Emerson FB2100 Field Replacement Manual

The Emerson FB2100 Field Replacement Manual provides comprehensive instructions for the safe removal, replacement, and verification of key components in the FB2100 series flow computer/controller in a field environment. This manual is intended for qualified technicians and covers safety precautions, required tools, step-by-step procedures for major assemblies, post-replacement checks, and troubleshooting guidelines to ensure proper system restoration and operation.

1. Safety and Precautions 2. Tools and Equipment Required 3. Unit Overview and Major Assemblies 4. Component Replacement Procedures 5. Post-Replacement Verification and Calibration 6. Troubleshooting Post-Replacement Issues 7. Parts List and Ordering Information 8. Regulatory and Compliance Information

Safety and Precautions

Before performing any field replacement, review all safety warnings to prevent injury and equipment damage.

Hazard	Precaution
Electrical Shock	Ensure power is disconnected and locked out/tagged out (LOTO) before opening the enclosure.
Process Release	Isolate, depressurize, and drain the process line according to site procedures before disconnecting any tubing.
Electrostatic Discharge (ESD)	Wear a grounded wrist strap when handling circuit boards and static-sensitive components.
Hot Surfaces	Allow the unit to cool if it has been operating in high-temperature environments.
Sharp Edges	Use appropriate gloves when handling metal enclosures and internal chassis.

WARNING! Only qualified personnel familiar with process instrumentation and electrical systems should perform these procedures. Failure to follow safety protocols can result in serious injury or death.

Tools and Equipment Required

Gather the following tools before beginning any replacement task.

Basic Hand Tools: Phillips and flat-head screwdrivers, hex key set, adjustable wrench.
ESD Protection: Grounded wrist strap, anti-static mat.
Electrical: Multimeter, wire strippers/crimpers, terminal block screwdriver.
Process: Tube benders, flare nut wrenches, pressure gauge for leak testing.
Specialized: Emerson communicator or laptop with configuration software (if applicable).
Safety: Safety glasses, insulated gloves, LOTO kit.

CAUTION! Using incorrect or damaged tools can strip fasteners or damage components.

Unit Overview and Major Assemblies

The FB2100 consists of several key field-replaceable units (FRUs).

Main Electronics Module (MEM): Contains the CPU, memory, and primary I/O boards.
Power Supply Module: Converts incoming AC/DC power to internal voltages.
Display/Keypad Assembly: Front interface unit with LCD and membrane keys.
I/O Terminal Blocks: Removable blocks for analog/digital signal wiring.
Communication Modules: Optional cards for Modbus, Foundation Fieldbus, Ethernet.
Enclosure and Chassis: NEMA-rated housing and mounting frame.

Component Replacement Procedures

General steps apply to all replacements: Power Down, Isolate, Disconnect, Remove, Install, Reconnect, Verify.

Replacing the Main Electronics Module (MEM):

Perform LOTO and disconnect all process signals.
Label all wiring connections to the MEM terminal blocks.
Remove the front cover and unscrew the MEM retaining screws.
Carefully disconnect all ribbon cables and board connectors.
Slide the MEM out of its guide rails.
Insert the new MEM, reconnect all cables, and secure with screws.
Reinstall the cover.

Replacing the Display/Keypad:

Power down the unit.
Remove the bezel screws around the display.
Disconnect the flat-flex cable from the main board.
Remove the old assembly and install the new one.
Reconnect the cable and secure the bezel.

WARNING! Handle circuit boards by the edges only. Do not touch components or connectors.

Post-Replacement Verification and Calibration

After replacement, verify operation and calibrate as needed.

Power-Up: Restore power and observe for error codes on the display.
Basic Communication: Verify the unit communicates with the control system or configurator.
I/O Check: Simulate input signals and verify correct readings and output responses.
Flow Calibration: If a flow sensor/computer module was replaced, perform a zero and span calibration per the specific meter's manual.
Configuration Verification: Upload the saved configuration to the new module and verify all parameters.
Leak Test: For any process connections disturbed, perform a pressure/leak test before returning to service.

Tip: Always have a backup of the device configuration before starting any replacement.

Troubleshooting Post-Replacement Issues

Symptom	Possible Cause	Corrective Action
Unit does not power on	Incorrect power connection, faulty new power supply	Verify voltage at terminals, check fuse, reseat power supply connections.
Display is blank	Display cable not seated, configuration mismatch	Power down, reseat display cable, verify display type in configuration.
Communication failure	Wrong comms module, incorrect address/baud rate	Verify module type and configuration settings match the network requirements.
Inaccurate readings	Sensor not calibrated, wiring error	Perform sensor calibration, check wiring against terminal diagram.
Error code on startup	Hardware mismatch, module not recognized	Verify replacement part number is correct for this unit revision. Check for firmware updates.

Reset: A power cycle may clear transient errors. If problems persist, restore the original configuration and contact support.

Parts List and Ordering Information

Common Field Replaceable Units (FRUs) for the FB2100.

MEM Assembly: P/N: FB2100-MEM-01 (Rev. C or later)
Power Supply, 24VDC: P/N: FB2100-PS-24V
Display/Keypad Kit: P/N: FB2100-DISP-KIT
I/O Terminal Block Set: P/N: FB2100-TB-KIT
Enclosure Gasket: P/N: FB2100-GASKET
Complete Wiring Harness: P/N: FB2100-WH-01

Ordering: Contact Emerson Process Management or your local distributor. Provide the unit's serial number and current revision for correct part identification.

Regulatory and Compliance Information

The Emerson FB2100 is designed to comply with applicable standards when installed and maintained as specified.

EMC: Complies with IEC/EN 61326 for industrial environments. Safety: Designed per IEC 61010-1. Hazardous Areas: Models with appropriate certifications (e.g., ATEX, IECEx) must use certified replacement parts to maintain rating.

Disclaimer: This manual is for reference only. Emerson Process Management is not liable for damages resulting from improper installation, maintenance, or use of non-approved parts. Always follow site-specific procedures and local regulations.

For technical support, contact Emerson Process Management at 1-800-833-8314 or visit www.emersonprocess.com.