ABB CGWB 13 User manual

Heatable Sample Gas Lines
CGWB 13, TBL 01S, TBL 01C, TBL 01E
Operator’s Manual 42/2324 EN Rev. 5

i
Contents
Preamble 2
Specified Use 3
Safety Information 4
Guide for the Installation 6
Assembly 7
Unpacking.....................................................................................................................................................7
Assembling or Shortening the Heatable Sample Gas Line ...........................................................................8
Laying the Heatable Sample Gas Line Correctly........................................................................................13
Assembly of the Temperature Controller....................................................................................................16
Electrical Installation 17
Requirements and Procedures for Electrical Connection............................................................................17
Electrical Connections of Sample Gas Lines..............................................................................................19
Electrical Connections for the Temperature Controller ..............................................................................20
Operation of the Temperature Controller 21
Operator Panel of the Temperature Controller............................................................................................21
Operation of the Temperature Controller....................................................................................................22
Technical Data 27
Heatable Sample Gas Line CGWB 13........................................................................................................27
Heatable Sample Gas Lines TBL 01-S, TBL 01-C, TBL 01-E...................................................................28
Putting out of Service and Packing 30
Putting out of Service .................................................................................................................................30
Packing for Return......................................................................................................................................31
Index 32

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Contents of this Operator's Manual
This Operator's Manual contains all information required to be able to
install, put into operation and operate the heatable sample gas lines
CGWB 13, TBL 01-S, TBL 01-C and TBL 01-E safely and as specified.
The Operator's Manual also contain information about the operation of
the temperature controller type 703041. The complete Operator's Manual
of the temperature controller is a constituent of the scope of supply and
delivery.
Symbols and Typefaces in the Operator's Manual
WARNING denotes safety instructions which must be followed when
handling the device, in order to prevent danger to user.
NOTE denotes information about particular features with regard to the
handling of the device and the use of this Operator's Manual.
1, 2, 3, ... denotes the reference numbers in the figures.
Spare Parts
You can order spare parts via our service "Parts OnLine". You will find
Parts OnLine on the Internet at "http://www.abb.com/partsonline".
Further Details on the Internet
You will find further details about the products and services of ABB
Analyzer Technology on the Internet at "http://www.abb.com/analytical".
Preamble

3
Further Information
If the information in this Operator's Manual does not cover a particular
situation, ABB after sales service will be pleased to provide further
information.
Please contact your local service representative. For emergencies, please
contact
ABB Service,
Telephone: [phone], Telefax: +49-(0)621-38193129031,
E-mail: [email protected]
Specified Use
The heatable sample gas lines of the types CGWB 13, TBL 01-S,
TBL 01-C and TBL 01-E are used to prevent the formation of condensate
when the sample gas is being fed from the gas sampling point to the gas
analyzer.
Any other application is not compliant with the specified use.
Observation of this Operator’s Manual is also part of the specified use.
Specified Use

4
Requirements for Safe Operation
In order to operate in a safe and efficient manner the device should be
properly handled and stored, correctly 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 operator's manual,
The safety information affixed to the device,
The applicable safety precautions for installing and operating
electrical devices,
Safety precautions for working with gases, acids, condensates, etc.
National Regulations
The regulations, standards and guidelines cited in this operator's manual
are applicable in the Federal Republic of Germany. The applicable
national regulations should be followed when the device is used in other
countries.
Safety Information

5
Device Safety and Safe Operation
The device is designed and tested in accordance with EN 61010 Part 1,
"Safety Provisions for Electrical Measuring, Control, Regulation and
Laboratory Instruments" and has been shipped ready for safe operation.
To maintain this condition and to assure safe operation, read and follow
the safety information in this manual. Failure to do so can put persons at
risk and can lead to device damage as well as damage to other systems
and devices.
Protective Lead Connection
The protective lead (ground) should be attached to the protective lead
connector before any other connection is made.
Risks of a Disconnected Protective Lead
The device can be hazardous if the protective lead is interrupted inside or
outside the device or if the protective lead is disconnected.
Risks Involved in Opening the Covers
Current-bearing components can be exposed when the covers or parts are
removed, even if this can be done without tools. Current can be present at
some connection points.
Risks Involved in Working with an Open Device
All work on a device that is open and connected to power should only be
performed by trained personnel who are familiar with the risks involved.
When Safe Operation can no Longer be Assured
If it is apparent that safe operation is no longer possible, the device
should be taken out of operation and secured against 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.

