ABB SCC-S User manual

SCC-S Sample gas feed unit
Operator’s Manual 42/2359 EN Rev. 1

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Contents
Preface 3
Safety Information 4
Specified Use 4
Safety Instructions 5
Preparation for Installation 7
Requirements for the Installation Site, Power Supply 7
Sample Gas Inlet Conditions 8
Scope of Delivery 8
Dimensional Drawing 9
Sample Gas Feed Unit Installation 10
Unpacking the Sample Gas Feed Unit 10
Mounting the Sample Gas Feed Unit 11
Connecting the Gas Lines 13
Connecting the Electrical Leads 14
Sample Gas Feed Unit Start-Up 17
Power Supply and Sample Gas Activation 17
Sample Gas Pump Control 18
Peltier Cooler Control 19
Maintenance 20
Replacing the Condensate Pump Hose 20
Replacing the Condensate Pump Pressure Rollers and Springs 22
Replacing the Diaphragm and Valve Plates in the Diaphragm Pump 24
Checking Gas Path Seal Integrity 27
Troubleshooting 28
Shutting Down and Packing 29
Shutting Down the Sample Gas Feed Unit 29
Packing the Sample Gas Feed Unit 30
Annex 31
Pneumatic Diagrams 31
Circuit Diagrams 35
Index 38

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Content of the Operator's Manual
This operator's manual contains all the information you need to install,
commission, operate and maintain the SCC-S sample gas feed unit safely and in
accordance with the regulations.
This operator's manual contains information on all the functional units in the
SCC-S sample gas feed unit. The delivered sample gas feed unit may differ from
the version described.
Further Information
Internet
You will find information about the products and services of ABB Analytical on
the Internet at "http://www.abb.com/analytical".
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".
Service Contact
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: automation[email protected]
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.
Preface

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Specified Use
Specified Use
The SCC-S sample gas feed unit is designed for continuous dosed sample gas
feeding.
The SCC-S sample gas feed unit with Peltier cooler is additionally designed for
cooling the sample gas and separating and removing the condensate.
Any other application is not compliant with the specified use.
Observation of this operator's manual is also part of the specified use.
The SCC-S sample gas feed unit must not be used
For feeding mixtures of gas/air or gas/oxygen that are capable of ignition
during normal service,
For feeding flammable gas which may form an explosive mixture with air or
oxygen, and
In a potentially explosive atmosphere or in hazardous areas.
CHAPTER 1
Safety Information

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Safety Instructions
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.
Device Safety and Safe Operation
The device is designed and tested in accordance with the relevant safety
standards 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 operator's 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.

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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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Requirements for the Installation Site, Power Supply
Short Gas Paths
The sample gas feed unit should be installed as close as possible to the gas
analyzer.
Adequate Air Circulation
Ensure adequate natural air circulation around the sample gas feed unit. Avoid
heat buildup.
Protection against Adverse Environmental Conditions
The sample gas feed unit should be protected from
Cold,
Heat sources such as the sun, furnaces, boilers,
Large temperature variations,
Strong blasts,
Accumulations of dust and dust infiltration,
Corrosive atmospheres,
Vibration.
Environmental Conditions
Ambient temperature +10 to +40 °C during operation
–25 to +60 °C during storage and transport
Relative air humidity 75 % year-round average, 95 % on 30 days per year,
occasional light condensation permissible
Power Supply
Input voltage 230 VAC, 10 %, 50 Hz or 115 VAC, 10 %, 60 Hz
Power consumption 230 VAC, 50 Hz: max. 300 VA
CHAPTER 2
Preparation for Installation

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Sample Gas Inlet Conditions
Sample Gas Inlet Conditions
Sample gas pressure pabs = 70 to 105 kPa (0.7 to 1.05 bar)
Sample gas flow rate Gas path: 7 to 70 l/h
Bypass: 15 to 150 l/h (not in versions with Peltier cooler)
Sample gas inlet temperature +10 to +50 °C
Sample gas inlet dew point Version without Peltier cooler: The sample gas dew point should be at least 5 °C
below the lowest ambient temperature throughout the sample gas path. If this is
not the case, then a sample gas cooler unit or a condensate trap is required.
Version with Peltier Cooler: max. 50 °C (at max. +25 °C ambient temperature)
Scope of Delivery
Scope of Delivery
Quantity Description
1 SCC-S Sample gas feed unit
1 Power supply cable, length 2 m
1 Socket plug, 8-pole, for signal line connection
2 Operator’s manuals (1 copy in German, 1 in English)

