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ABB CEMcaptain GAA610-M, Operating Instruction

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ABB CEMcaptain GAA610-M Operating Instruction Download Page 18

18 

GAA610-M

 ADVANCED EMISSION GAS MONITORING SYSTEM  |  OI/GAA610-M-EN REV. B 

 

 

5

 

Preparation for Installation 

 

Safety instructions 

 

  

  

 CAUTION 

Injury hazard due to heavy weight 

Depending on the version, the gas analyzer cabinet weighs 
approx. 240 kg (529 lb)! 
•  A suitable lifting device (crane, block and tackle, lifting 

truck, etc.) is required for transport, setting upright and 
installation! 

•  Only use the handling lugs provided to connect any lift 

cables to the analyzer cabinet. 

 

 

Note 

•  The system must be installed by ABB or by personnel trained 

by ABB. 

•  When installing the analyzer system, in addition to this 

operating instruction, comply with the information 
contained in the drawings set. 

•  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 the enclosed accessories are not lost. 
•  Keep the packaging material for future shipping needs. 
 

 

Installation – Overview 

1.  Prepare the gas sampling probe installation site, see 

Choosing the extraction point

 on page 18. 

2.  Prepare the analyzer cabinet installation site, see 

Requirements for the installation site

 on page 18. 

3.  Install the gas sampling probe and filter unit, see 

Probe tube 

and filter unit installation

 on page 25. 

4.  Install the sample gas line, see 

Sample gas line installation

 

on page 27. 

5.  Install the back-purging unit (if applicable), see 

Back-purging 

unit installation

 on page 29. 

6.  Install the analyzer cabinet, see 

Analyzer cabinet installation

 

on page 30. 

7.  Install the instrument air and test gas supply  

(if applicable), see 

Gas connections

 on page 31. 

8.  Connect the gas lines to the analyzer cabinet, see 

Connecting the gas lines

 on page 32. 

9.  Connect the electrical leads to the analyzer cabinet, see 

Electrical connections

 on page 33. 

 

 

 

 

 

 

Requirements for the installation site 

 

 

 

 DANGER 

Risk of explosion 

The analyzer system must not be installed in hazardous 
locations. 

 

 

Choosing the extraction point 

The extraction point must be suitable for extracting a 
representative specimen flow. 
In case of emission monitoring of exhaust gases, the extraction 
point is specified in accordance with responsible technical 
inspection authority, e.g. classification society. 
 

 

Wall tube installation 

 

1

  Wall tube 

2

  Wall tube mounting flange 

3

  Gasket 

4

  Sample probe tube flange 

5

  Flow direction 

Figure 7:  Wall tube installation, Dimensions in mm (inch) 

 
Install the wall tube with mounting flange (DN 65, PN 6, facing 
type A to EN 1092-1; not supplied) at the extraction point in such 
a way that the sampling probe tube can be easily installed and 
removed. 
 
The sampling probe tube must be easily accessible to allow 
maintenance work to be performed. Align the boreholes of the 
mounting flange in relation to the flow direction 

5

 of the 

process gas. 
 

 

Summary of Contents for CEMcaptain GAA610-M

Page 1: ...t An increased uptime is provided with the GAA610 M by its robust and simple design as well as its innovative digital features allowing for tailoring services to your needs It is proven for use on boa...

Page 2: ...ions 17 Packaging 17 Returning devices 17 5 Preparation for Installation 18 Safety instructions 18 Installation Overview 18 Requirements for the installation site 18 Choosing the extraction point 18 W...

Page 3: ...Cycle time factory setting 42 Optimum cycle time setting 42 Cycle time minimum value 42 Event controlled start of the back purging procedure by filter plugging 42 Adjustment of the cycle time 42 Post...

Page 4: ...ells with test gas 78 Checking the seal integrity 78 When is the seal integrity check needed 78 Procedure 78 Replacing the filter element in the filter unit 79 Soot filter 81 Changing of the filter fi...

Page 5: ...ved and must be fully legible at all times The operating company must strictly observe the applicable national regulations relating to the installation function testing repair and maintenance of elect...

Page 6: ...ectly installed and set up properly operated and correctly maintained Personnel qualifications Only persons familiar with the installation set up operation and maintenance of comparable devices and ce...

Page 7: ...system or in the integrated analyzers Doing so will damage gas path seal integrity If system internal gas paths are opened a seal integrity check must be performed with a leak detector thermal conduct...

