Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
http://www.processanalytic.com
World Class 3000
Oxygen Analyzer
with IFT 3000 Intelligent
Field Transmitter
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
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 per-
formance, 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.
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
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 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
Page Summary
Page D-1 Updated Figure D-1, MPS 3000 to include hinge.
Effective May, 1996 Rev. 2.2
Page Summary
Page D-11 Updated replacement parts list to reflect new part numbers.
Effective January, 1997 Rev. 2.3
Page Summary
Page D-1
Page D-2
Page D-5
Page D-7
Page D-11
Added warning to read new safety instructions.
Corrected Table D-1 Specifications listing, 1
st
entry.
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
Page Summary
--- Changed test gas to calibration gas and reference gas to reference
air throughout the appendix.
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.
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
Rosemount Analytical Inc. A Division of Emerson Process Management i
World Class 3000
TABLE OF CONTENTS
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
2
Alarm Setpoints.................................................................................... 3-2
3-5 Configuring Efficiency Calculations ............................................................................... 3-2
3-6 Configuring the Relay Outputs ..................................................................................... 3-2
4-0 CALIBRATION ................................................................................................................ 4-1
4-1 Analog Output Calibration ............................................................................................. 4-1
4-2 System Calibration ......................................................................................................... 4-1
5-0 GENERAL USER INTERFACE (GUI) OPERATION .................................................. 5-1
5-1 Overview.......................................................................................................................... 5-1
5-2 Deluxe Version IFT Displays and Controls................................................................. 5-2
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
2
Sub-Menu.................................................................................................. 5-4
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
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
ii Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
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
LIST OF ILLUSTRATIONS
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
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
Rosemount Analytical Inc. A Division of Emerson Process Management iii
World Class 3000
LIST OF TABLES
Table 4-1. Automatic Calibration Parameters......................................................................... 4-8
Table 5-1. Sample HELP Messages....................................................................................... 5-3
Table 5-2. MAIN menu ............................................................................................................ 5-3
Table 5-3. PROBE DATA Sub-Menu ...................................................................................... 5-4
Table 5-4. CALIBRATE O
2
Sub-Menu .................................................................................. 5-10
Table 5-5. SETUP Sub-Menu ............................................................................................... 5-12
Table 5-6. Efficiency Constants ............................................................................................ 5-14
Table 6-1. IFT Status Codes ................................................................................................... 6-2
Table 6-2. Heater Troubleshooting ......................................................................................... 6-3
Table 6-3. Cell Troubleshooting.............................................................................................. 6-5
Table 6-4. IFT Troubleshooting............................................................................................... 6-7
Table 6-5. MPS Troubleshooting ............................................................................................ 6-8
Table 6-6. Performance Problem Troubleshooting................................................................. 6-9
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
iv Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
World Class 3000
NOTE
!
Only one probe can be calibrated at a time.
Probe calibrations must be scheduled
appropriately in multiple probe applications.
PREFACE
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 Ana-
lyzer. We recommend that you familiarize yourself with the Overview and Installation sec-
tions before installing your emissions monitor.
The overview presents the basic principles of the oxygen analyzer along with its perform-
ance characteristics and components. The remaining sections contain detailed proce-
dures and information necessary to install and service the oxygen analyzer.
DEFINITIONS
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this
publication.
Highlights an operation or maintenance
procedure, practice, condition, state-
ment, etc. If not strictly observed, could
result in injury, death, or long-term
health hazards of personnel.
Highlights an operation or maintenance
procedure, practice, condition, state-
ment, etc. If not strictly observed, could
result in damage to or destruction of
equipment, or loss of effectiveness.
NOTE
Highlights an essential operating procedure,
condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a manual illus-
tration number. It is not a part number, and is not related to the illustration in any technical
manner.
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
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 compliance with the Low Voltage Directive. Non-
EU 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.
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, hazard-
ous 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. Cer-
tain 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 follow-
ing standards: EN61010-1, IEC417, and ISO3864.
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
Rosemount Analytical Inc. A Division of Emerson Process Management P-3
World Class 3000
GLOSSARY OF TERMS
Abrasive Shield
An optional component that shields the probe from high velocity particulate entrained in the flue
gas stream.
Automatic Calibration
An automatic calibration can only be performed if the system is equipped with an MPS 3000 Mul-
tiprobe 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 calibra-
tion gases under direction from the IFT.
Calibration
The process of measuring gases of a known concentration, and comparing that known concen-
tration 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
2
values.
Cold Junction Compensation
A method for compensating for the small voltage developed at the junction of the thermocouple
leads in the probe junction box.
Dead Band
The range through which a signal can be varied without initiating a response. In the IFT 3000,
dead band is used to prevent an oxygen signal near 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 out-
put 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 se-
quencing for up to four probes.
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
P-4 Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
Reference Air
Provides a known oxygen concentration to the reference side of the oxygen sensing cell.
Semiautomatic Calibration
Semiautomatic calibration is performed when the system does not include an MPS 3000 Multi-
probe Calibration Gas Sequencer. The IFT 3000 provides prompts to direct the user to switch
calibration gases when performing the calibration.
Thermocouple
An electrical device made of two dissimilar metals. A thermocouple develops a millivolt signal
proportional to its temperature.
Vee Deflector
Protects the optional ceramic diffusor from the process gases. The vee deflector must be posi-
tioned so it points toward the direction of the process gas flow. See Figure 2-2 for an illustration of
the vee deflector.
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
Rosemount Analytical Inc. A Division of Emerson Process Management P-5
World Class 3000
WHAT YOU NEED TO KNOW
BEFORE INSTALLING AND WIRING A ROSEMOUNT IFT 3000
INTELLIGENT FIELD TRANSMITTER
WITH WORLD CLASS 3000 PROBE
1. What is the line voltage being supplied to the IFT 3000?
Write the line voltage here __________
2. Use the following drawing, Figure 1, to identify which parts of the World Class 3000 system
are included in your system. Components in the shaded area are optional components.
WC PROBE 3000
STACK
THERMOCOUPLE
(OPTIONAL)
HPS 3000
(OPTIONAL)
LINE
VOLTAGE
LINE
VOLTAGE
IFT 3000
LINE
VOLTAGE
MPS 3000
(OPTIONAL)
CALIBRATION
GAS
BOTTLES
29850003
Figure 1. Complete World Class 3000 System
Instruction Manual
IB-106-300NH Rev. 4.2
July 2002
P-6 Rosemount Analytical Inc. A Division of Emerson Process Management
World Class 3000
QUICK START GUIDE
Use this Quick Start Guide if ...
1. You are using a World Class 3000 probe.
2. You are NOT using any optional components. Optional components are shown in the
shaded area in Figure 1.
3. You are familiar with the installation requirements for the IFT 3000 Intelligent Field Trans-
mitter and World Class 3000 probe.
4. You are familiar with the procedures for changing the jumpers located in the IFT 3000, as
described in Section 2, Installation.
If you cannot use the Quick Start Guide, turn to Section 2, Installation, in this Instruction
Bulletin.
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