure 2-13. Outline of Heater Power Supply .......................................................................... 2-17
Figure 2-14. Wiring Layout for Complete IFT 3000 System with HPS (Sheet 1of 2)............... 2-18
Figure 2-15. Heater Power Supply Wiring Connections .......................................................... 2-20
Figure 2-16. Jumper Selection Label ....................................................................................... 2-21
Figure 2-17. Jumpers on HPS Mother Board........................................................................... 2-21
Figure 2-18. MPS Module ........................................................................................................2-22
Figure 2-19. MPS Gas Connections ........................................................................................2-23
Figure 2-20. MPS Probe Wiring ............................................................................................... 2-24
Figure 4-1. Typical Calibration Setup....................................................................................... 4-4
Figure 4-2. Portable Rosemount Oxygen Calibration Gas Kit ................................................. 4-5
Figure 4-3. Typical Portable Calibration Setup ........................................................................ 4-6
Figure 4-4. Typical Automatic Calibration System................................................................... 4-7
Figure 5-1. Deluxe Version IFT Displays and Controls............................................................ 5-2
Figure 5-2. Quick Reference Chart .......................................................................................... 5-5
World Class 3000
LIST OF ILLUSTRATIONS
ii Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
Table 4-1. Automatic Calibration Parameters......................................................................... 4-8
Table 5-1. Sample HELP Messages....................................................................................... 5-3
Table 5-2. MAIN menu............................................................................................................ 5-3
Table 5-3. PROBE DATA Sub-Menu...................................................................................... 5-4
Table 5-4. CALIBRATE O
Table 5-5. SETUP Sub-Menu ............................................................................................... 5-12
Table 5-6. Efficiency Constants ............................................................................................ 5-14
Table 6-1. IFT Status Codes................................................................................................... 6-2
Table 6-2. Heater Troubleshooting ......................................................................................... 6-3
Table 6-3. Cell Troubleshooting.............................................................................................. 6-5
Table 6-4. IFT Troubleshooting............................................................................................... 6-7
Table 6-5. MPS Troubleshooting ............................................................................................ 6-8
Table 6-6. Performance Problem Troubleshooting................................................................. 6-9
Instruction Manual
IB-106-300NH Rev. 4.2

LIST OF TABLES

Sub-Menu.................................................................................. 5-10
2
July 2002
Rosemount Analytical Inc. A Division of Emerson Process Management iii
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
World Class 3000
iv Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
The 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. We recommend that you familiarize yourself with the Overview and Installation sec­tions before installing your emissions monitor.
The overview presents the basic principles of the oxygen analyzer along with its perform­ance characteristics and components. The remaining sections contain detailed proce­dures and information necessary to install and service the oxygen analyzer.
NOTE
!
Only one probe can be calibrated at a time. Probe calibrations must be scheduled appropriately in multiple probe applications.
PREFACE
DEFINITIONS
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.
Highlights an operation or maintenance procedure, practice, condition, state­ment, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.
NOTE
Highlights an essential operating procedure, condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
Highlights an operation or maintenance procedure, practice, condition, state­ment, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE TO USERS

The 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.
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
FOR THE WIRING AND INSTALLATION
The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non­EU states should also comply with the following unless superseded by 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 of all earth terminals must be maintained at all times.
3. Mains supply cords should comply with the requirements of IEC227 or IEC245.
World Class 3000
IMPORTANT

SAFETY INSTRUCTIONS

OF THIS APPARATUS
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 a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.
7. Where equipment or covers are marked with the symbol to the right, hazard­ous voltages are likely to be present beneath. These covers should only be removed when power is removed 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 danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Cer­tain surfaces may remain hot to the touch.
9. Where equipment or covers are marked with the symbol to the right, refer to the Operator 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.
P-2 Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
Abrasive Shield
An optional component that shields the probe from high velocity particulate entrained in the flue gas stream.
Automatic Calibration
An automatic calibration can only be performed if the system is equipped with an MPS 3000 Mul­tiprobe Calibration Gas Sequencer. Once a calibration is initiated by the operator or by the IFT on a scheduled interval, all calibration actions are performed by the IFT. The MPS switched calibra­tion gases under direction from the IFT.
Calibration
The process of measuring gases of a known concentration, and comparing that known concen­tration to the actual values sensed by the instrument. After reading the calibration gases, the IFT automatically adjusts the slope and constant values to ensure that the system is correctly reading the process gas O
Cold Junction Compensation
A method for compensating for the small voltage developed at the junction of the thermocouple leads in the probe junction box.
values.
2
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002

