Emerson 3000 instruction manual World Class

Page 113

World Class 3000

Instruction Bulletin

Appendix A Rev. 3.9 May 2005

Table A-2. Fault Finding (Continued)

Symptom

Check

Fault

Remedy

2.System responds to oxygen concentration changes but does not give correct indication

 

Good response, with

Recorder or remote

Calibration error

Recalibrate recorder or

 

incorrect indication

indicator

 

indicator. Reference Re-

 

 

 

 

corder Instruction Manual.

 

 

System calibration

Calibration error

Recalibrate system.

 

 

Probe mounting and con-

Air ingress into duct

Stop air leaks or resite

 

 

dition of duct

 

probe.

 

 

Cell mV input to

Failure of electronics

Check electronics

 

 

electronics

 

package.

 

 

 

 

3. System does not give

Calibration gas input port

Blocked port

Clean port. If the flue gas

 

accurate indication of

 

 

is condensing in the cali-

 

applied calibration gas

 

 

bration gas line, insulate

 

 

 

 

the back of the probe.

 

 

 

 

Make sure that the cali-

 

 

 

 

bration gas line is capped

 

 

 

 

between calibrations, or a

 

 

 

 

check valve is installed.

 

 

Ceramic diffusion element

Diffusion element cracked,

Replace diffusion element.

 

 

 

broken, or missing

 

4.

System takes a long

Diffusion element

Plugged diffusion element

Change diffusion element

 

time to return to flue

 

 

or snubber diffusion

 

gas value after calibra-

 

 

element.

 

tion gas is turned off

 

 

 

5.

Probe passes calibra-

Check calibration gas fit-

Leak in gasket, or calibra-

Repair leak.

 

tion, but appears to

ting.

tion gas fittings or tubing.

 

 

read high.

Check calibration gas

Leak in calibration gas

Repair hose or tubing/

 

 

 

 

hoses or tubing.

hose or tubing.

 

 

 

Cell flange corrugated

Leaking seal.

Replace seal.

 

 

seal.

 

 

 

 

If equipped with an abra-

Leaking gasket.

Replace gasket.

 

 

sive shield, check flange

 

 

 

 

mounting gasket.

 

 

6.

Probe passes calibra-

Flow calibration gas to the

Plugged diffuser element

Replace diffuser.

 

tion, but appears to

probe until reading stabi-

from high process par-

 

 

read low.

lizes. Shut off calibration

ticulate may cause a cali-

 

 

 

gas and note the time re-

bration shift.

 

 

 

quired to return to process

 

 

 

 

gas values. Time should

 

 

 

 

be <20 sec. (<40 sec. for

 

 

 

 

hazardous area probes).

 

 