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Basic Steps
NOTE
Please refer to the planning documents for the installation. Please also
refer to the technical data (see chapter "Technical Data" on page 27).
Step Action
1 Unpack the supplied parts (see section "Unpacking" on page 7).
2 If required, assemble or shorten the sample gas line (only types
CGWB 13 and TBL 01-C, see section "Assembling or Shortening
the Heatable Sample Gas Line" on page 8).
3 Install the heatable sample gas line (see section "Laying the Heatable
Sample Gas Line Correctly" on page 13).
4 Carry out the electrical connection (see section "Requirements and
Procedures for Electrical Connection" on page 17).
After you have carried out these steps, the sample gas line is operative.
Guide for the Installation

7
Unpacking
Unpacking
Step Action
1 Unpack the heatable sample gas line and the temperature controller.
2 Make sure that any accompanying accessories do not get lost.
3 Check the contents of the delivery to ensure that it is complete by
comparing the actual goods with the dispatch note.
NOTE
Keep the packing material for possible future transport.
If damage has occurred during transport due to improper handling, please
submit a damage report to the transport institution (railway company,
post office, forwarding agency) within seven days.
CHAPTER 1
Assembly

8
Assembling or Shortening the
Heatable Sample Gas Line
The heatable sample gas lines of the types CGWB 13 and TBL 01-C can
be shortened.
Important Components of the Sample Gas Line
(Dimensions in mm)
1
Heating cable
2
Contact points with depressions
3
Process line
The contact points of the heating cable are approx. 580-600 mm apart.
WARNING
Danger of failure of the heatable sample gas line!
Ensure that you carry out all the requisite assembly and shortening
work as described in these instructions. The heating of the heatable
sample gas line must work perfectly over the entire length. Otherwise
there is a danger of all the downstream modules and devices being
damaged by the formation of condensate.

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General Rules for Assembly or Shortening
Take note of the type of heatable sample gas line you are installing.
Refer to the order for the type. In addition, please refer to the
information in the specification sheet.
The shortening set supplied with sample gas lines which can be
shortened contains all the individual parts for quick and simple
assembly or shortening.
Both ends of the heatable sample gas line must be assembled for
operation.
The inner gas hose line must be longer than the surrounding
sheathing after shortening.
Small depressions in the heating cable mark the contact points of the
hottest points in the cable. They are 600 mm apart in each case.
You must separate and insulate the heating cable, so that the last
contact point is not more than 100 mm from the end of the cable.
If the last contact point is 600 mm away from the end of the cable in
the worst case, the maximum heating power is no longer available
over a cable length of approx. 500 mm.
Reduce the sample gas line to the requisite length between the gas
sampling point and gas analyzer or sample gas cooler by shortening
and not by coiling on account of the danger of condensate being
formed.
Insulate the ends of the heating cables separately and do not connect
them to each other.

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Assembling or Shortening the Sample Gas Line CGWB 13
(Dimensions in mm)
Step Action
1
Cut back the sheathing of the sample gas line by approx. 250 mm
Cut the heating cable, so that it projects approx. 100 mm and the last
contact point is not more than 100 mm away from the end of the cable.
NOTE
Take note of the contact points in the heating cable and do not
cut at a contact point. If necessary, cut the sample gas line to
length by a further 250 mm.
1
Sample gas line
2
Sealing compound
3
Heating cable
2
Push back the heat insulation and encapsulate the end of the sheathing
with the silicone sealing compound "End sealant" from the shortening
set.

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3
Splice the heating cable and strip the end insulation of one of the two
wires of the heating cable by 10 mm.
1
Heating cable with protective braiding
2
Resistance wire
3
Insulated copper conductor, strip 10 mm!
4
Insulated copper conductor
4
Insulate the cable ends with the enclosed shrink sleeve.
1
Heating cable with protective braiding
2
Shrink sleeve
5
Pass the end piece over the process line.
1
Sample gas line
2
End piece

12
6
Use a heat gun (maximum temperature 120 °C!) to fuse the end of the
sample gas line and the end piece with the shrink sleeve.
1
Shrink sleeve
2
Sealing compound
NOTE
The maximum temperature of the heat gun may not exceed
120 °C, otherwise the shrink sleeve will be damaged!
7
Encapsulate the process line inlet with "End sealant".
Assemble or Shorten the Sample Gas Line TBL 01-C
A shortening set is enclosed with the sample gas line TBL 01-C.
Instructions for assembling and shortening the sample gas line are a
constituent of the shortening set.

13
Laying the Heatable Sample Gas
Line Correctly
WARNING
Danger of overheating!
Follow all the instructions in this section. The heatable sample gas line
may be damaged through overheating or it may malfunction if it is laid
incorrectly.
Fundamentals for Laying the Sample Gas Line
Do not lay the heated sample gas line in
a thermowell.
When laying the sample gas line, avoid
the formation of water locks, particularly
at the sampling points.
Do not lay the heated sample gas line in
a cable tray together with other electrical
or pneumatic lines, especially not in an
enclosed cable tray.
When laying the heated sample gas lines
on exposed C-profiles with BBS cable
clips:
Do not overtighten the cable clips, in
order to prevent damage to the sample
gas line through crushing.

