Emerson 3000 manual Probe Recalibration, Cell Replacement

Page 50

Instruction Manual

Appendix A Rev. 3.6 July 1998

World Class 3000

SERVICE AND NORMAL MAINTENANCE

!NOTE

UPON COMPLETING INSTALLATION, MAKE SURE THAT THE PROBE IS TURNED ON AND OPERATING PRIOR TO FIRING UP THE COMBUSTION PROCESS. DAMAGE CAN RESULT FROM HAVING A COLD PROBE EXPOSED TO THE PROCESS GASES.

During outages, and if possible, leave all probes running to prevent condensation and prema- ture aging from thermal cycling.

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

A-9 OVERVIEW

This section describes routine maintenance of the oxygen analyzer probe. Spare parts referred to are available from Rosemount. Probe disas- sembly kit 3535B42G01 contains the required spanner and hex wrenches. Refer to the follow- ing section of this appendix for part numbers and ordering information.

Install all protective equipment covers and safety ground leads after equip- ment repair or service. Failure to in- stall covers and ground leads could result in serious injury or death.

A-10 PROBE RECALIBRATION

The oxygen analyzer system should be cali- brated when commissioned. Under normal cir- cumstances the probe will not require frequent calibration. When calibration is required, follow the procedure described in the Instruction Bulle- tin applicable to your electronics package.

A-11 CELL REPLACEMENT

This paragraph covers oxygen sensing cell re- placement. Do not attempt to replace the cell until all other possibilities for poor performance have been considered. If cell replacement is needed, order cell replacement kit, Table A-3.

The cell replacement kit contains a cell and flange assembly, corrugated seal, setscrews, socket head cap screws, and anti-seize com- pound. Items are carefully packaged to preserve

precise surface finishes. Do not remove items from packaging until they are ready to be used. Spanner wrenches and hex wrenches needed for this procedure are part of an available special tools kit, Table A-3.

Wear heat resistant gloves and cloth- ing to remove probe from stack. Nor- mal operating temperatures of diffusor and vee deflector are approximately 600° to 800°F (316° to 427°C). They could cause severe burns.

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

Do not remove cell unless it is certain that replacement is needed. Removal may damage cell and platinum pad. Go through complete troubleshooting procedure to make sure cell needs re- placement before removing it.

a.Disconnect and lock out power to electron- ics. Shut off and disconnect reference air and calibration gas supplies from probe junction box, Figure A-16.Wearing heat re- sistant gloves and clothing, remove probe assembly from stack carefully and allow to cool to room temperature. Do not attempt to work on unit until it has cooled to a comfort- able working temperature.

