ABB CEMcaptain GAA610-M Operating Instruction Download Page 21

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GAA610-M

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

Dimensions

Analyzer cabinet

Vibration damper

Mounting plate for vibration dampers

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 40

8 kg (18 lb)

Filter unit, heated, with protective case

20 kg (44 lb)

Back Purging Unit

Approx. 5 kg (11 lb)

Heated sample gas line type TBL01-S

1 kg/m (2.2 lb/m)

Summary of Contents for CEMcaptain GAA610-M

Page 1: ...nt 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 board by all major classification societies and complies with Marpol Annex IV requirements and NOx Technical Code 2008 ABB has the right gas analyzer to allow vessels to stay compliant with current and ...

Page 2: ...tions 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 Wall tube installation 18 Short gas paths 19 Protection from adverse ambient conditions 19 Installation indoors 19 Dimensions and space requirement 19 Installation site stability 19 Climatic Condition...

Page 3: ...2 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 purge time 42 Post purge time duration 42 Guide for the post purge time 42 Adjustment of the post purge time 42 10 Commissioning and operation 43 Safety instructions 43 When safe operation can no lo...

Page 4: ...cells 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 filling and the filter element 81 Aqua stop filter 82 Changing the aqua stop filter 82 Ambient air filter zero gas 82 Changing the ambient air filter 82 Analyzer air conditioner 83 Compressor 83 Inlet ...

Page 5: ...oved 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 electrical products Warnings The warnings in these instructions are structured as follows DANGER The signal word DANGER indicates an imminent danger Failure to observe this information will result in deat...

Page 6: ...rectly 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 certified as being capable of such work should work on the device Special information and precautions These include The content of this operating instruction The safety information affixed to the devic...

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 conductivity when the device is reassembled Notes on data safety This product is designed to be connected to and to communicate information and data via a network interface It is operator s sole responsibil...

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 information in this Operating Instruction does not cover a particular situation ABB Service will be pleased to supply additional information as required Please contact your local service representative...

Page 9: ...nalyzer 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 can affect the operating ability of the gas analyzer and distort the measurement result Therefore additional devices such as the sampling probe the sample gas line the sample gas cooler pumps and filt...

Page 10: ...culated 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 further use in the process control system Digital output The following digital signals are provided for the process control system of the ship System failure common alarm Maintenance Maintenance Request...

Page 11: ...e 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 back purging Directly below them is the temperature controller for the heated sample gas line In the middle of the status signal board are red LEDs for the Common Alarm and for the condensate level al...

Page 12: ...gas 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 back purging system via the filter chamber can be integrated The filters are cleaned with pressurized air every 12 hours cyclically or automatically when the flow is below the minimum value At the entra...

Page 13: ...infrared 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 of a specific wavelength in the infrared wavelength range Sample Gas Cooler SCC C 1 Temperature controller 2 Condensate pump Figure 3 Sample Gas Cooler SCC C The sample gas cooler defines the water c...

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 monitor the sample gas flow through the analyzer The following parameters are considered Typical flow 60 l h Minimum flow level 40 l h Maximum flow level 80 l h Flow error 10 l h If the flow violates ...

Page 15: ...marking 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 configuration number m Model name Figure 5 Name plate example Plates and symbols The following labels and symbols are attached to the analyzer system or to the individual components Label Symbol Meaning Cons...

Page 16: ...ore 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 any lift cables to the analyzer cabinet The lift cable must be long enough to have an angle of at least 60 relative to the top of the cabinet when under tension If this is not done the handling lugs...

Page 17: ...e 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 Pack the device in an adequately large box lined with shock absorbent material e g foam material The thickness of the cushioning material should be adequate for the weight of the device and the mode o...

Page 18: ...as 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 3...

Page 19: ...r 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 recommended Dimensions and space requirement Refer to Dimensions on page 21 in the drawings set Installation site stability The installation site floor must be plane and the wall capable of supporting the c...

Page 20: ...rging 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 conditioning components If the compressed air is not dry and clean this will result in damage to the sample conditioning components valves filters sample gas cooler sample gas feed unit as well as to the...

Page 21: ...mpers 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 40 8 kg 18 lb Filter unit heated with protective case 20 kg 44 lb Back Purging Unit Approx 5 kg 11 lb Heated sample gas line type TBL01 S 1 kg m 2 2 lb m ...

Page 22: ...pe 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 heated filter unit power supply 5 Cable gland for heated filter unit alarm signal L1 500 mm 19 7 in 1000 mm 39 4 in Figure 9 Type 40 probe tube and filter unit ...

Page 23: ...purging 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 valve SOV1 6 Stainless steel pipe 10 mm O D to be intalled by customer Figure 10 Backpurging panel ...

