Emerson 3000 instruction manual MPS Problem, MPS Troubleshooting Problem

Page 94

Instruction Manual

IB-106-300NH Rev. 4.3 May 2005

World Class 3000

6-7 MPS PROBLEM

MPS problems can occur with a status of C Err, R Hi, TGLow. The O2 reading can be 0% to

99%, and probe data will be in the normal ranges. Consider two conditions, A and B.

Refer to Table 6-5 to troubleshoot problems with the MPS.

Table 6-5. MPS Troubleshooting

Problem

Cause

Corrective Action

Status is NoGas.

Cell mV is between -20 to 120 mV.

1.Regulator or plumbing fault. The test gas pressure is low for the indicated probe [20 to 25 psig (138 to 172 kPa gage)].

Check test gas pressure [should be 20 psig (138 kPa gage)], regulator, and lines. Reset, repair, or replace the regulator as needed. If only one probe has low flow [less than 5 scfh (2.4 L/min)], check lines, needle valve, connectors, and MPS solenoid for that probe.

2. Test gas low.

Replace empty test gas cylinder with full cylinder. Verify O2 concentration.

3. Wiring fault.

Confirm proper wiring and continuity between MPS and electronics. Repair as needed.

4. Pressure switch fault.

Pressure switch is factory set at 16 psig (68.9 kPa gage). Set test gas regulator pressure to 20 psig (138 kPa gage) to avoid nuisance alarms. Replace faulty switch with a new one if test gas supply is good.

Status is ResHi or CalEr.

Cell mV is between -20 to 120 mV.

The CalEr occurs when the slope calculated from the last calibration was out of range. CalEr can be caused by leaks, a faulty diffusor or sensor cell, erroneous test gas values, or not enough test gas time. Each test gas should be supplied for at least three minutes.

1. Flowmeter set incorrectly.

The flowmeter for each probe must be set individually. Flow should be 5 scfh (2.4 L/min).

2. Wiring fault.

Confirm proper wiring and continuity between MPS and electronics.

3. Piping fault. Faulty gas line or regulator.

Check gas line, valves, and regulators for blockage or corrosion. Repair or replace as needed.

4. Solenoid fault.

Verify nominal 24 VDC at HI GAS, LOW GAS, IN CAL, and CAL RET connections. Voltages should drop to about 4 VDC. If voltage is present but solenoid does not work, replace the solenoid.

5. Termination board fault.

Verify 24 VDC at J11 on termination board. Repair or replace termination board or connectors as needed.

6. Power supply fault.

Verify power supply fuses and output are good and that line voltage is present at J1. Repair or replace the power supply as needed.

7. Power fault.

Check fuses, mains, and circuit breakers. Repair or replace as needed.

6-8 Troubleshooting

Rosemount Analytical Inc. A Division of Emerson Process Management

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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.

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