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Emerson 3000 manual Preface, Definitions, Note To Users, Instruction Bulletin

Models: 3000

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PREFACE

World Class 3000

Instruction Bulletin

106-300NE Rev. 3.4 May 2000

!CAUTION

If the HPS 3000 and World Class 3000 probe are used with any of the following model electronics; 218, 225, 218A, and TC200, read appropriate set point adjustment in Instruction Bulletin (IB) 106-300NE to prevent damage to the World Class 3000 probe.

PREFACE

The purpose of this manual is to provide information concerning the components, func- tions, installation and maintenance of this particular oxygen analyzer.

Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, state- ment, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.

Highlights an operation or maintenance procedure, practice, condition, state- ment, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure, condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illus- tration number. It is not a part number, and is not related to the illustration in any technical manner.

Rosemount Analytical Inc. A Division of Emerson Process Management

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Emerson 3000 manual Preface, Definitions, Note To Users, Instruction Bulletin

Contents

Instruction Bulletin World ClassREAD THIS PAGE BEFORE PROCEEDING ESSENTIAL INSTRUCTIONSSummary HIGHLIGHTS OF CHANGESEffective October, 1995 Rev PageEffective February, 1998 Rev. PageSummary Added safety sheetsEffective May, 1997 Rev. PageSummary Page P-2World Class TABLE OF CONTENTSInstruction Bulletin Instruction Bulletin LIST OF ILLUSTRATIONSInstruction Bulletin PREFACEDEFINITIONS NOTE TO USERSFOR THE WIRING AND INSTALLATION OF THIS APPARATUS SAFETY INSTRUCTIONSInstruction Bulletin Instruction Bulletin 1-1COMPONENT CHECKLIST OF TYPICALSYSTEM PACKAGE CONTENTS SECTION DESCRIPTIONd.Features c.System ConfigurationInstruction Bulletin e.Handling the Oxygen Analyzer Instruction BulletinInstruction Bulletin HEATER POWER SUPPLYPROBE HEAD WIRING Figure 1-3.Typical System WiringInstruction Bulletin SECTION INSTALLATIONBOTTOM VIEW Figure 2-1.Probe Installation Sheet 1 ofInstruction Bulletin 106-300NERev. 3.4 MayInstruction Bulletin Figure 2-1.Probe Installation Sheet 2 of2-4Installation Figure 2-1.Probe Installation Sheet 3 ofInstruction Bulletin CONSTRUCTION INSTALLATION FOR METAL WALL STACK OR DUCTINSTALLATION FOR MASONRY Instruction BulletinInstruction Bulletin Figure 2-1.Probe Installation Sheet 5 ofFigure 2-2.Orienting the Optional Vee Deflector c. Service RequiredFigure 2-3.Outline of Heater Power Supply Instruction BulletinInstruction Bulletin HEATER POWER SUPPLYPROBE HEAD WIRING 2-8InstallationInstruction Bulletin Figure 2-5.Heater Power Supply Wiring Connections2-2HEATER POWER SUPPLY INSTALLATION a.Mechanical InstallationFigure 2-6.Jumper Selection Label Instruction BulletinFigure 2-7.Jumpers on HPS Mother Board Instruction BulletinWorld Class 2-12InstallationInstruction Bulletin Instruction Bulletin SECTION SETUPInstruction Bulletin 3-3MODEL 218A ELECTRONICS SETUPb.Heater Set Point Adjustment Figure 3-3.Main PCB Model TC200 EPROM Replacement3-4MODEL TC200 VERITRIM ELECTRONICS SETUP a.EPROM ReplacementFigure 3-4.Main PCB Model 132 EPROM Replacement 3-5MODEL 