Page 24: ...30 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 cabinet and sample handling components Sample probe power supply 230 V AC 50 60 Hz Cable Entry M20 Cable gland for customer supply cable Cable Type 3 2 5 mm2 Probe Heater Alarm Signal Cable Entry M20 ...

Page 25: ...he 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 solenoid valve S0V2 D Backpurging air inlet from solenoid valve S0V1 1 Flange 2 Internal thread connection for probe tube 3 Filter element 4 Housing with thermal Insulation 5 Cover with thermal insulation 6...

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 filter unit to the flange of the wall tube Use the green seal from the accessories pack to seal the space between the flanges of wall tube and filter unit 3 Mount the heating sleeve on the filter unit 4...

Page 27: ...ing 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 the sample gas line Figure 14 Laying the sample gas line A Do not lay the heated sample gas line in a thermowell B When laying the sample gas line avoid the formation of water locks particularly at th...

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 not wrap the sample gas line Ensure that the area near the temperature sensor is exposed This results in error free temperature measurement Wall break through Incorrect Correct Figure 18 Wall break thr...

Page 29: ...nding 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 Before the installation Observe the Piping plan in the drawings set Installation site The distance between the back purging unit and the sampling probe should be as short as possible and must not exceed...

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 site requirements The loading capacity of the wall must be high enough to bear the weight of the analyzer cabinet Follow the Layout plan in the drawings set The vibration dampers are ready pre installe...

Page 31: ...tting 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 Condensate water drain port Tube fitting DN 6 4 mm PVDF TP10 Condensate water drain port From air condition 10 mm tube Instrument air inlet Located at the backpurging panel see Backpurging Unit on page 23 10...

Page 32: ...ting 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 points when connecting the exhaust air pipe The measured stack gas must be returned to the process or discharged in a suitable exhaust duct Use PTFE or stainless steel as the material for the exhaus...

Page 33: ...xamples 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 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 cabinet and sample handli...

Page 34: ...sage 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 supply TS4 SOV2 M20 Backpurge unit SOV2 power supply TS7 M20 Condensate bottle level alarm switch TS8 M20 Sample probe heater alarm signal Ground bolt for ground wire ...

Page 35: ...e 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 monitoring 0 Digital outputs k Digital input for SO2 measuring range control SO2 CO2 ratio aff Ratio calculation of SO2 CO2 to ensure plausible values on zero level Signal is to be used for operation Figu...

Page 36: ...tion 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 System status signals X64 Power out for heated sample gas line X62 Backpurging Condensat level Pt100 Sample gas line X65 Analogue outputs X68 Ethernet port ...

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 blow Current outputs Terminals CO2 0 to 20 X65 1 2 SO2 0 to 250 ppm X65 3 4 SO2 CO2 ratio 0 to 250 X65 5 6 X65 7 8 Shield X65 S Current output 4 to 20 mA Maximum load 750 Ω Resolution 16 bit Design Joi...

Page 38: ...nnected 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 installed near the analyzer cabinet in order to be able to completely disconnect the latter from the power supply Mark the mains isolator in such a way that assignment to the device to be separated can ...

Page 39: ...of 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 values and status signals as well as analog input digital input and digital output signals to host systems e g standard Windows applications via M DDE server Modbus slave protocol in the RTU Remote Ter...

Page 40: ...ck 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 effective pressure pulses also with lower airflow rate Two solenoid valves SOV1 SOV2 The gas sample probe with filter unit The GAA610 M control program Control of the back purging procedure The back purgi...

Page 41: ...outputs 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 Status is off Back purging probe filter The back purging procedure continues with the back purging of the probe filter To increase the cleaning effect the compressed air is applied not continuously but ...

Page 42: ...robe 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 result and the probe filter is purged free in between Adjustment of the cycle time To adjust the cycle time the parameters of the AO2020 program must be changed Please contact ABB service Post purge tim...

Page 43: ...inst 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 transport stresses Transportation restraints removal 1 Sample Gas Feed Unit SCC F transportation restraints 2 Sample Gas Cooler SCC C transportation restraints Figure 29 Position of transportation restrai...

Page 44: ...own 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 ambient temperatures indicated on the nameplate voids all warranties The moisture that the enclosure air can contain is limited If moisture flows from the drain tube continuously this can only mean th...

Page 45: ...e 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 value drift is acceptable The latter depends on the size of the measurement range Readiness sample gas supply At the end of the warm up phase the analyzer system is ready for operation and automatically...

Page 46: ...t 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 needed It is protected in the following manner from being stopped by another HMI On entering the Calibrate menu the level 1 password is automatically assigned Therefore any other HMI must at least ent...

Page 47: ...d 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 path and thus allows the operator to see where the system is in the menu tree Additionally it shows the name of the analyzer being processed The information field in measurement mode In the measurem...

Page 48: ...ing 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 remote HMI It shows that an automatic calibration process is running in the gas analyzer Display of status messages When a status message is generated by the Message insert function block its short text i...