A-16 Appendices

Rosemount Analytical Inc. A Division of Emerson Process Management

Page 49 Page 51
Image 50
Page 49 Page 51
Contents World Class Essential Instructions Summary Highlights of ChangesEffective October, 1995 Rev Effective June, 1996 RevEffective May, 1997 Rev PageSummary Effective February, 1998 Rev PageSummaryTable of Contents World ClassList of Illustrations Typical System PackagePreface DefinitionsWorld Class Overview Component Checklist of Typical System Package ContentsSection Description System Configuration FeaturesTypical System Installation Existing Electronics Heater Power SupplyProbe Head Wiring ProbeInstallation Section InstallationEither make necessary repairs or install Oxygen Analyzer ProbeProbe Installation Sheet 1 Probe Installation Sheet 2 Probe Installation Sheet 3 Probe Installation Sheet 4 Probe Installation Sheet 5 Service Required Orienting the Optional Vee DeflectorElectrical Installation of Heater Power Supply Heater Power Supply Installation Electrical ConnectionsSelection JM1 Fuses JM2 World Class Section Setup Electronics SetupModel 218A Electronics Setup G02 G04Heater Set Point Adjustment Model TC200 Veritrim Electronics SetupEprom Replacement Model 132 Digital Electronics Setup Main PCB Model 132 Eprom ReplacementSection Troubleshooting System TroubleshootingWorld Class Section Return of Material World Class Section Appendices World Class Oxygen Analyzer Probe General Figure A-2. Main Probe ComponentsTable A-1. Specifications for Oxygen Analyzing Equipment.1 Probe Tube Assembly Probe Assembly ExteriorCell and Flange Assembly Snubber Diffusion AssemblyInner Probe Assembly Cell GeneralProbe Junction BOX Cable AssemblyAbrasive Shield Assembly Probe OptionsView a Figure A-8. Ceramic Diffusion/Dust Seal Assembly Ceramic Diffusion AssemblyBypass Probe Options Probe Mounting Jacket OptionsFigure A-13. Bypass Probe Option Sheet 1 Figure A-13. Bypass Probe Option Sheet 2 Extended Temperature By-Pass Arrangements 2400 F 1300 C Group Code DescriptionTable A-2. Fault Finding Symptom Check Remedy Probe TroubleshootingProbe Faults OverviewWorld Class Figure A-14. Flowchart of Probe Related Problems, #1 Figure A-15. Flowchart of Probe Related Problems, #2 Cell Replacement Probe RecalibrationFigure A-16. Cell Wiring Connection General Element ReplacementOptional Ceramic Diffusion World Class Replacement of Contact Thermocouple Assembly Figure A-19. Probe Junction Box Mechanical ConnectionsContact Heater Screws Not Shown Thermocoupler World Class Figure A-22. Oxygen Analyzer Probe, Cross-Sectional View Figure A-23. High Temperature Corrosive Environment Kit Replacement Parts Figure A-10 4841B03G02 Stainless Steel Diffuser Assembly Appendix B, REV HPS 3000 Heater Power Supply Description Front SideTable B-1. Specifications for Heater Power Supply Theory of OperationHPS 3000 Troubleshooting Overview HPS 3000 TroubleshootingSymptom Figure B-4. HPS Troubleshooting Flowchart, #1Figure B-5. HPS Troubleshooting Flowchart, #2 Figure B-6. HPS Troubleshooting Flowchart, #3 Mother Board Replacement Fuse ReplacementTransformer Replacement Daughter Board Replacement Figure B-7. Heater Power Supply, Exploded View Table B-2. Replacement Parts for Heater Power Supply Part Number DescriptionWorld Class Section Index World Class Warranty World Class 3000 Probe Serial No Order No HPS
Related manuals
Manual 88 pages 63.05 Kb Manual 60 pages 24.1 Kb Manual 88 pages 36.41 Kb Manual 32 pages 13.16 Kb Manual 22 pages 3.64 Kb Manual 184 pages 52.9 Kb

3000 specifications

The Emerson 3000 is a cutting-edge control system designed to enhance the efficiency, reliability, and precision of industrial operations. Employed across various sectors such as oil and gas, pharmaceutical, food and beverage, and power generation, the Emerson 3000 has gained recognition for its robustness and versatility.

One of the main features of the Emerson 3000 is its advanced process control capability. With integrated control algorithms, it can optimize complex processes in real-time, resulting in significant improvements in production rates and reduced operational costs. The system's predictive analytics capabilities enable operators to anticipate equipment failures and maintenance needs, allowing for proactive management and minimizing downtime.

The Emerson 3000 features a modular architecture, providing flexibility for scaling and customization. Operators can easily tailor the system to fit specific application needs, whether it requires additional control loops or integration with other systems. This adaptability is particularly beneficial for facilities planning for future expansions or modifications.

Another technology highlight of the Emerson 3000 is its seamless integration with the latest Internet of Things (IoT) advancements. The system is designed to communicate effectively with a variety of smart devices and sensors, harnessing data to create insightful analytics that drive operational excellence. This connectivity empowers businesses to leverage big data for improved decision-making and increased agility.

Additionally, the Emerson 3000 incorporates state-of-the-art cybersecurity measures to safeguard critical data and operations. With built-in security protocols and regular updates, the system protects against emerging cyber threats, ensuring the integrity of the control network.

User experience is also a focal point of the Emerson 3000. The intuitive graphical user interface presents complex data in a user-friendly format, making it easier for operators to monitor system performance and respond to alerts quickly. This ease of use contributes to enhanced safety and operational efficiency.

In summary, the Emerson 3000 represents a fusion of advanced process control, modular design, IoT connectivity, robust cybersecurity, and user-centric interface, making it an ideal choice for industries seeking to enhance their operational performance while adapting to ever-evolving technological landscapes.
Top Page Image Contents