ABB SCC-E Manual de usuario

AnalyzeIT

Continuous Gas Analyzers – Sample Conditioning

SCC-E Sample Gas Feed Unit

Operator’s Manual 42/2358 EN Rev. 1

SCC-E

2 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1

Contents

Page

Preface 3

General Safety Information 4

Safety Tips for Handling Electronic Measurement Devices 5

Chapter 1 Preparing the Installation

Normal Operation 6

Requirements for the Installation Site 6

Power Supply 7

Sample Gas Inlet Conditions 7

Scope of Delivery 7

Dimensional Drawing 8

Chapter 2 Sample Gas Feed Unit Installation

Installing the Sample Gas Feed Unit 9

Connecting the Sample Gas Pipes 10

Connecting the Electrical Cables 11

Chapter 3 Sample Gas Feed Unit Start-Up

Power Supply and Sample Gas Activation 12

Sample Gas Pump Control 13

Cooler Control 13

Chapter 4 Maintenance

Replacing the Condensate Pump Hose 14

Replacing the Condensate Pump Pressure Rollers and Springs 16

Replacing the Diaphragm and Valve Plates in the Diaphragm Pump 18

Checking the Gas Paths for Leaks 21

Troubleshooting 22

Chapter 5 Shutting Down and Packing the Feed Unit

Shutting Down the Feed Unit 23

Packing the Feed Unit 23

Appendix

Description 24

Circuit Diagrams 25

42/23-58 EN Rev. 1 SCC-E Sample Gas Feed Unit Operator’s Manual 3

Preface

Contents of this

Operator’s Manual

This operator’s manual contains all the information you need to install, commission,

operate and maintain the SCC-E sample gas feed unit safely and in accordance

with the regulations.

This operator’s manual contains information on all the function units of the sample

gas feed unit. It is possible that the sample gas feed unit that you have been

supplied with could differ from the model described here.

Additional Document Specification Sheet “System Components and Accessories for Sample Gas

Conditioning”, Document No. 10/23-5.20 EN

This publication can be ordered from your authorized ABB representative or from

ABB Automation Products GmbH, Analytical Division, Marketing Communication,

Fax: +49 69 79 30-45 66, E-mail: [email protected]

Further Details

on the Internet

You can find further information on ABB Analytical products and services on the

internet: “http://www.abb.com/analytical”.

Identifies safety information to be heeded during unit operation

in order to avoid risks to the operator.

Identifies specific information on operation of the unit as well as

on the use of this manual.

Symbols and

Typefaces

1, 2, 3, ... Identifies reference numbers in the figures.

This operator’s manual is protected by copyright. The translation, duplication and distribution in any form,

even in a revised edition or in extracts, in particular as a reprint, by photomechanical or electronic repro-

duction or in the form of storage in data processing systems or data networks are prohibited without the

consent of the copyright holder and will be prosecuted under civil and criminal law.

4 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1

General Safety Information

Requirements for

Safe Operation

In order to operate in a safe and efficient manner the unit should be properly

handled and stored, correctly installed and started, properly operated and

carefully maintained.

Personnel

Qualifications

Only persons familiar with the installation, set-up, operation and maintenance of

comparable equipment and certified as being capable of such work should work

on the unit.

Important Notes and

Regulations

It is important to comply with:

•The content of this operator’s manual

•The safety information affixed to the unit

•The applicable safety precautions for installing and operating electrical devices

•Safety precautions for working with gases, acids, condensates, etc.

National Regulations The regulations, standards and guidelines cited in this operator’s manual are

applicable in the Federal Republic of Germany. The applicable national regulations

should be followed when the unit is used in other countries.

Unit Safety and

Safe Operation

The unit is designed and tested in accordance with EN 61010 Part 1, “Safety

Provisions for Electrical Measuring, Control, and Laboratory Instruments” and has

been shipped ready for safe operation.

To maintain this condition and to assure safe operation, read and follow the safety

information identified with the symbol in this manual. Failure to do so can put

persons at risk and can lead to unit damage as well as damage to other systems

and instruments.

Additional

Information

If the information in this manual does not cover a particular situation, ABB Service

is prepared to supply additional information as needed.

Contact your local ABB service representative or

ABB Service, Telephone: +49-180-5-12 35 80, Fax: +49-6 21-3 81-5135,

E-mail: callcenter[email protected]

42/23-58 EN Rev. 1 SCC-E Sample Gas Feed Unit Operator’s Manual 5

Safety Tips for Handling Electronic Measurement Devices

Protective Lead

Connection

The protective lead should be attached to the protective lead connector before

any other connection is made.

Risks of Loss of

Protective Lead

Continuity

The unit can be hazardous if the protective lead is interrupted inside or outside the

unit or if the protective lead is disconnected.

Proper Operating

Voltage

The unit voltage must be set to match the line voltage before the power supply is

activated.

Risks Involved in

Opening the Covers

Current-bearing components can be exposed when the covers or parts are

removed, even if this can be done without tools. Current can be present at some

connection points.

Risks Involved in

Working with an

Open Unit

The unit must be disconnected from all power sources before any maintenance

work is performed. Work on a unit that is open and connected to power should

only be performed by trained personnel who are familiar with the risks involved.

Charged Capacitors The unit capacitors can retain their charge even when the unit is disconnected

from all power sources.

Use of Proper Fuses Only fuses of the specified type and rated current should be used as replacements.

Never use patched fuses. Do not short-circuit the fuse holder contacts.

When Safe Operation

can no Longer be

Assured

If it is apparent that safe operation is no longer possible, the unit should be taken

out of operation and secured against unauthorized use.

The possibility of safe operation is excluded:

•If the unit is visibly damaged

•If the unit is no longer operational

•After prolonged storage under adverse conditions

•After severe transport stresses.