Page 49: ...s 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 lower edge of the screen are known as softkeys A softkey is the combination of the button and its designation in the softkey line A softkey does not have any set function but is assigned a function for...

Page 50: ...s 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 HELP ENTER BACKSPACE Select menu items Calibration Data Configure Enter numbers 0 to 9 Entering text When text such as sample components or user names needs to be entered an image of the numeric key...

Page 51: ...tered 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 parameter is called up for editing by pressing the assigned number key Example Figure 31 Select parameters Example 1 Press the 4 button to call up the parameter for editing ...

Page 52: ...es 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 selected directly using the softkeys Numbers on the keyboard are assigned to the individual parameters the assignment is specified above the respective parameter e g Press key 4 The parameter is call...

Page 53: ...nu 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 to the menu items at these levels Some user groups are set up at the factory A user group can be made up of one or more users Password NOTICE Damage to the configuration of the gas analyzer After ente...

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 analyzer automatically switches to measuring mode if the user does not actuate a button for about five minutes time out or the user presses the MEAS key twice in a row If the user presses the MEAS k...

Page 55: ...tensively 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 table For some menu items individual sub menu items are on a higher password level These apply especially to those sub menu items which allow access to function block applications Note The Change passwo...

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

Page 57: ...s 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 Accept the time settings Press the softkey SET TIME to accept the modified time settings Selecting user interface language Menu path MENU Configure System Language Language selection Two user interfac...

Page 58: ...vices 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 times in the event of a fault thereby increasing the availability of your gas analyzers Dynamic QR Code is compatible with both the ABB app my Installed Base and standard QR Code scanner apps Handlin...

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 System controller 101 System controller shut down at For information shows date and time 102 System controller starts up at For information shows date and time as well as warm or cold start 103 Install M...

Page 60: ...to 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 interrupted x x Check the system bus connection to the indicated system bus module Check the power supply system of the indicated system bus module 210 The system bus module configuration has changed x ...

Page 61: ...lest 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 calibrations exceeds the permissible range x 308 A computational error occurred during the calculation of the measured value x x Notify Service 309 The temperature regulator is defective x See the status mes...

Page 62: ...on 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 configuration with the test and calibration software 334 No new measured values from the analog digital converter x x Defective I O board Replace the board 335 The measured value exceeds the range of the ...

Page 63: ...alog 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 Service 400 A calculation error occurred during calculation of the measurement value x x Notify Service 401 The flow rate exceeds upper or lower limit value 1 x Check sample gas path Notify Service 4...

Page 64: ...e 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 zero calibration incomplete System bus communication fault during calibration For information 524 Initial zero calibration started x For information not logged 525 Linearization impossible Linearizati...

Page 65: ...rence 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 Flow rate too low at this point x x Currently not used System Cooler 1100 Cooler temperature too high x x Sample gas feed module pump is automatically turned off Check the system cooler and sample ga...

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 service life when using chemical cleaners and flush with an inert gas in order to avoid any cleaning agent influence on measurement results Inaccurate Temperature Indication Defective temperature con...

Page 67: ...t 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 Supply Fuse Failure only for Limas21 power supply Wrong voltage setting on power supply Use the proper voltage setting Change the fuse G fuse element per EN 60127 2 4 A rating slow blow for 115 VAC and...

Page 68: ...the 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 the service department Analyzer cabinet problems Problem Cause Solution Flow to analyzer not constant too low Solenoid valve plugged Untie sampling line on both ends of the solenoid valve and careful...

Page 69: ...Loss 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 run start capacitor Check air conditioner Unit blows breakers Undersized breaker fuse or not time delayed Short in system Check air conditioner Getting water in enclosure Drain plugged Drain tube kinke...

Page 70: ...e 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 Information System overview an exact description of the problem or status as well as the status message number That way the service staff will be able to quickly help you Please also have the analyzer data she...

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 during normal operation and maintenance works A seal integrity check of the analyzer system has to be performed at regular intervals CAUTION Risk of injury due to corrosive condensates Condensates ar...

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 the condenser fins from the sample gas cooler SCC C X See Page 85 Replacing the diaphragm and valve plates of the sample gas feed unit SCC F X See Page 86 Replace the aqua stop filter X See Page 82 Sea...

Page 73: ...Cleaning 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 broom and a vacuum cleaner Clean the outside of the analyzer cabinet with a wet towel and mild cleaning agents Pay attention that no droplets invade the cabinet Status LEDs The three LEDs next to the sc...

Page 74: ...eration 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 If used the flow from test gas bottle has to be as similar to the flow via the membrane pump as possible The flow of the test gas bottle can be regulated via the pressure valve on top of the bottle ...