Page 8: ...Measurement Analytics No 4528 Kangxin Highway Pudong New District Shanghai 201319 P R China Tel 86 0 21 6105 6666 Fax 86 0 21 6105 6677 Email china instrumentation cn abb com Service address If the in...

Page 9: ...alyzer cannot process the sample without further treatment as e g an excessive dust content temperature and dew point excessive or insufficient pressure and interference components in the sample gas c...

Page 10: ...ulated O2 option 0 to 25 Vol CO option 0 to 500 ppm Inputs and outputs Analog output The measured concentrations of CO2 and SO2 as well as the ratio SO2 CO2 are available as 4 to 20 mA signals for fur...

Page 11: ...Sample Gas Cooler SCC C Front panel On top is the NDIR gas analyzer AO2020 Uras26 Below on the left side of the status signal board are signal lamps as indication of activity of measuring point and b...

Page 12: ...as line is the connection and supplying line between sample probe and analyzer cabinet The probe and the sample gas line are heated to avoid condensation To clean the filters in the sample probe a bac...

Page 13: ...nfrared source lamp a sample cell a wavelength filter and the infrared detector The sample gas is pumped into the sample cell and the gas concentration is measured electro optically by its absorption...

Page 14: ...unit sucks the sample from the exhaust gas and continuously feeds the gas analyzer with the sample gas The pump is a diaphragm pump If the pump fails a flow alarm occurs Flow control The flow meters m...

Page 15: ...arking 5 Manufacture date 6 Type approval marking 7 Observe operating instruction symbol 8 Permissible ambient temperature range 9 Power supply 0 Measuring Components k Order number l Product configur...

Page 16: ...re installation Transporting the device Transporting the analyzer cabinet NOTICE Potential damage to the device Damage to the device due to improper transport Use the handling lugs provided to connect...

Page 17: ...air tight in 0 2 mm thick polyethylene including a desiccant e g silica gel The amount of desiccant used should be adequate for the package volume and the probable shipping time at least 3 months 2 P...

Page 18: ...s line see Sample gas line installation on page 27 5 Install the back purging unit if applicable see Back purging unit installation on page 29 6 Install the analyzer cabinet see Analyzer cabinet insta...

Page 19: ...installation aboard a ship Thereby the installation location height is naturally limited to sea level The analyzer cabinet is only suitable for installation indoors An air conditioned room is recomme...

Page 20: ...ging GAA610 M Instrument air inlet conditions Quality Oil free dry with dew point 20 C 4 F Pressure Min 400 kPa 60 psig Max 600 kPa 90 psig Air consumption 0 2 Nm3 day NOTICE Damage to the sample cond...

Page 21: ...pers 3 Maintenance area Figure 8 Dimensions analyzer cabinet mm in Weight of the individual system components Component Weight Analyzer cabinet 240 kg 441 lb depending on configuration Probe tube type...

Page 22: ...e 40 probe tube B Heated filter unit 1 Backpurging air inlet from solenoid valve S0V2 2 Backpurging air inlet from solenoid valve S0V1 3 Sample gas outlet heated sample gas line 4 Cable gland for heat...

Page 23: ...urging panel B Filter unit 1 Pressure regulator 2 Instrument air inlet 10 mm O D Tube fitting for stainless steel pipe 3 Pressure buffer tank 4 Backpurging solenoid valve SOV2 5 Backpurging solenoid v...

Page 24: ...0 V AC 50 60 Hz Single Phase NON UPS power supply fuse external 25A Cable Entry M25 Cable gland for customer supply cable Cable Type 3 10 mm2 Grounding cable 6 mm2 Connecting cables between analyzer c...

Page 25: ...e Piping plan in the drawings set Make sure that the wall tube is installed at the extraction point see Filter unit overview A Sample gas inlet B Sample gas outlet C Backpurging air inlet from solenoi...

Page 26: ...Filter unit installation 1 Screw the probe tube 6 into the sample gas inlet 8 of the filter unit 2 Insert the pre assembled probe tube with filter unit in the wall tube and screw the flange of the fil...

Page 27: ...ng plan in the drawings set Connect the sample gas line to the filter unit gas sampling probe Route the sample gas line through the opening provided in the top of the cabinet Fundamentals for laying t...

Page 28: ...line with other materials otherwise the sample gas line will overheat at these points Do not cover the area near the temperature sensor otherwise the rest of the sample gas line will cool down B Do no...

