Emerson 3000 Section Installation, Oxygen Analyzer Probe Installation, Selecting Location

Page 37

World Class 3000

Instruction Manual

IB-106-300NH Rev. 4.3 May 2005

SECTION 2

INSTALLATION

2-1 OXYGEN ANALYZER (PROBE)

INSTALLATION

Before starting to install this equip- ment, read the "Safety instructions for wiring and installation of this appara- tus" at the front of this Instruction Manual. Failure to follow the safety in- structions could result in serious in- jury or death.

a.Selecting Location

1.The location of the probe in the stack or flue is most important for maximum accuracy in the oxygen analyzing pro- cess. The probe must be positioned so that the gas it measures is representa- tive of the process. Best results are normally obtained if the probe is posi- tioned near the center of the duct (40 to 60% insertion). A point too near the edge or wall of the duct may not pro- vide a representative sample because of the possibility of gas stratification. In addition, the sensing point should be selected so that the process gas tem- perature falls within a range of 50° to 1300°F (10° to 704°C). Figure 2-1 pro- vides mechanical installation references.

2.Check the flue or stack for holes and air leakage. The presence of this con- dition will substantially affect the accu- racy of the oxygen reading. Therefore, either make necessary repairs or install the probe upstream of any leakage.

3.Ensure that the area is clear of ob- structions internal and external that will interfere with installation. Allow ade- quate clearance for removal of probe (Figure 2-1).

4.If the probe is to be mounted outside, subject to rain and snow conditions, make sure the back of the probe (out- side of the duct) is insulated to prevent the formation of flue gas condensate in the calibration gas lines.

Do not allow the temperature of the probe junction box to exceed 300°F (149°C) or damage to the unit may re- sult. If the probe junction box tempera- ture exceeds 300°F (149°C), the user must fabricate a heat shield or provide adequate cooling air to the probe junc- tion box.

b.Mechanical Installation

1.Ensure that all components are avail- able for installation of the probe. En- sure that the system cable is the required length. If equipped with the optional ceramic diffusor element, en- sure that it is not damaged.

2.The probe may be installed intact as it is received. It is recommended that you disassemble the adapter plate for each installation.

NOTE

An abrasive shield is recommended for high velocity particulate in the flue stream (such as those in coal fired boilers, kilns, and recovery boilers). Vertical and horizontal brace clamps are provided for 9 ft and 12 ft (2.75 m and 3.66 m) probes to provide me- chanical support of the probe. Refer to Figure 2-1, sheet 5.

3.Weld or bolt adapter plate (Figure 2-1) onto the duct.

Rosemount Analytical Inc. A Division of Emerson Process Management

Installation 2-1

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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 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 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 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 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 Efficiency Calculations Setting the O2 Alarm SetpointsConfiguring the Relay Outputs 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 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 SUB-MENU Selection Parameters Description Setup Sub-MenuXfer Fnct Selected in the Setup sub-menuRange Values Normal Range Values Dual Range SetupEfficiency Constants Constant United States Europe GAS OILSpecial Troubleshooting Notes Section TroubleshootingSystem Troubleshooting 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 IFT Troubleshooting Problem IFT ProblemFaulty GUI or LDP IFT LED is Flashing 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 Cell and Flange Assembly Probe Assembly ExteriorProbe Tube 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 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 Troubleshooting MPS 3000 TroubleshootingTable D-2. Fault Finding Symptom Check Fault RemedyFigure 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 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 Replace Fuse Remove Power and Open CoverRemove Electronics Chassis from Enclosure 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 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 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.

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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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