GLOSSARY OF TERMS

Dead Band
The range through which a signal can be varied without initiating a response. In the IFT 3000, dead band is used to prevent an oxygen signal near an alarm setpoint from cycling the alarm on and off.
GUI
General User Interface. The GUI is the operator interface for the IFT 3000.
HART
A communications protocol using frequency shift keying (FSK) to transmit data on an analog out­put line without affecting the analog output signal.
HPS
Heater Power Supply. An HPS should be used to provide power for the probe heater if the probe is more than 150 ft (45 m) from the IFT.
IFT
Intelligent Field Transmitter.
In Situ
A method of analyzing process gases without removing them from the process stream.
MPS
Multiprobe Calibration Gas Sequencer. The MPS can provide automatic calibration gas se­quencing for up to four probes.
Rosemount Analytical Inc. A Division of Emerson Process Management P-3
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
Reference Air
Provides a known oxygen concentration to the reference side of the oxygen sensing cell.
Semiautomatic Calibration
Semiautomatic calibration is performed when the system does not include an MPS 3000 Multi­probe Calibration Gas Sequencer. The IFT 3000 provides prompts to direct the user to switch calibration gases when performing the calibration.
Thermocouple
An electrical device made of two dissimilar metals. A thermocouple develops a millivolt signal proportional to its temperature.
Vee Deflector
Protects the optional ceramic diffusor from the process gases. The vee deflector must be posi­tioned so it points toward the direction of the process gas flow. See Figure 2-2 for an illustration of the vee deflector.
World Class 3000
P-4 Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
BEFORE INSTALLING AND WIRING A ROSEMOUNT IFT 3000
1. What is the line voltage being supplied to the IFT 3000? Write the line voltage here __________
2. Use the following drawing, Figure 1, to identify which parts of the World Class 3000 system are included in your system. Components in the shaded area are optional components.
STACK
THERMOCOUPLE
(OPTIONAL )
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
WHAT YOU NEED TO KNOW
INTELLIGENT FIELD TRANSMITTER WITH WORLD CLASS 3000 PROBE
LINE
VOLT AGE
LINE VOLT AGE
HPS 3000
(OPTIONAL )
WC PROBE 3000
Figure 1. Complete World Class 3000 System
IFT 3000
LINE VOLT AGE
MPS 3000
(OPTIONAL )
CALIBRA TION
GAS
BOTTLES
29850003
Rosemount Analytical Inc. A Division of Emerson Process Management P-5
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
Use this Quick Start Guide if ...
1. You are using a World Class 3000 probe.
2. You are NOT using any optional components. Optional components are shown in the shaded area in Figure 1.
3. You are familiar with the installation requirements for the IFT 3000 Intelligent Field Trans­mitter and World Class 3000 probe.
4. You are familiar with the procedures for changing the jumpers located in the IFT 3000, as described in Section 2, Installation.
If you cannot use the Quick Start Guide, turn to Section 2, Installation, in this Instruction Bulletin.
World Class 3000
QUICK START GUIDE
P-6 Rosemount Analytical Inc. A Division of Emerson Process Management
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 ROSEMOUNT IFT 3000 INTELLIGENT FIELD TRANSMIT­TER WITH WORLD CLASS 3000 PROBE” on the preceding page.
1. Install the probe in an appropriate location on the stack or duct. Refer to Section 2, para­graph 2-1a for information on selecting a location for the probe.
2. Connect calibration gas and reference air to the probe.
3. Verify the jumper selection on the IFT 3000 power supply board, microprocessor board, and interconnect board, as shown in Figure 2.
