ABB CEMcaptain GAA610-M User manual

—
ABB MEASUREMENT & ANALYTICS |
OPERATING INSTRUCTION | OI/GAA610-M-EN REV. B
CEMcaptain GAA610
-M
Advanced emission gas monitoring system for marine
applications
—
ABB Measurement & Analytics
For your local ABB contact, visit:
www.abb.com/contacts
For more produc
t information, visit:
www.abb.com/analytical
Measurement made easy
OI/GAA610
-M-EN Rev. B 06.2021
—
GAA610
-M
Introduction
GAA610
-M is a multi-component analyzer system
continuously monitoring SO2/CO2 emissions of
vessels.
Reducing maintenance hassles during ship
operation has been the guiding
principle for
development. 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
classificatio
n 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 upcoming
regulations.
Additional Information
Additional documentation on CEMcaptain GAA610-M
is available for download free of charge at
www.abb.com/analytical.
Alternatively simply scan this code:
—
We reserve the right to make technical changes or modify the contents of this document
without prior noti
ce. 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 forbidden without prior written consent of ABB.
© ABB 2021 3KXG141006R4201

2 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
Table of contents
1Safety ........................................................................ 5
General information and instructions.................................5
Warnings..................................................................................5
Warranty provisions...............................................................5
Intended use............................................................................6
Improper use...........................................................................6
Safety instructions.................................................................6
Requirements for safe operation ....................................6
Personnel qualifications ...................................................6
Special information and precautions .............................6
National regulations..........................................................6
Safety of the equipment and safe operation.................6
Working with hazardous gases........................................ 7
Protective lead connection...............................................7
Risks involved in opening the covers ..............................7
When safe operation can no longer be assured ............7
Risks involved in opening the gas paths ........................7
Notes on data safety..............................................................7
Services and ports on the Ethernet interface................7
Access authorizations.......................................................7
Manufacturer’s address.........................................................8
Service address.......................................................................8
2Design and function................................................. 9
Measuring principle................................................................9
Device description..................................................................9
Type approvals ...................................................................9
Measurement ranges ...........................................................10
Inputs and outputs...............................................................10
Analog output ..................................................................10
Digital output ...................................................................10
System structure .................................................................. 11
System cabinet................................................................. 11
System schematic............................................................ 12
Sample Gas Cooler SCC-C............................................... 13
Sample Gas Feed Unit SCC-F .........................................14
3Product identification ............................................15
Name plate ............................................................................15
Plates and symbols ..............................................................15
Scope of delivery .................................................................. 15
4Transport and storage............................................16
Safety instructions...............................................................16
Inspection ..............................................................................16
Transporting the device ......................................................16
Transporting the analyzer cabinet ................................16
Unpacking the analyzer cabinet.....................................16
Storing the device ................................................................ 17
Ambient conditions......................................................... 17
Packaging .............................................................................. 17
Returning devices................................................................. 17
5Preparation 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 Conditions .........................................................19
Backpurging Unit ................................................................. 20
Design of the back-purging unit ................................... 20
Distance to sampling probe .......................................... 20
Protection from adverse ambient conditions............. 20
Instrument air supply ..................................................... 20
Power supply ........................................................................ 20
Sample gas inlet conditions ............................................... 20
Dimensions............................................................................21
Analyzer cabinet ...............................................................21
Type 40 probe tube and filter unit................................ 22
Backpurging Unit ............................................................ 23
Material required for installation....................................... 24
Gas sampling ........................................................................ 24
Gas lines............................................................................ 24
Mounting material........................................................... 24
Cable specification ......................................................... 24
6Installation...............................................................25
Probe tube and filter unit installation............................... 25
Before the installation.................................................... 25
Filter unit overview ......................................................... 25
Installation ....................................................................... 26
Sample gas line installation.................................................27
Installing the sample gas line.........................................27
Fundamentals for laying the sample gas line ..............27
Procedures for laying the sample gas line................... 28
Permissible values for laying the sample gas line ...... 29
Back-purging unit installation............................................ 29
Before the installation.................................................... 29
Installation site................................................................ 29
Connecting the compressed-air tubes ........................ 29
Analyzer cabinet installation .............................................. 30
Transporting the analyzer cabinet................................ 30
Unpacking the analyzer cabinet.................................... 30
Mounting the analyzer cabinet...................................... 30
Connecting the condensate water drain of the cabinet air
conditioner............................................................................30