Page 29: ...ding radius 300 mm Maximum clip distance 1 2 m with horizontal laying 3 5 m with vertical laying Lowest laying temperature 10 C Temperature of the sheathing max 60 C Back purging unit installation Bef...

Page 30: ...cabinet can lead to condensation 3 Remove the plastic sheet only once the analyzer cabinet is at room temperature This takes at least 24 hours Mounting the analyzer cabinet Observe the installation si...

Page 31: ...ting 4 6 1 mm TP7 Calibration gas inlet Tube fitting for PTFE pipe 4 6 1 mm TP8 Sample gas outlet Analyzer cabinet ATM vent Vent out room safety area Tube fitting for PTFE pipe 10 12 1 mm TP9 Condensa...

Page 32: ...ing the condensate bottle The Condensate bottle is connected to the sample gas cooler and must be emptied when alarm of level switch is displayed Connecting the sample gas outlet Observe the following...

Page 33: ...amples Cable specification Note All cables entering the system must comply with the flammability class VW1 FT1 or EN60332 1 2 2 2 Power supply lines Analyzer cabinet supply 230 V AC 50 60 Hz Single Ph...

Page 34: ...age TE1 M25 Power supply TE2 M20 Sample probe heater power supply TS1 M25 Analogue signals to DCS TS2 M20 Digital signals to from DCS TS3 M20 Modbus cable to DCS TS4 SOV1 M20 Backpurge unit SOV1 power...

Page 35: ...sensor from heated sample gas line TBL01 5 Analogue outputs 4 to 20 mA 6 Modbus interface 7 Ethernet interface 8 I O for sample probe and backpurging 9 Digital input for condensate bottle level monit...

Page 36: ...ion of the terminal strips on the back plate of the analyzer cabinet Terminal Description Terminal Description X60 Main power supply and power out for heated sample gas probe X63 Digital outputs Syste...

Page 37: ...um output power 300 W Internal fuse protection 6 A Backpurging unit Terminals Valve 1 X62 1 2 Valve 2 X62 3 4 Power supply output 24 V DC Maximum output current 1 A Internal fuse protection 2 A slow b...

Page 38: ...nected according to local regulations Differences in potential and signal interference must be taken into consideration Connecting the power supply Note An easily accessible mains isolator must be ins...

Page 39: ...f ships and observe the local conditions Connect the input wiring of the heated sample components temperature resistant as needed Digital communication Modbus communication Transmission of measured va...

Page 40: ...k purging of the filter unit components are integrated in the analyzer system as follows The back purging air panel with 6 bar pressure reduction valve pressure regulator and 2 l buffer tank for effec...

Page 41: ...utputs and limits are set on hold The display reports Probe purging The Modbus signal Sample line1 in purging is set to 1 The Modbus signal Line 1 in operation is set to 0 The lamp Line1 Measuring Sta...

Page 42: ...obe filter blocking occur caused by temporary larger amounts of dust with the result of a sample gas flow decrease beneath the admissible limit an additional back purging procedure is started as a res...

Page 43: ...nst unauthorized use The possibility of safe operation is excluded If the device is visibly damaged If the device no longer operates After prolonged storage under adverse conditions After severe trans...

Page 44: ...wn for the compressor suction and discharge pressures to equalize in order for the air conditioner to restart Operating the air conditioner below the minimum ambient temperature or above the maximum a...

Page 45: ...measurement values can be outside the ranges specified in the data sheet End of the warm up phase The warm up phase is over when the temperature and flow status messages are gone and the measured val...

Page 46: ...user input not confirmed with the ENTER key is lost and processes in progress e g calibration will be stopped Specifics for manual calibration Manual calibration runs at level 0 thus no password is n...

Page 47: ...into three panels Menu line Information field Softkey line The menu line The menu line appears at the upper edge of the screen A line separates it from the information field It shows the current menu...

Page 48: ...ng functions It prompts for the STATUS MESSAGE key to be pressed whenever a status message is pending It shows that a password is active It shows that the gas analyzer is being controlled from a remot...

Page 49: ...to the measurement mode to display values if the operator has not pressed a key in menu mode in the last five minutes time out Softkeys The six buttons under the screen and the softkey line at the lo...

Page 50: ...operating instruction entries to be made by the operator will not be identified by key symbols but by the following type styles these are examples only Press cancel keys Back Meas Press softkeys MENU...

Page 51: ...ered directly via the keyboard using the value input Numbers on the keyboard are assigned to the individual parameters the assignment is specified above the respective parameter e g Press key 4 The pa...