132 DIGITAL ELECTRONICS SETUPInstruction Bulletin Instruction Bulletin SECTION TROUBLESHOOTINGWorld Class 4-2TroubleshootingInstruction Bulletin Instruction Bulletin SECTION RETURN OF MATERIALInstruction Bulletin World Class5-2Return of Material SECTION APPENDICES APPENDIX B. HPS HEATER POWER SUPPLY FIELD MODULEInstruction Bulletin APPENDIX A World ClassFigure A-1.Oxygen Analyzer Probe Exploded View DESCRIPTION World ClassAPPENDIX A, REV WORLD CLASS 3000 OXYGEN ANALYZER PROBEAppendix A Rev. 3.6 July World Classc.Snubber Diffusion Assembly A-2PROBE ASSEMBLY EXTERIORa.Cell and Flange Assembly b.Probe Tube Assemblyd.Cell - General A-3INNER PROBE ASSEMBLYFigure A-5.Inner Probe Assembly World ClassFigure A-6.Probe Junction Box A-5CABLE ASSEMBLYA-6PROBE OPTIONS a.Abrasive Shield Assembly World ClassWorld Class Figure A-7.Abrasive Shield Assemblyc.Flame Arrestor Diffusion Assembly Figure A-8.Ceramic Diffusion/Dust Seal Assemblyb.Ceramic Diffusion Assembly Figure A-10.Ceramic Diffusion Assemblye.Bypass Probe Options Figure A-12.Snubber Diffusion/Dust Seal Assemblyd.Snubber Diffusion/Dust Seal Assembly World ClassFigure A-13.Bypass Probe Option Sheet 1 of World ClassFigure A-13.Bypass Probe Option Sheet 2 of World ClassA-10Appendices DESCRIPTION World ClassGROUP CODESymptom PROBE TROUBLESHOOTINGA-8PROBE TROUBLESHOOTING a.Probe Faults Table A-2.Fault FindingWorld Class Table A-2.Fault Finding ContinuedSymptom FaultA-14Appendices World ClassAppendices A-15 World ClassA-9OVERVIEW SERVICE AND NORMAL MAINTENANCEA-11CELL REPLACEMENT World ClassWorld Class Figure A-16.Cell Wiring ConnectionFigure A-17.Removal of Optional Diffusor Figure A-18.Cell Replacement KitELEMENT REPLACEMENT World ClassWorld Class b. Replacement ProcedureFigure A-19.Probe Junction Box Mechanical A-13REPLACEMENT OF CONTACT ANDTHERMOCOUPLE ASSEMBLY World ClassInner Probe Assembly Figure A-21.Heater, Strut, and Backplate AssemblyWorld Class Appendix A Rev. 3.6 July World ClassWorld Class a. Installation ProcedureWorld Class Figure A-23.High Temperature - CorrosiveEnvironment Kit Figure and REPLACEMENT PARTSTable A-3.Replacement Parts for Probe World ClassIndex No Table A-3.Replacement Parts for Probe ContinuedWorld Class Figure andB-1DESCRIPTION APPENDIX B, REV. HPS 3000 HEATER POWER SUPPLYWorld Class DESCRIPTIONSIDE Figure B-2.Heater Power Supply, InteriorWorld Class FRONTB-2THEORY OF OPERATION Table B-1.Specifications for Heater Power SupplyFigure B-3.Heater Power Supply Block Diagram World ClassB-3OVERVIEW HPS 3000 TROUBLESHOOTINGB-4HPS 3000 TROUBLESHOOTING World ClassFigure B-4.HPS Troubleshooting Flowchart, #1 SYMPTOMWorld Class World Class Figure B-5.HPS Troubleshooting Flowchart, #2World Class Figure B-6.HPS Troubleshooting Flowchart, #3Appendices B-7 Supply Field Module. Replacement parts re SERVICE AND NORMAL MAINTENANCEThis section describes service and routine maintenance of the HPS 3000 Heater PowerWorld Class B-9DAUGHTER BOARD REPLACEMENTFOR PURCHASE SEPARATELY. FOR LIST OF Figure B-7.Heater Power Supply, Exploded ViewWorld Class NOTE NOT ALL PARTS SHOWN ARE AVAILABLEFIGURE and INDEX NO REPLACEMENT PARTSWorld Class LEGEND FOR FIGURE B-7B-12Appendices World ClassSECTION INDEX Instruction Bulletin World Class7-2Index 2461 3333/5-00 WARRANTYHPS Part No World Class 3000 Probe Part No. ________________Serial No Order No