4. Install the IFT 3000 in the desired location. Refer to Section 2, paragraph 2-2a for informa­tion on selecting a location for the IFT 3000.
5. Wire the probe to the IFT as shown in Figure 2.
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
6. Connect line voltage to the IFT as shown in Figure 2.
7. Apply power to the IFT 3000. Allow sufficient time for the probe to reach normal operating temperature. The time required will vary based on process temperature and other variables.
8. Perform a manual (semiautomatic) calibration. Press the CAL key on the GUI. Select the PERFORM CALIBRATION sub-menu. “Press ENTER to start Manual Calibration” will appear on the LCD display. Press ENTER to start the calibration process. Follow the in­structions on the LCD display. Refer to Section 4, Calibration, for more information on per­forming a calibration.
Rosemount Analytical Inc. A Division of Emerson Process Management P-7
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
PROBE JUNCTION
BOX WIRING
GN CELL -VE
OR CELL +VE
YE CHROMEL
RD ALUMEL
GN
BK
HEATER
}
World Class 3000
WORLD CLASS
PROBE
BK
123456 78
BL
YE
RD
OR
PROBE MV -
PROBE MV +
PROBE TC +
GNE
PROBE TC -
LINE VOLTAGE SECTION
100 V.A.C. 120 V.A.C. 220 V.A.C. 240 V.A.C.
LINE VOLTAGE
JUMPERS ON IFT
POWER SUPPLY
JUMPER
(INSTALL) JM3, JM7, JM2 JM8, JM7, JM1
JM6, JM5, JM2 JM6, JM5, JM1
BOARD
WH
R
BK
H
J1
3D39122G REV
POWER SUPPLY BOARD
LINE VOLTAGE SECTION
100 V.A.C.
JM3, JM7, JM2
120 V.A.C.
JM8, JM7, JM1
220 V.A.C.
JM6, JM5, JM2 JM6, JM5, JM1
240 V.A.C.
JUMPER
(INSTALL)
J2 J3 J4
3D39120G REV
INTERCONNECT BOARD
J1
J5
J6
J5 J6
J7
SHIELD STACK TC ­STACK TC +
J8 J9
SHIELD
L
LINE
VOLTAGE
BK WH
GN PU
OR
BL YE
RD
H
EN
ER
PROBE TC -
RD YE
PROBE TC +
SHIELD
BL
PROBE MV PROBE
OR
-
MV+
JM1
NOTES:
INSTALL JUMPER ACROSS TERMINALS 13 AND 14.
INSTALL JUMPER ACROSS TERMINALS 7 AND 8.
29850002
Figure 2. Wiring Layout for World Class 3000 System without HPS or MPS
P-8 Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
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 CALIBRATION sub-menu.
4. Press the ENTER key.
5. Turn on the high calibration gas.
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
QUICK REFERENCE GUIDE
6. When the O
7. Turn off the high calibration gas and turn on the low calibration gas.
8. Press Enter.
9. When the O
10. The LCD display will show “Resistance Check”. When the display changes to “Turn off low calibration gas”, turn off the low calibration gas and press ENTER.
11. When the oxygen reading has stabilized at the process value, press ENTER.
Setting up the Analog Output
1. Press the SETUP key.
2. Select the Analog Output sub-menu.
3. Set the SOURCE to O Dual Range O
4. Set the AOUT TYPE to the desired setting. Note that the setting must agree with the position of the analog output selector switch. If you will communicate with the IFT using HART com­munications, the AOUT TYPE must be set to HART 4-20mA.
5. Select Range Setup and press ENTER.
6. Set the Xfer Fnct to Lin or Log, as desired.
7. Select Range Values and press ENTER.
reading is stable, press ENTER.
2
reading is stable, press ENTER.
2
. For information on configuring the analog output for Efficiency or
, refer to Section V, Operation.
2
2
8. Set the High End to the oxygen concentration to be represented by the high analog output value, i.e., 20mA or 10V.
9. Set the Low End to the ox ygen conc entr at ion to be repres ent ed b y the low anal og outp ut value, i.e., 0 or 4mA or 0V.
10. Press the ESC key until you are back at the Main menu.
Rosemount Analytical Inc. A Division of Emerson Process Management P-9
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002