Page 52: ...s for detailed information see Chapter Configuration in the operating instruction OI AO2000 11 Operation Selecting and changing parameters Key Entry Using the key entry preset parameter values can be...

Page 53: ...u items can only be changed by authorized users User Group The definition of a user group is that every user that belongs to it has access entitlement at certain password levels i e can make changes t...

Page 54: ...change any menu items on all password levels accessible at the user s level 11 Operation Password protection Duration of the change privilege The change privilege remains in place until either the gas...

Page 55: ...ensively at most menu items e g into the various measurement components or into the selection and adjustment of values Password levels For each menu item its password level 0 1 2 3 is shown in the tab...

Page 56: ...56 GAA610 M ADVANCED EMISSION GAS MONITORING SYSTEM OI GAA610 M EN REV B 11 Operation Menu structure...

Page 57: ...applies only when the time zone has been selected from the continent country city list and not from the GMT values list Condition as delivered The gas analyzer is factory set to the GMT 1 time zone A...

Page 58: ...ices smartphone tablet etc Dynamic QR Code represents an innovative communication path for the user enabling improved case specific assistance from the ABB service team This helps to shorten response...

Page 59: ...measures in case of status messages Status messages table No Text S A W F Reaction Remark Run time error 1 21 Runtime error 1 to Runtime error 21 Notify Service if these messages occur repeatedly Syst...

Page 60: ...o the database x x The system bus module software version is not compatible with that of the system controller update the system controller software 209 The system bus connection to this module is int...

Page 61: ...est installed measuring range for measurements on plants subject to approval and pursuant to the 27th and 30th BImSchV Federal Regulation on Immissions 307 The amplification drift between two calibrat...

Page 62: ...n of the measurement value x x Notify Service I O devices 332 Auxiliary voltage failure on I O board x x Defective I O board Replace the board 333 Unavailable I O type configured x x Correct the confi...

Page 63: ...log digital converter x x Notify Service 399 The measured value overshoots the range of the analog digital converter x x Check the sample gas concentration Check connectors in the gas analyzer Notify...

Page 64: ...of preamplifier override 520 Initial zero calibration started For information 521 Initial zero calibration ended For information 522 Initial zero calibration interrupted For information 523 Initial z...

Page 65: ...ence to the function block type 1001 Condensate penetration Overall message for guiding reaction to condensate penetration not logged 1002 Flow rate too high at this point x x Currently not used 1003...

Page 66: ...dust is removed before the sample gas enters the sample gas cooler eliminate sublimates prior to this point Clean the sample gas lines and cooling system consider the effects of corrosion and reduced...

Page 67: ...Problem in measured signal processing View status messages Identify cause and repair Blinking E in mA Value Readout Problem in output current circuit Identify cause e g line break and repair Power Su...

Page 68: ...he emitter CAUTION The emitter temperature is approx 60 C in the thermostat version of the Uras26 Replace the AO2020 unit or consult service contact Have the emitter and modulator assembly checked by...

Page 69: ...oss of refrigerant Check air conditioner Compressor tries to start but won t run Low line voltage at start Should be 10 of rated voltage Compressor motor stuck Bad contactor Bad overload switch Bad ru...

Page 70: ...of the system housing as well as in the analyzer data sheet the software version of the system controller and the system modules the software version is located in the menu MENU Diagnostic Informatio...

Page 71: ...trained personnel only WARNING Risk of injury due to harmful gases Some of the gases measured with the analyzer system are harmful to health Therefore the sample gas must not escape from the gas path...

Page 72: ...Replace the oil soot filter if applicable X See Page 81 Clean replace the air condition filter X See Page 83 Replacing the hose at the hose pump from the sample gas cooler SCC C X See Page 84 Clean th...

Page 73: ...leaning hints Never use water or any solvents to clean parts inside the analyzer cabinet Always operate the analyzer system with cabinet door closed Remove dust inside the analyzer cabinet using a bro...

Page 74: ...ation you will also get a lossless operation as long as the gas concentration and the inlet humidity do not vary significantly Calibration Principles Preconditions Ambient air temperature 5 C to 40 C...

Page 75: ...ion Data Automatic Calibration Password 081500 By default a zero and endpoint calibration is performed daily at 7 00 am Manual start Figure 36 Control page The automatic calibration can be manually st...