6 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1

Chapter 1 Preparing the Installation

Normal Operation

Normal Operation The SCC-E sample gas feed unit is designed for continuous dosed sample gas

feeding.

The SCC-E sample gas feed unit with Peltier cooler is additionally designed for

cooling the sample gas and separating and removing the condensate.

The SCC-E sample gas feed unit must not be used

•for feeding mixtures of gas/air or gas/ oxygen that are capable of ignition during

normal service,

•for feeding flammable gas, which can combine with air or oxygen to form an

ignition-capable mixture, or

•in a potentially explosive atmosphere or in hazardous areas.

Requirements for the Installation Site

Short Gas Feed Paths The sample gas feed unit should be installed as close as possible to the gas

analyzer.

Adequate

Air Circulation

Ensure adequate natural air circulation around the sample gas feed unit. Avoid

heat accumulation.

Protection against

Adverse

Environmental

Conditions

The sample gas feed unit should be protected from

•Cold,

•Radiated heat, e.g. from the sun, kilns or boilers,

•Temperature fluctuations,

•Strong air movement,

•Dust deposits and dust penetration,

•Corrosive atmosphere,

•Vibration.

Climatic Conditions Ambient temperature In operation: +10 to +45 °C

During Storage and transport: –25 to +60 °C

Relative humidity ≤75 % year-round average, ≤95 % on 30 days per

year, occasional light condensation permissible

42/23-58 EN Rev. 1 SCC-E Sample Gas Feed Unit Operator’s Manual 7

Power Supply

Power Supply Input voltage 230 VAC, 50 Hz or 115 V AC, 60 Hz

Power consumption 230 V AC, 50 Hz: 1.05 A, 240 VA

Sample Gas Inlet Conditions

Sample Gas Inlet

Conditions

Sample gas pressure pabs = 70 to 105 kPa (0.7 to 1.05 bar)

Sample gas flow 7 to 70 l/h

Sample gas inlet temperature +10 to +50 °C

Sample gas inlet dew point Version without cooler: The dew point of the sample

gas must be at least 5 °C lower than the lowest

ambient temperature anywhere in the sample gas

feed path. If this is not the case, then a sample gas

cooler unit or a condensate trap is required.

Version with Peltier cooler: max. 50 °C

Scope of Delivery

Quantity Description

1 SCC-E Sample Gas Feed Unit

2 Operator’s Manuals (1 copy in German, 1 in English)

Scope of Delivery

1 Diaphragm Pump Spare Parts Set

The mounting brackets are fitted in the factory.

8 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1

Dimensional Drawing

Fig. 1

Dimensional Drawing

(Dimensions in mm)

3.0

SCC-E

Te s t G a s

Sample Gas

Alarm Pump

248 36

17,5 185

220

372,5

30025 47,5

37,75 101,5

246

263

220

1Sample gas inlet

2Test gas inlet

3Sample gas outlet

4Power supply and status signal cables

5Flow meter with needle valve

6Peristaltic pump 1)

7Condensate monitor 1) /diaphragm filter

8Red LED indicator “condensate alarm” 1)

9Pump switch

10 Temperature controller for cooler 1)

11 3-way cock “sample gas/test gas”

12 Condensate outlet 1)

13 4 x M5 threaded holes in ground plate

1) only in version with Peltier cooler and condensate pump

•You should allow for the additional space required for the cooling air inlet on the

left side of and above the unit.

•The mounting brackets are fitted in the factory, with about 2.5 cm projection to

the rear wall.

•Slope max. 5°.

42/23-58 EN Rev. 1 SCC-E Sample Gas Feed Unit Operator’s Manual 9

Chapter 2 Sample Gas Feed Unit Installation

•If there is shipping damage which points to improper handling, file a damage

claim with the shipper (railway, mail or freight carrier) within seven days.

•Make sure that none of the enclosed accessories are lost during unpacking (see

section “Scope of Delivery”, page 7).

•Keep the shipping box and packaging material for future shipping needs.

Installing the Sample Gas Feed Unit

Step Action

Mount the sample gas feed unit on the wall using 4 M6 screws (not

supplied). The mounting brackets required for this purpose are

mounted on the rear of the side panels in the factory.

To enable the cooling air to pass unobstructed out of the

sample gas feed unit to the rear, the projection of the mounting

brackets of around 2.5 cm to the rear wall, which is set up in

the factory, must not be reduced.

2 If necessary, remove the condensate outlet hose from the peristaltic

pump and pull it out backwards.

Install the

Sample Gas Feed Unit

on the Wall

3 If necessary, remove the handle and close the threaded holes.

Step Action

1 Unscrew the mounting brackets from the rear of the side panels and

screw them securely at the front of the side panels, flush with the front

panel, using the threaded holes provided for this purpose.

Exchange the fittings flange on the case cover with the blank flange

on the rear wall.

Take care not to bend or squash any hoses.

3 If necessary, remove the handle and close the threaded holes.

4 If necessary, remove the adhesive pads from the bottom.

Install the

Sample Gas Feed Unit

in a 19-inch

Cabinet/Rack

5 Mount the feed unit in a 19-inch cabinet/rack using 4 M5 screws.

Step Action

1 Unscrew the mounting brackets from the rear of the side panels.

If necessary, exchange the fittings flange on the case cover with the

blank flange on the rear wall.

Desktop Installation

Take care not to bend or squash any hoses.

10 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1

Connecting the Sample Gas Pipes

Fig. 2

Gas Connections

(View from above)

Sample

Gas In

Sample

Gas Out

Tes t

Gas In

Gas Connections The gas connections are PPH screw connections for DN 4/6 mm hose.

Connect Gas Pipes Connect the gas pipes to the gas inlets and outlet. The gas pipes should be made

from material that is suited to the measuring task.

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