HART COMMUNICATOR FAST KEY SEQUENCES

Toggle Analog Output Tracking View O2 Value
World Class 3000
Perform Calibration Analog Output Upper Range Value
2313 324
Trim Analog Output Analog Output Lower Range Value
24 325
2312 111
View Analog Output
121
Technical Support Hotline:
For assistance with technical problems, please call the Customer Support Center (CSC). The CSC is staffed 24 hours a day, 7 days a week.
Phone: 1-800-433-6076
In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Rosemount’s field service throughout the US and abroad.
Phone: 1-800-654-RSMT (1-800- 6 54-77 68)
Rosemount may also be reached via the Internet through e-mail and the World Wide Web:
E-mail: GAS.CSC@emersonprocess.com
World Wide Web: www.processanalytic.com
P-10 Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
1

DESCRIPTION AND SPECIFICATIONS

Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
SECTION 1
1-1 COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
A typical Rosemount World Class 3000 Oxygen Analyzer with IFT 3000 Intelligent Field Trans-
1
mitter should contain the items shown in Figure 1-1. Record the part number, serial number, and order number for each component of your sys­tem in the table located on the first page of this manual.
1. Intelligent Field Transmitter
2. Instruction Bulletin
3. Multiprobe Calibration Gas Sequencer (Optional)
4. Heater Power Supply (Optional)
5. Oxygen Analyzer (Probe)
6. System Cable
7. M Adapter Plate with mounting hardware and gasket
2
8. Reference Air Set (If MPS not supplied)
9. HART
®
Communicator Package (Optional)
3
4
5
21190001
HART
MAN4275A00
October1994
Communicator
o
FISHER-ROSEMOUNT
English
TM
8
9
6
7
Figure 1-1. Typical System Package
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
World Class 3000

