SICK SCPS3300 Bedienungsanleitung

MMMI

MMMOPERATING INSTRUCTIONS

O P E R A T I N G I N S T R U C T I O N S

SCPS3300

Gas Sampling System

28025339/V1-0/2020-03| SICKO P E R A T I N G I N S T R U C T I O N S | SCPS3300

Subject to change without notice

Described Product SCPS3300

Document ID 8025339

Manufacturer SICK AG AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

www.sick.com

Production Location SICK AG AG

Gisela-Sick-Str. 1 · 79276 Reute · Germany

Legal Information This work is protected by copyright. Any rights derived from the copyright shall be reserved

for SICK AG. Reproduction of this document or parts of this document is only permissible

within the limits of the legal determination of Copyright Law. Any modification, reduction or

translation of this document is prohibited without the express written permission of SICK

AG.

The trademarks stated in this document are the property of their respective owner.

Original Document This document is an original document of SICK AG.

CONTENT

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Subject to change without notice

1 About this Document ................................................................................ 7

1.2 Purpose of this Document ..............................................................................7

1.3 Target Group....................................................................................................7

1.4 Further Information.........................................................................................7

1.5 Additional Technical Documentation/Information ........................................8

1.6 Document Conventions...................................................................................8

2 Important Safety Instructions .................................................................. 9

2.1 Intended Use ...................................................................................................9

2.2 Supplemental Directives.................................................................................9

2.3 Requirements for the Qualification of Personnel .......................................... 9

2.4 Potential Hazards..........................................................................................10

2.5 Safety Devices...............................................................................................11

2.6 System Warranty ...........................................................................................11

2.7 RoHS-Directive ..............................................................................................11

2.8 Safety Conventions .......................................................................................12

2.9 Warning Signs on System Components .......................................................12

2.10 Mandatory Signs ...........................................................................................13

2.11 Safety Instructions ........................................................................................14

3 System Description .................................................................................17

3.1 SCP3000 - Gas Sampling System ................................................................18

3.1.1 Water Cooled Gas Sampling Probe ..............................................19

3.1.2 Shock Blow Device........................................................................20

3.1.3 Dust Filter......................................................................................21

3.1.4 Heated Sampling Line ..................................................................21

3.1.5 Rotation Device.............................................................................22

3.1.6 Retraction Device .........................................................................23

3.1.7 Sealing Box ...................................................................................24

3.1.8 Protection Tube.............................................................................24

3.1.9 On-site Control Panel with Signal Column ...................................25

3.1.10 Cooling Device ..............................................................................26

3.1.11 Control Cabinet .............................................................................27

3.1.12 Pneumatic/Compressed Air Service Unit ....................................27

3.1.13 MCS300P - Multicomponent Analysis System ............................28

3.1.14 MPR - Meeting Point Router (option) ...........................................29

4 Installation ................................................................................................31

4.1 Requirements for the System Location........................................................32

4.2 Probe Position ...............................................................................................32

4.3 Retraction Device..........................................................................................35

4.3.1 Installation Procedure ..................................................................36

4.4 Rotation Device and Sampling Probe ..........................................................41

4.4.1 Probe Axis Fine Tuning .................................................................42

4.4.2 Sealing Flange ..............................................................................42

Content

CONTENT

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4.5 Control Cabinets ........................................................................................... 43