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Procedure for Laying the Sample Gas Line
incorrect correct
Do not lay the heatable sample gas
lines directly side-by-side in an
enclosed duct or shaft. This results in
heat accumulation.
Ensure that the hoses do not touch.
Maintain a distance of 25 mm. Provide
adequate ventilation. Heat can be
conducted away as a result.
Prevent powdery substances,
adhesives or other thermally
insulating materials from soiling the
heated sample gas line. Otherwise,
overheating will occur at these
points.
If soiling occurs, clean the materials and
remedy the cause. Heat can be conducted
away again as a result.
Avoid heat accumulation through
wrapping the heatable sample gas
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.
Do not wrap the sample gas line. Ensure
that the area near the temperature sensor
is exposed. This results in error-free
temperature measurement.
Do not lay the heatable sample gas
line in wall break-throughs which are
subsequently sealed with a sealing
compound under any circumstances.
The sample gas line will be destroyed
by overheating in this case!
When laying the heatable sample gas line
through a wall break-through, use
bulkhead plates with conduit thread cable
glands, in order to provide adequate
cooling of the sample gas line.

15
Avoid bundling or laying several
heatable sample gas lines, so that
they touch each other. This results in
overheating at the contact points.
Lay several heatable sample gas lines
separately with a distance of at least
2.5 cm and provide adequate ventilation.
Heat can be conducted away as a result.
Do not squeeze the heat insulation in
mounting brackets tightly together,
so that the outer braiding is pressed
on to the heat conductor. If you
disregard this, damage to the
protective braiding and the heatable
sample gas line may occur.
Tighten the BBS cable clips sufficiently
but not excessively, in order to prevent
damage to the protective braiding and the
heatable sample gas line.
Permissible Values for Laying the Sample Gas Line
Comply with the following values when laying the heatable sample gas
line:
Characteristic Permissible value
Basic version 50 mMaximum line length
Version with
anti-frost heater
65 m
Basic version 300 mm
Minimum bending radius
Version with
anti-frost heater
300 mm
With horizontal
laying
1.2 m
Maximum clip distance
With vertical laying 3.5 m
Lowest laying temperature -10 °C
Temperature of the sheathing max. 60 °C

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Assembly of the
Temperature Controller
Design of the Temperature Controller Type 703041
(dimensions in mm)
56124
1
1Attachment for top-hat rail TS35
Installation of the Temperature Controller Type 703041
Step Action
1 Install the temperature controller on the top-hat rail in the rail-mount
housing.

17
Requirements and Procedures for
Electrical Connection
WARNING!
Please observe the relevant national safety regulations for the
construction and operation of electrical installations as well as the
following safety instructions.
Before connecting the power supply, check that the operating voltage
on the rating plate is the same as the mains voltage.
The protective-conductor terminal must be connected to a protective
conductor before any other connections are set up.
The device can be dangerous if the protective conductor is interrupted
inside or outside the device or the protective-conductor terminal is
disconnected.
WARNING!
You must be able to disconnect the device from the power supply! For
this purpose, install a 2-pin mains isolator in the power supply line,
since the device does not have its own power switch.
NOTE
Lay the signal lines separate from the power supply lines. Carefully plan
the combination of signal lines in cables.
CHAPTER 2
Electrical Installation

18
What material is required?
Select the required line material as per the planning documents.
Connect the Signal Lines
Step Action
1 Unscrew the casing cover of the temperature controller.
2 Push the cable through the conduits into the casing.
3 Connect the signal lines to the terminals according to the connecting
diagrams (see section "Electrical Connections for the Temperature
Controller" on page 20).
Connect the Power Supply
Before connecting the device:
Check that the operating voltage on the rating plate is the same as the
mains voltage.
Ensure that the power supply leads are adequately fuse-protected
(miniature circuit-breakers).
Install either a mains isolator in the power supply leads or a
switchable socket near the device, thus making it possible to
disconnect all poles of the device and the switching units from the
power supply if necessary.
Connect the power supply as follows:
Step Action
1 Connect the power supply leads to the terminals according to the
connecting diagrams.
2 Put on the casing cover and screw it tight.
3 Connect the power supply leads to the power supply (see sections
Electrical Connections of Sample Gas Lines on page 19
Electrical Connections for the Temperature Controller on page 20).
The heatable sample gas line can be put into operation after it has been
connected to the power supply.