Rosemount Analytical Inc. A Division of Emerson Process Management

Appendices A-13

Page 112 Page 114
Image 113
Page 112 Page 114
Contents World Class Essential Instructions Effective May, 1999 Rev Highlights of ChangesSummary Effective November, 2001 RevEffective May, 2005 Rev Appendix a Effective July, 2002 Rev Effective January, 1995 Rev Appendix BEffective February, 1992 Rev Page Effective June, 1994 Rev Appendix DRevised view of check valve in Figure D-3 Effective June, 1999 Rev Appendix EFiguration. Revised replacement parts list Effective June, 1995 Rev Appendix JEffective April, 1995 Rev Page World Class Table of ContentsList of Illustrations Calibrate O2 Sub-Menu List of TablesWorld Class Definitions PrefaceWorld Class Glossary of Terms Semiautomatic Calibration Reference AirThermocouple Vee DeflectorComplete World Class 3000 System What YOU Need to KnowUse this Quick Start Guide if Quick Start GuideQuick Start Guide for IFT 3000 Systems Line Voltage Jumper Section Install Performing a Manual Semiautomatic Calibration Setting up the Analog OutputTechnical Support Hotline Hart Communicator Fast KEY SequencesComponent Checklist of Typical System Package Contents Section Description and SpecificationsSystem Description System OverviewScope System Features System ConfigurationWorld Class Standard HPS World Class World Class Selecting Location Section InstallationOxygen Analyzer Probe Installation Probe Installation Sheet 1 Probe Installation Sheet 2 Probe Installation Sheet 3 Probe Installation Sheet 4 Probe Installation Sheet 5 Orienting the Optional Vee Deflector Reference Air Package Service RequiredElectrical Connections Intelligent Field Transmitter IFT InstallationPower Supply Board Jumper Configuration IFT Power Supply Board Jumpers Wiring Layout for IFT Systems without HPS Jumper Configuration Condition during Microcontroller failure Switch SW3Heater Power Supply Installation Output JumperIFT Microprocessor Board 10. Interconnect Board Jumper Configuration Refer to -16 for fuse locations and specifications 12. Outline of Heater Power Supply Electrical ConnectionsJ8 + + Conductor 14. Heater Power Supply Wiring Connections 16. Jumpers on HPS Mother Board Gas Connections Multiprobe Calibration GAS Sequencer Installation18. MPS Gas Connections Refer to -19 for fuse locations and specifications19. MPS Probe Wiring World Class Configuring the Analog Output Section SetupSetting Calibration Parameters OverviewConfiguring the Relay Outputs Setting the O2 Alarm SetpointsConfiguring Efficiency Calculations Analog Output Calibration CalibrationSystem Calibration OverviewLiquid Carbonic GAS Corp Specialty GAS Laboratories Calibration MethodsScott Environmental TECHNOLOGY, INC. Scott Specialty Gases % O Portable Rosemount Analytical Oxygen Calibration Gas Kit Fully Automatic Calibration Typical Automatic Calibration System Figure analog output Automatic Calibration ParametersCalibration Record For Rosemount Analytical In Situ O2 Probe World Class Hart Communicator Interface Devices Section General User Interface GUI OperationIndex No Control/LED Description Deluxe Version IFT Displays and ControlsMENU, SUB-MENU, Help Or Parameter Name Message Probe Data Quick Reference ChartCalibrate O2 Help KEYSUB-MENU Selection Parameter Description Calibrate O2 SUB-MENU Setup SUB-MENUProbe Data Sub-Menu Quick Reference Chart Sheet 1 Quick Reference Chart Sheet 2 Quick Reference Chart Sheet 3 Quick Reference Chart Sheet 4 Quick Reference Chart Sheet 5 Calibrate O2 Sub-Menu XD XH SUB-MENU Selection Parameters Description Setup Sub-MenuRange Values Selected in the Setup sub-menuXfer Fnct Normal Range Values Dual Range SetupEfficiency Constants Constant United States Europe GAS OILSystem Troubleshooting Section TroubleshootingSpecial Troubleshooting Notes IFT Status Codes Heater Troubleshooting Problem Heater ProblemWorld Class Cell Troubleshooting Problem Cell ProblemStatus is LowO2 Cell mV = -127 mV Status is ResHi or CalEr Cell mV = -20 to 120 mV normalStatus is Res Hi Cell mV = -120 to 20 mV Faulty GUI or LDP IFT LED is Flashing IFT ProblemIFT Troubleshooting Problem MPS Troubleshooting Problem MPS ProblemStatus is NoGas Cell mV is between -20 to 120 mV Status is ResHi or CalEr Cell mV is between -20 to 120 mVPerformance Problem