4.5.1 Electrical Connections.................................................................. 44

4.5.2 Pneumatic Connections ............................................................... 44

4.6 MCS300P - Multicomponent Analysis System ............................................ 45

4.6.1 Bus Connections .......................................................................... 45

4.7 Cooling Unit................................................................................................... 46

4.7.1 Water to Water Cooling Unit......................................................... 46

4.7.2 Water to Air Cooling Unit .............................................................. 47

5 Commissioning ........................................................................................ 49

5.1 Operating Modes .......................................................................................... 49

5.1.1 Local Mode ................................................................................... 49

5.1.2 Automatic Mode ........................................................................... 49

5.2 Dust Filter Unit .............................................................................................. 50

5.3 Water to Water Cooling Unit......................................................................... 50

5.4 Water to Air Cooling Unit .............................................................................. 51

5.5 Setting and Monitoring Devices ................................................................... 51

5.6 Probe Position Check ................................................................................... 51

5.7 Automatic Mode............................................................................................ 52

5.8 MCS300P - Multicomponent Analysis System ............................................ 52

6 Operation .................................................................................................. 55

6.1 Control Cabinet ............................................................................................. 55

6.2 Local Panel.................................................................................................... 56

6.3 Operation Modes .......................................................................................... 57

6.3.1 Local Mode ................................................................................... 57

6.3.2 Automatic Mode ........................................................................... 57

6.4 Operating the Retraction Device .................................................................. 57

6.5 Emergency Retraction .................................................................................. 57

6.6 Back Flushing ............................................................................................... 58

6.7 Anti-Stick Routine ......................................................................................... 58

6.8 Dust Filter...................................................................................................... 58

6.9 MCS300P ...................................................................................................... 58

6.9.1 MCS300P Signals......................................................................... 59

6.9.2 MCS300P Modes ......................................................................... 60

7 Maintenance............................................................................................. 61

7.1 Leak Test....................................................................................................... 62

7.1.1 Leak Test 1 - Complete System Check with Negative Pressure . 62

7.1.2 Leak Test 2 - Complete System Check with Zero Gas ................ 64

7.1.3 Leak Test 3 - Probe and Filter Check with Positive Pressure ..... 66

8 Troubleshooting ....................................................................................... 69

8.1 Alarms ........................................................................................................... 69

8.2 Reset Alarms................................................................................................. 71

8.3 Action Table - SCPS3300 ............................................................................. 71

CONTENT

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9 Technical Data .........................................................................................73

CONTENT

68025339/V1-0/2020-03| SICKO P E R A T I N G I N S T R U C T I O N S | SCPS3300

Subject to change without notice

8025339/V1-0/2020-03| SICK AG O P E R A T I N G I N S T R U C T I O N S | SCPS3300

Subject to change without notice

ABOUT THIS DOCUMENT 1

1 About this Document

1.1 Limitation of Liability

1.2 Purpose of this Document

This document describes the SCPS3300 - Gas Sampling System.

1.3 Target Group

This document is intended for qualified personnel which are authorized to work on the

SCPS3300.

1.4 Further Information

Special local conditions

Follow all local laws, technical rules, and company-internal operating directives applicable

at the respective installation site of the SCPS3300.

Preserving the documents

This document and the additional technical documentation and information must be:

●Available for reference.

●Passed on to new system operator or new employees.

Note

This document regarding the SCPS3300:

●contains information required during the life cycle of the System.

●is available to all those people who work with the System.

●read this document carefully and make sure that you understand the content fully

before working with the System.

Note

Applicable standards and regulations, the latest state of technological development and

many years of knowledge and experience have all been taken into account, when assem-

bling the data and information contained in this document.

The manufacturer accepts no liability for damage caused by:

●Failing to observe this document.

●Non-compliance of notices and regulations.

●Unauthorized mounting and installations.

●Arbitrary technical and other modifications.

●Use of unauthorized spare parts, consumables and accessories.

●Unauthorized modifications, adjustments and/or manipulation of software.

●Do not carry out regular maintenance work and its documentation.

With special variants, where optional extras have been ordered, or owing to the latest

technical changes, the actual scope of delivery may vary from the features and illustra-

tions shown here.

88025339/V1-0/2020-03| SICKO P E R A T I N G I N S T R U C T I O N S | SCPS3300

Subject to change without notice

1ABOUT THIS DOCUMENT

1.5 Additional Technical Documentation/Information

●Technical System-Documentation (EPLAN):

– SCP3000 - Gas Sampling System

Technical data

Wiring diagram

Terminal diagram

– MCS300P - Multicomponent Analysis System

Gas flow diagram

Wiring diagram

Terminal diagram

●Operating instructions of the following system components:

1.6 Document Conventions

Required tools

▸Instruction

Instruction result

All units of measurement in this document are originally metric units.

Subject to change without notice.

Images might differ from actual design.

Component Manufacturer

MCS300P - Multicomponent Analysis System SICK

SCP3000 - Gas Sampling System SICK

Refer to another document.