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Dimensional Drawing
Dimensional drawing (dimensions in mm)
1 Sample gas inlet
2 Sample gas outlet, bypass outlet and test gas inlets via ball valve or solenoid
valve
3 Power supply connection and electrical connection for status signal, solenoid
valve control and 24 VDC
4 Ball valve for infeed of test gas
5 Flow monitor with needle valve (Option: second flow monitor for bypass)
6 Peristaltic pump (Option: second peristaltic pump for external cooler)
7 Membrane filter or condensate monitor
8 LED indicator for condensate alarm, red
9 Pump switch
10 Temperature controller for cooler
NOTE
When mounting, allow for the additional space required for the cooling air outlet
on the left and right side of the unit (min. 3.5 cm).
Remark: The illustration shows options. The scope and features of the ordered
version may differ.

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Unpacking the Sample Gas Feed Unit
In the event of transport damage attributable to improper handling, instigate
damage assessment by the carrier (rail, post office, forwarder) within seven days.
Make sure that none of the enclosed accessories are lost during unpacking.
Keep the transport box and padding material for any future transportation which
might be necessary.
CHAPTER 3
Sample Gas Feed Unit Installation

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Mounting the Sample Gas Feed Unit
NOTES
Max. inclination of the instrument 5°. A distance of at least 1 height unit from
devices which develop heat is required for the version with Peltier cooler. When
mounting, allow for the additional space required for the cooling air outlet on the
left and right side of the unit (min. 3.5 cm).
Sample Gas Feed Unit Installation on the Wall
Mount the sample gas feed unit to the wall using 4 M6 screws (not supplied).
The fixing brackets required for this purpose are screwed securely on the rear of
the side panels in the factory.
To enable the cooling air to pass unobstructed into the unit to the rear, the
projection of the fixing brackets of approx. 2.5 cm to the rear wall, which is set
up in the factory, must not be reduced.
Sample Gas Feed Unit Installation in a 19-Inch Cabinet/Rack
If necessary, remove the adhesive pads from the bottom.
If necessary, install mounting rails in the cabinet/rack.
Mount the sample gas feed unit in a 19-inch cabinet/rack using 4 M6 screws (not
supplied).
Desktop Installation
If necessary, unscrew the mounting brackets from the rear of the side panels.
If necessary, exchange the fittings flange with the blank flange.

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Exchanging the Fittings Flange with the Blank Flange
View from behind
1 Loosen the 2 fixing screws and open the housing cover.
2 Loosen the 4 fixing screws each on the fittings flange and on the blank
flange.
3 Exchange the fittings flange with the blank flange. Take care not to bend or
squash any hoses.
4 Close the housing cover and secure it with the 2 fixing screws.
The sample gas inlet port can be swiveled by 90°.

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Connecting the Gas Lines
Gas connections (view from above)
Gas Connections
The gas connections are PVDF or PPH fittings for DN 4/6 mm hose.
Gas Line Connection
Connect the gas lines to the gas inlet and outlet fittings. The gas lines should be
made from material that is suited to the measuring task.

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Connecting the Electrical Leads
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.
Use only fuses of the specified type and rated current as replacements. Never
use patched fuses. The fuse holder must not be short-circuited.
NOTE:
The signal lines should be routed separately from the power supply lines.

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Connecting the Signal Lines
Signal line connections
1–3 Status signal of the cooler, flow and condensate monitoring: potential-free
changeover contact, contact load 24 V DC/AC, 1 A
4 Activation of solenoid valve Sample/Test gas
5 Activation of solenoid valve Test gas 1
6 Activation of solenoid valve Test gas 2
7 Internal power supply 0 V
8 Internal power supply +24 V DC
"Inside SCC-S" means: The connection diagram shows the internal wiring of the
sample gas feed unit.
The integrated power supply can also be used for the supply of external solenoid
valves:
Terminal 7 = 0 V, terminal 8 = +24 V, maximum capacity 30 VA at 24 V DC.
Connect the signal lines (recommendation: 1.5 mm2) to the 8-pole socket plug (in
scope of delivery).

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Connecting the Power Supply
1 Make sure the voltage setting shown on the rating plate matches the line
voltage.
The operating voltage cannot be switched over.
2 Make sure the power supply leads have an adequately dimensioned
protective device (breaker).
3 Install a switched outlet or a breaker in the power supply wiring near the
sample gas feed unit. This should allow the sample gas feed unit to be
completely disconnected from the power supply if necessary.
The disconnection device should be easily accessible and identified in such a
way that its relationship to the equipment that it is designed to disconnect
can be clearly seen.
4 Connect the delivered power supply cable to the power supply.
The sample gas feed unit may start when the power supply is connected.

