Emerson 3000 instruction manual Optional Ceramic Diffusion Element Replacement, General

Page 118

Instruction Bulletin

Appendix A Rev. 3.9 May 2005

World Class 3000

PIN

WRENCH

RETAINER

OPTIONAL CERAMIC

DIFFUSION ELEMENT

SETSCREW

 

HUB

CEMENT

CEMENT

PORT

FILLET

 

VEE

DEFLECTOR

21240026

Figure A-19. Removal of Optional Diffusor

and Vee Deflector

PROBE TUBE

(NOT INCLUDED

IN KIT)

CORRUGATED

SEAL

CELL AND

FLANGE

ASSEMBLY

SOCKET HEAD

CAP SCREWS

CALIBRATION GAS

PASSAGE

g.Rub a small amount of anti-seize on both sides of new corrugated seal.

h.Assemble cell and flange assembly, corru- gated seal, and probe tube. Make sure the calibration tube lines up with the calibration gas passage in each component. Apply a small amount of anti-seize compound to screw threads and use screws to secure assembly. Torque to 55 in-lbs (4 N•m).

i.Apply anti-seize compound to threads of cell assembly, hub, and setscrews. Reinstall hub on cell assembly. Using pin spanner wrenches, torque to 10 ft-lbs (14 N•m). If applicable, reinstall vee deflector, orienting apex toward gas flow. Secure with setscrews and anti-seize compound. Torque to 25 in-lbs (2.8 N•m).

j.On systems equipped with an abrasive shield, install dust seal gaskets, with joints 180o apart.

k.Reinstall probe and gasket on stack flange. If there is an abrasive shield in the stack, make sure dust seal gaskets are in place as they enter 15o reducing cone.

l.Turn power on to electronics and monitor thermocouple output. It should stabilize at 29.3 ±0.2 mV. Set reference air flow at 2 scfh (56.6 L/hr). After probe stabilizes, calibrate probe per Instruction Bulletin applicable to your electronics package. If new components have been installed, repeat calibration after 24 hours of operation.

21240009

Figure A-20. Cell Replacement Kit

e.If contact assembly is damaged, replace contact and thermocouple according to paragraph A-13, Replacement of Contact and Thermocouple Assembly.

f.Remove and discard corrugated seal. Clean mating faces of probe tube and retainer. Remove burrs and raised surfaces with block of wood and crocus cloth. Clean threads on retainer and hub.

A-12 OPTIONAL CERAMIC DIFFUSION

ELEMENT REPLACEMENT

a.General

The diffusion element protects the cell from particles in process gases. It does not nor- mally need to be replaced because the vee deflector protects it from particulate erosion. In severe environments the filter may be broken or subject to excessive erosion. Ex- amine the diffusion element whenever re- moving the probe for any purpose. Replace if damaged.

