ABB SCC-F Bedienungsanleitung

SCC-F Sample gas feed unit

Operator’s manual 42/23-51 EN Rev. 3

2 SCC-F Sample gas feed unit Operator’s manual 42/23-51 EN Rev. 3

Contents

Page

Preface 3

Chapter 1Safety information 4

Intended application, instrument designs 4

General safety information 5

Safety tips for handling electronic measurement devices 6

Chapter 2Preparing the installation 7

Requirements for the installation site 7

Power supply 8

Sample gas inlet conditions 8

Scope of delivery 8

Chapter 3Installation and start-up 9

Installing the sample gas feed unit 9

Installing the sample gas feed unit and sample gas cooler side-by-side 11

Connecting the electrical leads: Notes 14

Connecting the electrical leads: SCC-F without I/O card 15

Connecting the electrical leads: SCC-F with I/O card 18

Setting up the I/O card in the gas analyzer 22

Connecting the sample gas pipes 22

Power supply activation, lead time 23

Chapter 4Maintenance 24

Replacing the dosing pump hose 24

Replacing the dosing pump pressure rollers and springs 26

Replacing the diaphragm and valve plates in the diaphragm pump 28

Checking the gas paths for leaks 31

Troubleshooting 31

Chapter 5Shutting down and packing 32

Shutting down the sample gas feed unit 32

Packing the sample gas feed unit 33

Appendix 34

Use and functions of the sample gas feed unit 34

Description 35

Pneumatic diagrams 36

I/O card 38

Operating specifications 39

Index 40

42/23-51 EN Rev. 3 SCC-F Sample gas feed unit Operator’s manual 3

Preface

Content of the

operator’s manual

This operator’s manual contains all the information you will need to safely and

efficiently install, start-up, operate and maintain the SCC-F sample gas feed unit.

This operator’s manual contains information on all the functional units in the

sample gas feed unit. The delivered sample gas feed unit may differ from the

version described.

Further information

on the Internet

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

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

Additional

information

If the information in this operator’s manual does not cover a particular situation,

ABB Service will be pleased to supply additional information as required.

Please contact your local service representative. For emergencies, please contact

ABB Service,

Telephone: +49-(0)180-5-222580, Telefax: +49-(0)621-38193129031,

E-mail: [email protected]m

Symbols and

typefaces

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.

, ... 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-F Sample gas feed unit Operator’s manual 42/23-51 EN Rev. 3

Chapter 1 Safety information

Intended application, instrument designs

Intended application The SCC-F sample gas feed unit is designed for continuous dosed feeding of

sample gas.

The SCC-F 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.

Standard model The sample gas feed unit is intended for installation in non-hazardous areas. It

complies with EN 61010 Part 1 “Safety requirements for electrical equipment for

measurement, control and laboratory use” and with standards CAN/CSA-C22.2

No. 61010-1-12 and UL Std. No. 61010-1 (3rd Edition).

Certificate no. 70010607.

Version for

Class I, Div. 2

The sample gas feed unit is certified to

Class 2258 02 Process Control Equipment – For Hazardous Locations – Certified

to Canadian Standards and

Class 2258 82 Process Control Equipment – For Hazardous Locations – Certified

to U.S. Standards

for use in hazardous areas Class I, Division 2, Groups A, B, C and D, temperature

code T4, ambient temperature max. +50 °C.

The approval includes the testing in accordance with the relevant Canadian CSA

and US American guidelines.

Certificate no. 1105720.

Details on the

rating plate

The details on the rating plate are applicable for the version of the sample gas feed

unit.

42/23-51 EN Rev. 3 SCC-F Sample gas feed unit Operator’s manual 5

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.

6 SCC-F Sample gas feed unit Operator’s manual 42/23-51 EN Rev. 3

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 work-

ing with an open unit

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

work is performed.

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.

WARNING

EXPLOSION HAZARD

Substitution of components may impair suitability for Class I, Division 2.

Do not disconnect equipment unless power has been switched off or the area is

known to be non-hazardous.

I/O connectors must only be connected to Class 2 circuits.

42/23-51 EN Rev. 3 SCC-F Sample gas feed unit Operator’s manual 7

Chapter 2 Preparing the installation

Requirements for the installation site

Installation location

requirements

The sample gas feed unit is only intended for installation indoors.

The max. altitude of the installation site may not exceed 2000 m above sea level.

The installation site must be stable enough to bear the weight of the sample gas

feed unit (max. 15 kg)!

Short gas 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 environ-

mental 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: +5 to +45 °C

Storage and transport: –25 to +60 °C

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

occasional light condensation permissible

8 SCC-F Sample gas feed unit Operator’s manual 42/23-51 EN Rev. 3

Power supply

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

Power consumption max. 185 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 Gas paths 1 and 2 max. 100 l/h,

bypass max. 200 l/h

Sample gas inlet temperature +10 to +50°C

Sample gas inlet dew point 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.

Scope of delivery

Scope of delivery Quantity Description

1 SCC-F sample gas feed unit

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

8 Fastening screws M5 x 12 (4 x recessed head, 4 x hexagon socket;

for installing side-by-side with the SCC-C sample gas cooler)

1 Rubber bushing with 18 mm inside diameter

(for the cables to/from the SCC-C sample gas cooler)

1 Power supply connection cable, 3-conductor, length approx. 50 cm

1 Connection cable, 2-conductor, length approx. 40 cm

The fixing brackets are fitted in the factory.

42/23-51 EN Rev. 3 SCC-F Sample gas feed unit Operator’s manual 9

Chapter 3 Installation and start-up

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 8).

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

Installing the sample gas feed unit

Figure 1

Dimensional drawing:

Sample gas feed unit

(Dimensions in mm)

1 Sample gas inlet

2 Sample gas outlet

3 Cable bushings

4 Flow monitor with needle valve

5 Dosing pump

6 Condensate monitor

7 LED display and reset switch for

condensate and flow alarm

You must take the additional space requirement into account

adjacent to the unit on the left-hand side for the cooling air inlet

(approx. 10 cm),

in front of and underneath the unit for running and connecting the reagent pipes

to the dosing pump (option) and

above the unit for running and connecting the sample gas lines and the

electrical leads.

The fixing brackets are fitted in the factory, with about 2.5 cm projection to the

rear wall. This projection must not be reduced.

Slope max. 5°.

The user is responsible for the secure mounting of the unit.

Figure 1 shows options. The scope and features of the ordered version may

differ.

Continued on next page

nsicht

View Z

326.5

3.81.5

220

246

263

10 SCC-F Sample gas feed unit Operator’s manual 42/23-51 EN Rev. 3

Installing the sample gas feed unit, continued

Installation of the sample gas feed unit and the sample gas cooler side-by-side is

described on page 11.

Sample gas feed unit

installation on a

mounting plate

Step Action

1 Fit the unit to the mounting plate using 4 M6 screws (not supplied). The

fixing brackets required for this purpose are screwed securely on the

rear of the side panels in the factory.

To enable the cooling air to pass unobstructed out of the unit to

the rear, the projection of the fixing brackets of around 2.5 cm to

the rear wall, which is set up in the factory, must not be reduced.

Sample gas feed unit

installation in a 19-inch

cabinet /rack

Step Action

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

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

cover, using the drill holes provided for this purpose.

2 Install the unit in a 19-inch cabinet/rack using 4 M6 screws.

Release the diaphragm

pumps transportation

restraints

Step Action

1 Use a Ph2 crosshead screwdriver to loosen the two M6x25 screws in

the base plate.

Retain the screws in case the unit needs to be transported again

in the future.

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