Page 76: ...the concentration of the test gas can be entered For the zero point ambient air can be used therefore the concentration of SO2 is 0ppm Confirm your settings You must wait a little until the measured...

Page 77: ...rming the basic calibration The basic calibration is performed for each sample component It is recommended to perform the basic calibration in zero and endpoint If a new basic calibration is performed...

Page 78: ...t the system should use ambient air 1 Open the menu MENU Maintenance Test Analyzer spec adjustm Measure cal cell 2 Please wait until the measured value is stable Figure 40 3 If this is the case confir...

Page 79: ...t cover 1 Turn off power supply to the probe heater F63 2 Activate the Maintenance Mode on the control panel 3 Open the cover of the filter unit 4 Turn the T handle counter clockwise direction This pu...

Page 80: ...r holder 10 Insert A the filter holder back into the Filter housing 11 Turn the bridge counter clockwise A 1 Filter housing 2 Filter holder 3 Filter retainer 4 Brige 5 T handle Figure 45 Pusch in the...

Page 81: ...medium in an environmentally friendly manner 5 Close and seal the condensate drain 6 Unscrew the filter housing 7 Dispose of the soiled raschig rings in an environmentally friendly manner 8 Unscrew th...

Page 82: ...stop filter in the sample gas line Make sure the installation direction is correct gas inlet at the bottom 6 Turn on main switch 7 Check the seal integrity according to the description in Checking th...

Page 83: ...oil Note Do not run the air conditioner for extended periods of time with the filter removed Particles of dust lint etc can plug the fins of the condenser coil which will give the same reaction as a p...

Page 84: ...he handles press the moving belt 1 together and turn the s clip 2 in a clockwise direction as far as its limit stop 5 Remove the moving belt 1 from the pump head and pull the old hose 3 by the hose co...

Page 85: ...do the 8 fastening screws on the covering hood release the cable lug of the protective leads from the quick terminal on the inside of the covering hood then lift the covering hood off 6 Carefully blow...

Page 86: ...electrical connection 2 loosen two hex socket head screws 1 and remove mounting plate with the pumps from the sample gas feed unit s casing 4 Take off the pump hoses and clean the outside of the pump...

Page 87: ...e plates 18 Move the valve plates gently in a horizontal plane to ensure that they are not locked 19 Insert sealing rings in the spacer plate Fit the pump head 20 Using the fan impeller move the struc...

Page 88: ...ld always be transported and stored with the gas ports up Otherwise the oil in the compressor circuit could leak from the compressor cap The sample gas cooler must stand in its operating position for...

Page 89: ...isconnect the PE connection to it 5 The cooler can now be installed Install the new SCC C 1 Insert the prepared SCC C into the housing of the GAA610 M 2 Put the cables through the cable inlets of the...

Page 90: ...ety precautions The protective lead should be attached to the protective lead connector before any other connection is made NOTICE Damage to the SCC F Damage to the SCC F due to incorrect mains voltag...

Page 91: ...ttom view 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 pu...

Page 92: ...ble that you will have to acknowledge the error messages that have appeared after the system has been changed This is possible in the STATUS MESSAGE Replacing the AO2020 If there is a malfunction of t...

Page 93: ...it is ready for operation 6 The serial number of the SCC F must now be entered in the menu Proceed as follows MENU Configure System Setup system modules 7 Select the Cooler SCC F Application 8 Press C...

Page 94: ...densates according to applicable regulations Note Make sure the analyzer system is free of residual moisture that can freeze if low temperatures are encountered during shipping and storage Transportat...

Page 95: ...uct must be supplied to a specialist recycling company Do not use municipal waste collection points These may be used for privately used products only in accordance with WEEE Directive 2012 19 EU If t...

Page 96: ...Fuse protection 24V DC control of sample gas valve Y60 time lag fuse 2A F72 Fuse protection 24V DC control of blowback valves Y61 Y62 time lag fuse 2A F73 Fuse protection 24V DC signal lamps H61 H62...

Page 97: ...GAA610 M ADVANCED EMISSION GAS MONITORING SYSTEM OI GAA610 M EN REV B 97 Location diagram...

Page 98: ...98 GAA610 M ADVANCED EMISSION GAS MONITORING SYSTEM OI GAA610 M EN REV B 18Appendix Piping diagram...

Page 99: ...ompany Address Contact person Telephone Fax Email Device details Type Serial no Reason for the return description of the defect Was this device used in conjunction with substances which pose a threat...

Page 100: ...notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document We r...

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