1-2 SYSTEM OVERVIEW

a. Scope
This Instruction Bulletin has been designed to supply details needed to install, startup, operate, and maintain the Rosemount World Class 3000 Oxygen Analyzer with IFT 3000 Intelligent Field Transmitter. The Intel­ligent Field Transmitter (IFT) can be inter­faced with one World Class 3000 probe. The IFT provides all necessary intelligence for controlling the probe and optional MPS 3000 Multiprobe Calibration Gas Se­quencer. Appendices at the back of this manual detail each component and option from the standpoint of troubleshooting, re­pair, and spare parts.
Operator/Technician interface to the IFT can be provided from the displays and key­pads on the front panel, and remotely through HART utilizing the 4-20 mA out-put signal from the IFT interconnect board. HART Communi­cator IFT applications are detailed in Appendix J.
b. System Description
The Rosemount Oxygen Analyzer (Probe) is designed to measure the net concentration of oxygen in an industrial process; i.e., the oxygen remaining after all fuels have been oxidized. The probe is permanently posi­tioned within an exhaust duct or stack and performs its task without the use of a sam­pling system.
The equipment measures oxygen percent­age by reading the voltage developed across a heated electrochemical cell, which consists of a small yttria-stabilized, zirconia disc. Both sides of the disc are coated with porous metal electrodes. When operated at the proper temperature, the millivolt output voltage of the cell is given by the following Nernst equation:
®
communications protocol,
Where:
1. P2 is the partial pressure of the oxygen in the measured gas on one side of the cell,
2. P1 is the partial pressure of the oxygen in the reference 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, in­strument air (20.95% oxygen) as a ref­erence air.
When the cell is at operating temperature and there are unequal oxygen concentra­tions across the cell, oxygen ions will trave l from the high partial pressure of oxygen side to the low partial pressure side of the cell. The resulting logarithmic output voltage is approximately 50 mV per decade. Be­cause the magnitude of the output is pro­portional to the logarithm of the inverse of the sample of the oxygen partial pressure, the output signal increases as the oxygen concentration of the sample gas decreases. This characteristic enables the oxygen analyzer to provide exceptional sensitivity at low oxygen concentrations.
Oxygen analyzer equipment measures net oxygen concentration in the presenc e of all the products of combustion, including water vapor. Therefore, it may be considered an analysis on a "wet" basis. In comparison with older methods, such as the Orsat ap­paratus, which provides an analysis on a "dry" gas basis, the "wet" analysis will, in general, indicate a lower percentage of oxygen. The difference will be proportional to the water content of the sampled gas stream.
EMF = KT log10(P1/P2) + C
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
1
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
c. System Configuration
The equipment covered in this manual con­sists of three major components: the oxy­gen analyzer (probe), the intelligent field transmitter (IFT), and an optional heater power supply (HPS). The HPS is required where the cable run between the probe and the electronics is greater than 150 ft (45 m). There is also an optional multiprobe calibra­tion gas sequencer (MPS) to facilitate automatic calibration of the probe.
Probes are available in five length options, giving the user the flexibility to use an in situ penetration appropriate to the size of the stack or duct. The options 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 probe temperature (in conjunction with the optional HPS), supply power, and provide isolated outputs that are proportional to the measured oxygen concentration. The oxy­gen sensing cell is maintained at a constant temperature by modulating the duty cycle of the probe heater. The IFT accepts millivolt signals generated by the sensing cell and produces outputs to be used by remotely connected devices. The IFT output is iso­lated and selectable to provide linearized voltage or current.
The heater power supply (HPS) can provide an interface between the IFT and the probe. The HPS contains a transformer for sup­plying proper voltage to the probe heater. The enclosure has been designed to meet NEMA 4X (IP56) specifications for water tightness; an optional enclosure to meet Class 1, Division 1, Group B (IP56) explo­sion proof is also available.
Systems with multiprobe and multiple IFT applications may employ an optional MPS 3000 Multiprobe Calibration Gas Se-
quencer. The MPS 3000 provides automatic calibration gas sequencing for up to four probes and IFTs to accommodate automatic calibration.
d. System Features
1. Unique and pat ent ed elec tro nic cel l protection action that automatically protects sensor cell when the analyzer detects reducing atmospheres.
2. Output vo lta ge and se ns it iv ity increase as the oxygen concentration decreases.
3. User friendly, menu driven operator interface with context-sensitive on-line help.
4. Field replaceable cell.
5. Analyzer constructed of rugged 316 LSS for all wetted parts.