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Power Supply and Sample Gas Activation
WARNING
Before activating the power supply check once again that the operating
voltage setting (see rating plate) matches the line voltage.
The needle valve must never be closed completely.
The sample gas must not be switched on until the cooler's lead time has
finished.
Power Supply and Sample Gas Activation
Version without Peltier Cooler
1 Activate the power supply.
2 The sample gas feed unit is ready for operation without delay.
3 The sample gas must not be switched on until the upstream cooler unit's lead
time has finished.
4 Set the sample gas flow using the needle valve (max. 70 l/h).
Version with Peltier Cooler
1 Activate the power supply.
2 The condensate pump starts to run.
3 The lead time is approx. 10 minutes.
The flow alarm and the cooler temperature alarm are present during the lead
time. The condensate alarm may also be present.
4 The lead time is finished and the sample gas feed unit is ready for operation
when the sample gas outlet temperature of the Peltier cooler is within the
factory-set limit values ("K1" LED on the temperature controller lights up
yellow). The sample gas pump starts to run if the "Pump" push-button is
pressed (lights up green).
The sample gas pump can be switched off with the "Pump" push-button.
5 The sample gas may be switched on.
6 Set the sample gas flow using the needle valve (max. 70 l/h).
CHAPTER 4
Sample Gas Feed Unit Start-Up

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Sample Gas Pump Control
Operation
The "Pump" push-button must always be pressed during operation (lights up
green).
The sample gas pump can be switched off with the "Pump" push-button, e.g. for
maintenance work.
Alarm
(only in the version with Peltier cooler)
The sample gas pump is switched off when
a condensate alarm ("Alarm" LED next to the "Pump" push-button lights up
red) or
a cooler temperature alarm ("K1" LED on the temperature controller is off)
is present. The "Pump" push-button continues to light up green.
After Power Failure
The jumper JP1 located on the circuit board can be used to set whether the
sample gas pump restarts automatically after a power failure:
Jumper in position 1–2: The sample gas pump does not restart (factory-set).
Jumper in position 2–3: The sample gas pump restarts automatically.

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Peltier Cooler Control
Cooler Control
State Indication
Controller LED K1 Controller LED K2
After start-up > 5 °C
(room temp.)
Off (pump off & status alarm) Lights up constantly yellow (cooling)
After lead time end
(approx. 10 min)
5.5 °C Lights up yellow (pump is
switched on1, status alarm
switches to "good" state)
Lights up constantly yellow (cooling)
Normal operation 3 °C Lights up yellow Blinks (cooler regulation)
> 3,5 °C Lights up yellow Lights up constantly yellow (cooling)Cooler overloaded
> 5 °C Off (pump off & status alarm) Lights up constantly yellow (cooling)
< 2,5 °C Lights up yellow OffAmbient temperature
too low < 0 °C Off (pump off & status alarm) Off
1 if no condensate alarm is present and sample gas pump us switched on
("Pump" push-button lights up green)
See section "Troubleshooting", page 28, for further information on cooler
problems.
Changing the Sample Gas Outlet Temperature
The set point for the sample gas outlet temperature (factory-set to +3 °C) can be
changed at the temperature controller:
1 Press key P; the set point is displayed.
2 Use arrow keys to adjust the set point.
3 Press key P; the new set point is stored.

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WARNING
The operations described in this chapter require specialized knowledge, and
sometimes involve the necessity of working on the sample gas feed unit with
its cover open and live. They must therefore only be carried out by qualified
and specially trained persons.
Replacing the Condensate Pump Hose
When does the hose need to be replaced?
Depending on the operating cycle, the condensate pump hose should be replaced
at least every 5 months.
NOTE
Use only an original pump hose as replacement part to ensure trouble-free
operation. Never lubricate the condensate pump hose.
WARNING
Residues from the condensate that the pump has been feeding may be found
in the pump hose and the connected hoses. These media can flow out when
the hose connections are opened. Take appropriate measures where needed to
collect such residues. The medium being fed may be corrosive and poisonous!
Appropriate precautions must be taken! Wear protective goggles and
protective clothing!
Condensate pump, hose and pump head with roller mounting
1 Moving belt 3 Hose 5 Pressure rollers
2 S-clip 4 Hose connections 6 Dovetail guides
CHAPTER 5
Maintenance