8025339/V1-0/2020-03| SICK AG O P E R A T I N G I N S T R U C T I O N S | SCPS3300

Subject to change without notice

IMPORTANT SAFETY INSTRUCTIONS 2

2 Important Safety Instructions

2.1 Intended Use

The SCPS3300 consist of the SCP3000 Gas Sampling System and the MCS300P - Multi-

component Analysis System.

The SCP3000 is used for sampling gas in high-temperature processes (up to 1,400 °C)

with high dust loads (up to 2,000 g/m3). The SCPS3300 is specially designed for sampling

gas at rotary kiln inlets in cement works.

The MCS300P measuring equipment serves for process monitoring of raw gas.

The measured medium is extracted at a sampling point and led through the cell of the

MCS300P (extractive measurement).

Intended use also includes compliance with this operating instructions, in particular the

safety instructions and the repair and maintenance conditions.

2.2 Supplemental Directives

▸Before working on the SCPS3300, read this document carefully and follow all safety

instructions and information.

▸Only qualified persons from the respective areas are permitted to work on the

SCPS3300.

▸Follow operating procedures.

▸Follow local regulations.

▸Observe local regulations for working with gas and electrical components.

▸Access to the SCPS3300 is restricted to authorized personnel only.

System damage/transport damage

▸Damage to individual components can lead to malfunctions of the entire system.

▸Do not ignore system components damaged during transport.

▸In the event of damage, contact SICK Service.

2.3 Requirements for the Qualification of Personnel

Only qualified personnel from the respective field are permitted to work on the system.

●Qualified personnel have the specialist training, skills, and experience, as well as knowl-

edge of the relevant regulations and standards, to be able to perform tasks delegated to

them and to detect and to avoid any potential dangers independently.

●Electricians have the specialist training, skills, and experience, as well as knowledge of

the relevant standards and provisions to be able to carry out work on electrical systems

and to detect and avoid any potential dangers independently.

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2IMPORTANT SAFETY INSTRUCTIONS

2.4 Potential Hazards

Toxic gases Toxic gases can lead to poisoning if the following is not observed:

▸Operate the system in adequately ventilated areas or rooms.

▸Use gas monitoring systems.

▸Only enter contaminated areas with PPE (breathing apparatus, gas detector).

▸Perform regular leakage tests.

Insertion/retraction Insertion/retraction during operation can lead to death or serious injury.

▸Note if yellow light on the on-site control panel flashes.

▸Leave dangerous area around the retraction device immediately.

Dangerous areas:

– in front of the sealing box at the kiln inlet chamber.

– close to the dust filter during probe rotation.

– on the retraction device drive.

Automatically retraction Automatically retracted probe due to power failure can lead to death or serious injury.

▸Leave the area around the retraction device immediately.

▸The pneumatic emergency drive triggers the retraction of the probe.

▸Due to power failure the yellow light at the signal column does not flash.

Unintentional insertion Unintentional insertion / retraction of the probe can lead to death or serious injury.

▸During all kind of works at the system secure the device against unintentional insertion

or retraction of the probe.

▸Lockout-Tagout the system.

▸Secure the working area against unauthorized interventions.

Explosive atmosphere Risk of explosion in an explosive atmosphere.

▸Do not operate the SCPS3300 in potentially explosive atmospheres.

Electric voltage Touching components that are live may result in death, burns or shock from electric shock.

Only qualified personnel may carry out electrical work on the system.

▸Before working on electrical components, observe the following safety rules:

▸ Disconnecting

▸ Secure against restarting

▸ Determine the absence of voltage

▸ Grounding and short-circuiting

▸ Cover or barrier adjacent live parts.

Hot surfaces Risk of injury from hot surfaces.

▸Do not touch hot surfaces.

▸Wear safety gloves and protective clothing.

Suspended loads Suspended loads can lead to injuries if the following is not observed:.

▸Never step under suspended loads.

▸Pay close attention when lifting loads.

▸Observe the lifting instructions to avoid injuries and accidents.

▸Use suitable undamaged lifting equipment.

▸Wear personal protective equipment (safety helmet, safety shoes).

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