Troubleshooting Performance Problem Process Response is SuspectWorld Class Section Return of Material World Class Section Appendices Appendix a Figure A-2. Main Probe Components Oxygen Analyzer Probe GeneralTable A-1. Specifications for Oxygen Analyzing Equipment.1 Probe Tube Assembly Probe Assembly ExteriorCell and Flange Assembly Cell General Inner Probe AssemblyAbrasive Shield Assembly Cable AssemblyProbe Junction BOX Probe OptionsView a Ceramic Diffusion Assembly Figure A-8. Ceramic Diffusion/Dust Seal AssemblyProbe Mounting Jacket Options Snubber Diffusion/Dust Seal AssemblyFigure A-15. Bypass Probe Option Sheet 1 Figure A-15. Bypass Probe Option Sheet 2 Group Code Description Extended Temperature By-Pass Arrangements 2400F 1300CProbe Troubleshooting Probe TroubleshootingProbe Faults Table A-2. Fault Finding Symptom Check RemedyWorld Class Figure A-16. Flowchart of Probe Related Problems, #1 Figure A-17. Flowchart of Probe Related Problems, #2 Probe Recalibration Service and Normal MaintenanceCell Replacement Figure A-18. Cell Wiring Connection General Optional Ceramic Diffusion Element ReplacementWorld Class Figure A-21. Probe Junction Box Mechanical Connections Replacement of Contact Thermocouple AssemblyContact Heater Screws Not Shown Thermocoupler World Class Figure A-24. Oxygen Analyzer Probe, Cross-Sectional View Figure A-25. High Temperature Corrosive Environment Kit Index No Replacement PartsFigure A-9 Figure B-1. HPS 3000 Heater Power Supply Field Module Appendix B, REV HPS 3000 Heater Power Supply DescriptionFront Theory of Operation Table B-1. Specifications for Heater Power SupplyOverview HPS 3000 Troubleshooting HPS 3000 TroubleshootingSymptom Figure 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 Part Number Description Table B-2. Replacement Parts for Heater Power SupplyWorld Class Figure D-1. MPS 3000 Multiprobe Calibration Gas Sequencer 20 to 160F -30 to 71C Figure D-3. Typical Automatic Calibration System Bebco Model Z-PURGE Rear View Troubleshooting MPS 3000 TroubleshootingTable D-2. Fault Finding Symptom Check Fault RemedyFigure D-5. MPS Troubleshooting Flowchart Power Supply Replacement Solenoid Valve Replacement4543 Condensation Drain Pressure Regulator MaintenancePressure Adjustments Adding Probes to the MPS Flowmeter AdjustmentsFigure D-6 1A97909H01 Power Supply World Class Interconnect Board Power Supply BoardGUI/LED Display Board Heater optionalPurge optional Table E-1. Specifications for Intelligent Field TransmitterHeater Power Supply Optional IFT IFT Troubleshooting IFT 3000 TroubleshootingMicroprocessor Status LED Equipment Status LCD DisplaysFigure E-3. IFT Troubleshooting Flowchart, #1 Symptom Microprocessor Board LED is Steady on Symptom Component Failure Table E-2. GUI Equipped IFT Fault FindingFigure E-6. Intelligent Field Transmitter, Exploded View Remove Electronics Chassis from Enclosure Remove Power and Open CoverReplace Fuse Figure E-7. Microprocessor Assembly Exploded View Replace Microprocessor Board Replace Power Supply BoardReplace Interconnect Board Replace FANFigure E-8. Electronics Chassis Exploded View Replace Transformer Install Electronics ChassisReplace Heater and Thermoswitch Figure E-9. Electronics Chassis Installation Ribbon Cable Replace GUI Assembly orClose Cover and Restore Power Figure E-8 1N04946G01 Transformer Figure J-1. Typical Hart Communicator Package, Model 275D9E Specifications Method 1, For Load Resistance 250 Ohms Hart Communicator Signal Line ConnectionsHart Communicator PC Connections Load Resistor See Note Hart Communicator OFF-LINE and ON-LINE Operations OperationMenu Tree for Hart Communicator World Class 3000 IFT ApplicationsFigure J-4. Menu Tree for IFT 3000 Applications Sheet 1 Figure J-4. Menu Tree for IFT 3000 Applications Sheet 2 Figure J-4. Menu Tree for IFT 3000 Applications Sheet 3 Troubleshooting Flowchart Figure J-5. Model 275D9E, Troubleshooting Flowchart Sheet 1 Figure J-5. Model 275D9E, Troubleshooting Flowchart Sheet 2 Returning Equipment to the Factory World Class Section Index World Class Rosemount Analytical Warranty World Class 3000 Probe HPS Serial No Order No IFT MPS
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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.
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