Emerson 3000 instruction manual System Configuration, System Features

Page 31

World Class 3000

Instruction Manual

IB-106-300NH Rev. 4.3 May 2005

c.System Configuration

The equipment covered in this manual con- sists of three major components: the oxy- gen analyzer (probe), the intelligent field transmitter (IFT), and an optional heater power supply (HPS). The HPS is required where the cable run between the probe and the electronics is greater than 150 ft (45 m). There is also an optional multiprobe calibra- tion gas sequencer (MPS) to facilitate automatic calibration of the probe.

quencer. The MPS 3000 provides automatic calibration gas sequencing for up to four probes and IFTs to accommodate automatic calibration.

d.System Features

1.Unique and patented electronic cell protection action that automatically protects sensor cell when the analyzer detects reducing atmospheres.

Probes are available in five length options, giving the user the flexibility to use an in situ penetration appropriate to the size of the stack or duct. The options on length are 18 in. (457 mm), 3 ft (0.91 m), 6 ft (1.83 m), 9 ft (2.7 m), or 12 ft (3.66 m).

The IFT contains electronics that control probe temperature (in conjunction with the optional HPS), supply power, and provide isolated outputs that are proportional to the measured oxygen concentration. The oxy- gen sensing cell is maintained at a constant temperature by modulating the duty cycle of the probe heater. The IFT accepts millivolt signals generated by the sensing cell and produces outputs to be used by remotely connected devices. The IFT output is iso- lated and selectable to provide linearized voltage or current.

The heater power supply (HPS) can provide an interface between the IFT and the probe. The HPS contains a transformer for sup- plying proper voltage to the probe heater. The enclosure has been designed to meet NEMA 4X (IP56) specifications for water tightness; an optional enclosure to meet Class 1, Division 1, Group B (IP56) explo- sion proof is also available.

Systems with multiprobe and multiple IFT applications may employ an optional MPS 3000 Multiprobe Calibration Gas Se-

2.Output voltage and sensitivity increase as the oxygen concentration decreases.

3.User friendly, menu driven operator interface with context-sensitive on-line help.

4.Field replaceable cell.

5.Analyzer constructed of rugged 316 LSS for all wetted parts.

6.The intelligent field transmitter (IFT) can be located up to 150 ft (45 m) from the probe when used without optional heater power supply (HPS). When the system includes the optional HPS, the HPS can be located up to 150 ft (45 m) from the probe and the IFT may be lo- cated up to 1200 ft (364 m) from the HPS.

7.All electronic modules are adaptable to 100, 120, 220, and 240 line voltages.

8.Five languages may be selected for use with the Intelligent Field Transmitter:

English Italian

French Spanish German

Rosemount Analytical Inc. A Division of Emerson Process Management

Description and Specifications 1-3

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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 February, 1992 Rev Appendix BEffective January, 1995 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 April, 1995 Rev Appendix JEffective June, 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 SpecificationsScope System OverviewSystem Description System Features System ConfigurationWorld 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 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 Efficiency Calculations Setting the O2 Alarm SetpointsConfiguring the Relay Outputs 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 O2Probe 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 SUB-MENU Selection Parameters Description Setup Sub-MenuXfer Fnct Selected in the Setup sub-menuRange Values Constant United States Europe GAS OIL Dual Range SetupNormal Range Values Efficiency ConstantsSpecial Troubleshooting Notes Section TroubleshootingSystem Troubleshooting 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 IFT Troubleshooting Problem IFT ProblemFaulty GUI or LDP IFT LED is Flashing 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 Cell and Flange Assembly Probe Assembly ExteriorProbe Tube 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 Cell Replacement Service and Normal MaintenanceProbe Recalibration 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 Transformer Replacement Fuse ReplacementMother Board 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 Pressure Adjustments Pressure Regulator MaintenanceCondensation Drain 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 Replace Fuse Remove Power and Open CoverRemove Electronics Chassis from Enclosure 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 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 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
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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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