A-18 Appendices

Rosemount Analytical Inc. A Division of Emerson Process Management

Page 117 Page 119
Image 118
Page 117 Page 119
Contents World Class Essential Instructions Summary Highlights of ChangesEffective May, 1999 Rev Effective November, 2001 RevEffective May, 2005 Rev Appendix a Effective July, 2002 Rev Effective February, 1992 Rev Appendix BEffective January, 1995 Rev Page Appendix D Effective June, 1994 RevRevised view of check valve in Figure D-3 Appendix E Effective June, 1999 RevFiguration. Revised replacement parts list Effective April, 1995 Rev Appendix JEffective June, 1995 Rev Page Table of Contents World ClassList of Illustrations List of Tables Calibrate O2 Sub-MenuWorld Class Preface DefinitionsWorld Class Glossary of Terms Thermocouple Reference AirSemiautomatic Calibration Vee DeflectorWhat YOU Need to Know Complete World Class 3000 SystemQuick Start Guide Use this Quick Start Guide ifQuick Start Guide for IFT 3000 Systems Line Voltage Jumper Section Install Setting up the Analog Output Performing a Manual Semiautomatic CalibrationHart Communicator Fast KEY Sequences Technical Support HotlineSection Description and Specifications Component Checklist of Typical System Package ContentsScope System OverviewSystem Description System Configuration System FeaturesWorld Class Standard HPS World Class World Class Oxygen Analyzer Probe Installation Section InstallationSelecting Location 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 Service Required Reference Air PackageIntelligent Field Transmitter IFT Installation Electrical ConnectionsPower Supply Board Jumper Configuration IFT Power Supply Board Jumpers Wiring Layout for IFT Systems without HPS Heater Power Supply Installation Condition during Microcontroller failure Switch SW3Jumper Configuration Output JumperIFT Microprocessor Board 10. Interconnect Board Jumper Configuration 12. Outline of Heater Power Supply Electrical Connections Refer to -16 for fuse locations and specificationsJ8 + + Conductor 14. Heater Power Supply Wiring Connections 16. Jumpers on HPS Mother Board Multiprobe Calibration GAS Sequencer Installation Gas ConnectionsRefer to -19 for fuse locations and specifications 18. MPS Gas Connections19. MPS Probe Wiring World Class Setting Calibration Parameters Section SetupConfiguring the Analog Output OverviewConfiguring Efficiency Calculations Setting the O2 Alarm SetpointsConfiguring the Relay Outputs System Calibration CalibrationAnalog Output Calibration OverviewCalibration Methods Liquid Carbonic GAS Corp Specialty GAS LaboratoriesScott Environmental TECHNOLOGY, INC. Scott Specialty Gases % O Portable Rosemount Analytical Oxygen Calibration Gas Kit Fully Automatic Calibration Typical Automatic Calibration System Automatic Calibration Parameters Figure analog outputCalibration Record For Rosemount Analytical In Situ O2 Probe World Class Section General User Interface GUI Operation Hart Communicator Interface DevicesDeluxe Version IFT Displays and Controls Index No Control/LED DescriptionCalibrate O2 Quick Reference ChartMENU, SUB-MENU, Help Or Parameter Name Message Probe Data Help KEYProbe Data Sub-Menu Calibrate O2 SUB-MENU Setup SUB-MENUSUB-MENU Selection Parameter Description 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 Setup Sub-Menu SUB-MENU Selection Parameters DescriptionXfer Fnct Selected in the Setup sub-menuRange Values Efficiency Constants Dual Range SetupNormal Range Values Constant United States Europe GAS OILSpecial Troubleshooting Notes Section TroubleshootingSystem Troubleshooting IFT Status Codes Heater Problem Heater Troubleshooting ProblemWorld Class Status is LowO2 Cell mV = -127 mV Cell ProblemCell Troubleshooting Problem Status is ResHi or CalEr Cell mV = -20 to 120 mV normalStatus is Res Hi Cell mV = -120 to 20 mV IFT Troubleshooting Problem IFT ProblemFaulty GUI or LDP IFT LED is Flashing Status is NoGas Cell mV is between -20 to 120 mV MPS ProblemMPS Troubleshooting Problem Status is ResHi or CalEr Cell mV is between -20 to 120 mVPerformance Problem Process Response is Suspect Performance Problem TroubleshootingWorld Class Section Return of Material World Class Section Appendices Appendix a Oxygen Analyzer Probe General Figure A-2. Main Probe ComponentsTable A-1. Specifications for Oxygen Analyzing Equipment.1 Cell and Flange Assembly Probe Assembly ExteriorProbe Tube Assembly Inner Probe Assembly Cell GeneralProbe Junction BOX Cable AssemblyAbrasive Shield Assembly Probe OptionsView a Figure A-8. Ceramic Diffusion/Dust Seal Assembly Ceramic Diffusion AssemblySnubber Diffusion/Dust Seal Assembly Probe Mounting Jacket OptionsFigure A-15. Bypass Probe Option Sheet 1 Figure A-15. Bypass Probe Option Sheet 2 Extended Temperature By-Pass Arrangements 2400F 1300C Group Code DescriptionProbe Faults Probe TroubleshootingProbe Troubleshooting 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 Cell Replacement Service and Normal MaintenanceProbe Recalibration Figure A-18. Cell Wiring Connection Optional Ceramic Diffusion Element Replacement GeneralWorld Class Replacement of Contact Thermocouple Assembly Figure A-21. Probe Junction Box Mechanical ConnectionsContact Heater Screws Not Shown Thermocoupler World Class Figure A-24. Oxygen Analyzer Probe, Cross-Sectional View Figure A-25. High Temperature Corrosive Environment Kit Replacement Parts Index NoFigure A-9 Appendix B, REV HPS 3000 Heater Power Supply Description Figure B-1. HPS 3000 Heater Power Supply Field ModuleFront Table B-1. Specifications for Heater Power Supply Theory of OperationHPS 3000 Troubleshooting Overview HPS 3000 TroubleshootingSymptom Figure B-5. HPS Troubleshooting Flowchart, #2 Figure B-6. HPS Troubleshooting Flowchart, #3 Transformer Replacement Fuse ReplacementMother Board 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 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 Table D-2. Fault Finding MPS 3000 TroubleshootingTroubleshooting Symptom Check Fault RemedyFigure D-5. MPS Troubleshooting Flowchart Solenoid Valve Replacement Power Supply Replacement4543 Pressure Adjustments Pressure Regulator MaintenanceCondensation Drain Flowmeter Adjustments Adding Probes to the MPSFigure D-6 1A97909H01 Power Supply World Class GUI/LED Display Board Power Supply BoardInterconnect Board Heater optionalTable E-1. Specifications for Intelligent Field Transmitter Purge optionalHeater Power Supply Optional IFT Microprocessor Status LED IFT 3000 TroubleshootingIFT Troubleshooting Equipment Status LCD DisplaysFigure E-3. IFT Troubleshooting Flowchart, #1 Symptom Microprocessor Board LED is Steady on Table E-2. GUI Equipped IFT Fault Finding Symptom Component FailureFigure E-6. Intelligent Field Transmitter, Exploded View Replace Fuse Remove Power and Open CoverRemove Electronics Chassis from Enclosure Figure E-7. Microprocessor Assembly Exploded View Replace Interconnect Board Replace Power Supply BoardReplace Microprocessor Board Replace FANFigure E-8. Electronics Chassis Exploded View Replace Heater and Thermoswitch Install Electronics ChassisReplace Transformer Figure E-9. Electronics Chassis Installation Close Cover and Restore Power Replace GUI Assembly orRibbon Cable Figure E-8 1N04946G01 Transformer Figure J-1. Typical Hart Communicator Package, Model 275D9E Specifications Hart Communicator Signal Line Connections Method 1, For Load Resistance 250 OhmsHart Communicator PC Connections Load Resistor See Note Hart Communicator Menu Tree for Hart Communicator OperationOFF-LINE and ON-LINE Operations 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.

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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.

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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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