6. The intelligent field transmitter (IFT) can be located up to 150 ft (45 m) from the probe when used without optional heater power supply (HPS). When the system includes the optional HPS, the HPS can be located up to 150 ft (45 m) from the probe and the IFT may be lo­cated up to 1200 ft (364 m) from the HPS.
7. All electronic modules are adaptable to 100, 120, 220, and 240 line voltages.
8. Five languages may be selected for use with the Intelligent Field Transmitter:
English Italian French Spanish German
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
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 electronics enclosure and makes use of an LCD and keypad.
(b) Optional HART Interface. The IFT's
4-20 mA output line transmits an analog signal proportional to oxy­gen level. The line also carries all information normally accessed by use of the General User Interface LCD and keypad. This information can be accessed through the following:
1 Rosemount Model 275 Hand-
held Communicator - The handheld communicator re­quires Device Descriptor (DD) software specific to the World Class 3000 product. The DD software will be supplied with many model 275 units, but can also be programmed into existing units at most Fisher­Rosemount service offices.
2 Personal Computer (PC) -
The use of a personal com­puter requires Cornerstone software with Module Library (ModLib) specific to the World Class 3000 product.
3 Selected Distributed Control
Systems - The use of distrib­uted control systems requires input/output (I/O) hardware and software which permit HART communications.
e. Handling the Oxygen Analyzer.
It is important that printed circuit boards and integrated circuits are handled only when adequate antistatic precautions have been taken to pre­vent possible equipment damage.
The oxygen analyzer is designed for industrial application. Treat each component of the system with care to avoid physical damage. The probe contains components made from ce­ramics, which are susceptible to shock when mishandled.
NOTE
Retain packaging in which the oxygen analyzer arrived from the factory in case any components are to be shipped to another site. This packag­ing has been designed to protect the product.
f. System Considerations
Prior to installation of your Rosemount World Class 3000 Oxygen Analyzer with Intelligent Field Transmitter make sure that you have all of the components necessary to make the system installation. Ensure that all the components are properly integrated to make the system functional.
Once you have verified that you have all the components, select mounting locations and determine how each component will be placed in terms of available power supply, ambient temperatures, environmental con­siderations, convenience, and serviceability. A typical system installation is illustrated in Figure 1-2. Figure 1-3 shows a typical sys­tem wiring. For details on installing the indi­vidual components of the system, refer to Section 2, Installation.
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
1
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
CALIBRATION
INSTRUMENT
AIR SUPPLY
(REF. AIR)
GAS
PRESSURE
REGULATOR
GASES
STACK
FLOWMETER
STANDARD
DUCT
OXYGEN ANALYZER (PROBE)
INTELLIGENT FIELD TRANSMITTER
MULTIPROBE
CALIBRATION GAS
SEQUENCER
}
ADAPTER PLATE
LINE VOLTAGE
ADAPTER
PLATE
CALIBRATION
GAS
GASES
STACK
OPTIONS
DUCT
OXYGEN ANALYZER (PROBE)
SUPPLY
INST. AIR
CAL GAS 1
CAL GAS 2
REFERENCE AIR
Figure 1-2. Typical System Installation
HEATER POWER SUPPLY
INTELLIGENT FIELD TRANSMITTER
}
LINE VOLTAGE
27270001
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
Instruction Manual
IB-106-300NH Rev. 4.2 July 2002
World Class 3000
Stack Thermocouple
(optional)
World Class 3000
Probe
2-Calibration Gas Lines
World Class 3000
Probe
Stack Thermocouple
(optional)
Wire [150 Ft (45 m) Max]
7-Conductor Cable
[150 Ft (45 m) Max]
by Customer
[300 Ft (90 m) Max]
2-Conductor T/C
(optional)
(HPS not required for lengths of less than 150 feet)
7-Conductor Cable
[150 Feet (45 m) Max]
2-Conductor T/C
Wire [150 Feet (45 m) Max]
(optional)
(OPTIONAL)
HPS 3000
HPS 3000
Explosion Proof Required only for Hazardous Area Applications, otherwise use NEMA 4X. Lengths Exceeding 150 ft (45 m).
(OPTIONAL)
MPS 3000
CALIBRATION GAS
SEQUENCER
Modular Design Up to 4 Probes
Line Voltage
Line Voltage
Calibration Gas
by
Customer
4 Twisted Pair Plus 2 Twisted Pair for Options [1200 Ft (364 m) Max]
Line Voltage
IFT 3000
Intelligent Field Transmitter
NEMA 4X Enclosure
Line Voltage 100 to 120 Volt 220 to 240 Volt
5 Conductor
[1000 Ft (309 m) Max]
Line Voltage
IFT 3000
Intelligent Field Transmitter
NEMA 4X Enclosure
Line Voltage 100 to 120 Volt 220 to 240 Volt
HART Model 275
Hand Held
Interface
Customer's Laptop with
Cornerstone Software
Control System
with HART
27270002
World Class 3000
Probe
7-Conductor Cable
[150 Ft (45 m) Max]
2-Calibration Gas Lines by Customer [300 Ft (90 m) Max]
Line Voltage
HPS 3000
Heater Power Supply
[Optional,
Required for > 150 Ft (45 m)]
4 Twisted Pair, plus 2 Twisted Pair
for Options [1200 Ft (364 m) Max]
Line Voltage
IFT 3000
Intelligent Field Transmitter
NEMA 4X Enclosure
Line Voltage 100 to 120 Volt 220 to 240 Volt
4-20 mA Output (Twisted Pair)
Termination in Control Room
Customer's Distributed
Interface Capability
Figure 1-3. World Class 3000 Typical Application with Intelligent Field Transmitters
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
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