Emerson 3000 instruction manual World Class

Page 119

World Class 3000

Instruction Bulletin

Appendix A Rev. 3.9 May 2005

Damage to the diffusion element may be- come apparent during calibration. Compare probe response with previous response. A broken diffusion element will cause a slower response to calibration gas.

Hex wrenches needed to remove setscrews and socket head screws in the following pro- cedure are available as part of a special tool 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 (300° to 425°C). They can cause severe burns.

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

It is not necessary to remove the cell unless it is certain that replacement is necessary. Cell cannot be removed for inspection without damaging it. Refer to paragraph A-11, Cell Replacement.

b.Replacement Procedure

1.Shut off power to electronics. Discon- nect cable conductors and remove ca- ble, Figure A-18. Shut off and disconnect reference air and calibration gas supplies from probe junction box. Wearing heat resistant gloves and clothing, carefully remove probe as- sembly from stack and allow to cool to room temperature. Do not attempt to work on unit until it has cooled to a comfortable working temperature.

2.Loosen setscrews, Figure A-19, using hex wrench from special tools kit, Table A-3, and remove vee deflector. Inspect setscrews. If damaged, replace with M-6 x 6 stainless setscrews coated with anti-seize compound.

3.On systems equipped with abrasive shield, remove dual dust seal gaskets.

4.Use spanner wrenches from special tools kit, Table A-3, to turn hub free from retainer.

5.Put hub in vise. Break out old diffusion element with chisel along cement line and 3/8 inch (9.5 mm) pin punch through cement port.

6.Break out remaining diffusion element by tapping lightly around hub with hammer. Clean grooves with pointed tool if necessary.

7.Replace diffusion element, using re- placement kit listed in Table A-3. This consists of a diffusion element, ce- ment, setscrews, anti-seize compound and instructions.

8.Test fit replacement element to be sure seat is clean.

Do not get cement on diffusion ele- ment except where it touches the hub. Any cement on ceramic element blocks airflow through element. Wip- ing wet cement off of ceramic only forces cement into pores.

9.Thoroughly mix cement and insert tip of squeeze bottle into cement port. Tilt bottle and squeeze while simultane- ously turning diffusion element into seat. Do not get any cement on upper part of diffusion element. Ensure com- plete penetration of cement around three grooves in hub. Cement should extrude from opposite hole. Wipe ex- cess material back into holes and wipe top fillet of cement to form a uniform fillet. (A Q-Tip is useful for this.) Clean any excess cement from hub with water.

10.Allow filter to dry at room temperature overnight or 1 to 2 hours at 200°F (93°C).

Rosemount Analytical Inc. A Division of Emerson Process Management

Appendices A-19

Page 118 Page 120
Image 119
Page 118 Page 120
Contents World Class Essential Instructions Effective November, 2001 Rev Highlights of ChangesEffective May, 1999 Rev SummaryEffective 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 Vee Deflector Reference AirSemiautomatic Calibration ThermocoupleComplete 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 Output Jumper Condition during Microcontroller failure Switch SW3Jumper Configuration Heater Power Supply InstallationIFT 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 Overview Section SetupConfiguring the Analog Output Setting Calibration ParametersConfiguring the Relay Outputs Setting the O2 Alarm SetpointsConfiguring Efficiency Calculations Overview CalibrationAnalog Output Calibration System CalibrationLiquid 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 ControlsHelp KEY Quick Reference ChartMENU, SUB-MENU, Help Or Parameter Name Message Probe Data Calibrate O2SUB-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 Constant United States Europe GAS OIL Dual Range SetupNormal Range Values Efficiency ConstantsSystem Troubleshooting Section TroubleshootingSpecial Troubleshooting Notes IFT Status Codes Heater Troubleshooting Problem Heater ProblemWorld Class Status is ResHi or CalEr Cell mV = -20 to 120 mV normal Cell ProblemCell Troubleshooting Problem Status is LowO2 Cell mV = -127 mVStatus is Res Hi Cell mV = -120 to 20 mV Faulty GUI or LDP IFT LED is Flashing IFT ProblemIFT Troubleshooting Problem Status is ResHi or CalEr Cell mV is between -20 to 120 mV MPS ProblemMPS Troubleshooting Problem Status is NoGas 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 AssemblyProbe Options Cable AssemblyAbrasive Shield Assembly Probe Junction BOXView 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 1300CTable A-2. Fault Finding Symptom Check Remedy Probe TroubleshootingProbe Troubleshooting Probe FaultsWorld 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 Symptom Check Fault Remedy MPS 3000 TroubleshootingTroubleshooting Table D-2. Fault FindingFigure 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 Heater optional Power Supply BoardInterconnect Board GUI/LED Display BoardPurge optional Table E-1. Specifications for Intelligent Field TransmitterHeater Power Supply Optional IFT Equipment Status LCD Displays IFT 3000 TroubleshootingIFT Troubleshooting Microprocessor Status LEDFigure 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 FAN Replace Power Supply BoardReplace Microprocessor Board Replace Interconnect BoardFigure 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 World Class 3000 IFT Applications OperationOFF-LINE and ON-LINE Operations Menu Tree for Hart CommunicatorFigure 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
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 76 pages 17.32 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