Page 75: ...tion 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 started on the display and control unit The easiest way to start the automatic calibration manually in the GAA610 M is from the control page You can find them in the overview by changing the pages with...

Page 76: ...p 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 value is stable If the measured value no longer changes confirm your setting The system now performs the calibration for the zero point Confirm the new measurement value again to save the calibration...

Page 77: ...orming 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 it is recommended to perform a pressure sensor calibration and a calibration reset first Pressure Sensor Calibration The pressure sensor calibration can be performed at MENU Maintenance Test Analyze...

Page 78: ...nt 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 confirm the setting with ENTER Checking the seal integrity When is the seal integrity check needed Complete seal integrity check of the analyzer system is reserved for certified service personnel It should...

Page 79: ...ut 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 pulls the filter holder via the filter retainer out of the filter housing 1 Bridge 2 Filter element Figure 42 Remove filter element 5 Turn the bridge clockwise A 6 Pull out filter element B 1 Filter ho...

Page 80: ...er 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 filter holder 12 Turn the T handle in clockwise direction This push the filter holder via the filter retainer in the filter housing 13 Press the filter into the housing until the two surfaces A are a...

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 the soiled filter element from the filter housing and dispose of it in an environmentally friendly manner 9 Screw the new filter element into the filter housing and seal the upper opening 1 Raschig rin...

Page 82: ...a 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 the seal integrity on page 78 8 Deactivate the Maintenance Mode on the control panel Ambient air filter zero gas 1 Ambient air filter Figure 49 Ambient air filter The ambient air filter is located outs...

Page 83: ...coil 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 plugged filter The condenser coil is not visible through the filter opening so protect it with a filter Continued operation under the above conditions can and will damage and shorten compressor life T...

Page 84: ...the 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 connections 4 to release it from the moving belt s guides 6 Press the pressure rollers 5 together and check the spring pressure if it is too weak then the pressure springs and possibly rollers should b...

Page 85: ...ndo 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 compressed air onto the condenser fins 1 7 Press the cable lug of the protective leads onto the quick terminal on the inside of the covering hood put the covering hood in place taking care not to tr...

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 Remove the pump head see Figure 52 5 Mark the head cap 1 spacer plate 3 and casing 5 with a felt pen This prevents the possibility of these parts being fitted incorrectly when the pump is reassembled...

Page 87: ...ve 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 structural diaphragm to its upper dead point 21 Place the spacer plate 3 the valve plates 7 sealing rings 8 and the head cap 1 on the casing in accordance with the markings 22 Check that the head cap is c...

Page 88: ...uld 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 about 24 hours prior to commissioning Remove the old SCC C Figure 53 SCC C cover screws 1 Switch off the entire system with the main switch 2 Open the front cover plate by unscrewing the two screws 1...

Page 89: ...disconnect 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 SCC C and connect them Make sure that the connection is correct X1 for 230 V AC 1 and X4 for the signal 2 Figure 55 Electrical connection SCC C 3 Carefully place the cover on the cooler While doing s...

Page 90: ...fety 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 voltage setting The sample gas feed unit voltage must be set to match the line voltage before the power supply is connected see rating plate Remove the old SCC F Figure 56 SCC F cover screws 1 Switch off t...

Page 91: ...ottom 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 purpose 2 Use a Ph2 crosshead screwdriver to loosen the transport lock 1 two M6 25 mm screws in the base plate 3 Unscrew all 8 screws of the cover Figure 56 3 Remove the cover and connection plate Pay ...

Page 92: ...ible 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 the AO2020 it may be necessary to replace it In the following the individual points are described step by step To replace the AO2020 adjustments must be made in the AO s menu Note A qualified electric...

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 CHANGE PW 081500 9 Now enter the individual electronics number you have noted Confirm your settings 10 Save the changed configuration MENU Configure System Save configuration ENTER 11 The system shoul...

Page 94: ...ndensates 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 Transportation restraints activation 1 Sample Gas Feed Unit SCC F transportation restraints 2 Sample Gas Cooler SCC C transportation restraints Figure 61 Position of transportation restraints Bottom view of ana...

Page 95: ...duct 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 there is no possibility to dispose of the old equipment properly our Service can take care of its pick up and disposal for a fee 16 Specification Note The device data sheet is available in the ABB dow...

Page 96: ...1 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 H63 H64 time lag fuse 2A F74 Fuse protection 24V DC u Remote CAN Bridge D60 time lag fuse 2A F75 Fuse protection 24V DC relay for signal doubling K61 K62 time lag fuse 0 5A F SCC F Fuse protection 23...

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: ...Company 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 or risk to health Yes No If yes which type of contamination please place an X next to the applicable items biological corrosive irritating combustible highly extremely combustible toxic explosive oth...

Page 100: ...r 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 reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or in parts is fo...

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ABB CEMcaptain GAA610-M, Operating Instruction

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