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ABB CEMcaptain GAA610-M, Инструкция по эксплуатации

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16 

GAA610-M

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

 

 

4

 

Transport and storage 

 

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. 

 

 

Inspection 

 

Check the devices immediately after unpacking for possible 
damage that may have occurred from improper transport. 
Details of any damage that has occurred in transit must be 
recorded on the transport documents. 
All claims for damages must be submitted to the shipper 
without delay and before 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 can be bent or 
the analyzer cabinet can be warped. 

 

Figure 6:  Lift-Up the analyzer cabinet 

 

Note 

It is strongly recommended that the analyzer cabinet is 
transported by a specialist firm, transported in a horizontal 
position! 
 

Unpacking the analyzer cabinet 

1.  Lift out the analyzer cabinet from the shipping box. 
2.  Do not remove the plastic sheet in which the analyzer cabinet 

is wrapped. Unpacking a cold analyzer 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. 

 

 

Содержание CEMcaptain GAA610-M

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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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