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 3
7Gas connections ......................................................31
Position and design of the gas connections .................... 31
Connecting the gas lines.....................................................32
Connecting the heated sample gas line .......................32
Calibration gas.................................................................32
Connecting the condensate bottle ...............................32
Connecting the sample gas outlet ................................32
8Electrical connections.............................................33
Safety instructions...............................................................33
Protective lead connection.............................................33
Notes ......................................................................................33
Cable specification...............................................................33
Cable glands..........................................................................34
Terminal assignment – Analyzer cabinet...........................35
Electrical Data ..................................................................37
Connecting the electrical leads .....................................38
Connecting the signal leads...........................................38
Connecting the power supply........................................38
Terminal assignment – Sample gas probe........................39
Electrical data...................................................................39
Electrical connection .......................................................39
Digital communication ........................................................39
Modbus® communication...............................................39
Ethernet communication................................................39
9Gas sampling with automatic back-purging ....... 40
General .................................................................................. 40
Filter plugging...................................................................... 40
Pump suction increase................................................... 40
Filter cleaning.................................................................. 40
Components for back-purging.......................................... 40
Control of the back-purging procedure ...................... 40
Start of the back-purging procedure ............................... 40
Start controlled by time................................................. 40
Start controlled by event ............................................... 40
Manually controlled start............................................... 40
Filter unit backpurging sequence..................................41
Switch over .......................................................................41
Cycle time ..............................................................................42
Cycle time duration .........................................................42
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 longer be assured ......... 43
Transportation restraints removal.................................... 43
Sample Gas Feed Unit SCC-F......................................... 43
Sample Gas Cooler SCC-C .............................................. 43
Analyzer cabinet air conditioner........................................44
Overload protection........................................................44
Principles of operation...................................................44
Start-up .................................................................................44
Prior to start-up...............................................................44
Power supply activation .................................................44
Function check.................................................................44
Date and time check .......................................................44
Warm-up phase ....................................................................45
End of the warm-up phase............................................. 45
Readiness, sample gas supply....................................... 45
Calibration........................................................................45
11 Operation................................................................ 46
General...................................................................................46
HMI priority ......................................................................46
Access lock .......................................................................46
LCD indicator........................................................................ 47
Menu levels of the LCD indicator .................................. 47
LCD display ...................................................................... 47
Display of status messages........................................... 48
Status LEDs......................................................................48
Numeric keypad...............................................................49
Cancel keys.......................................................................49
Softkeys............................................................................49
Entering text....................................................................50
Selecting and changing parameters ..................................51
Value Input ........................................................................51
Key Entry........................................................................... 52
Password protection........................................................... 53
Password Level ................................................................ 53
User Group ....................................................................... 53
Password.......................................................................... 53
Viewing Menu Items........................................................54
Changing Menu Items..................................................... 54
Change Privilege.............................................................. 54
Change password ........................................................... 54
Menu structure..................................................................... 55
Basic Setup ........................................................................... 57
Setting the time zone, date and time........................... 57
Selecting user interface language ................................ 57

4 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
12 Diagnosis / Troubleshooting................................ 58
Safety instructions...............................................................58
The Dynamic QR Code..........................................................58
Application........................................................................58
Handling............................................................................58
Dynamic QR-Code Accessing .........................................58
Status messages ..................................................................59
Information available as digital output........................59
Information displayed on the analyzer system ...........59
Possible status messages...................................................59
“Status messages” table ................................................59
SCC-C – Sample gas cooler problems............................... 66
SCC-F – Sample gas feed unit problems ...........................67
AO2020 Gas analyzer problems..........................................67
AO2020-Uras26 problems .................................................. 68
Analyzer cabinet problems................................................. 68
Analyzer cabinet air conditioner problems...................... 69
Notify Service........................................................................70
Who should you contact for further help? ...................70
Before you notify Service … ...........................................70
If the Service Dept. has been informed …....................70
Returning devices.................................................................70
13 Maintenance ............................................................71
Safety instructions............................................................... 71
Maintenance plan .................................................................72
Spare parts ............................................................................72
Spare parts information .................................................72
Analyzer cabinet – Visual inspection..................................73
Visual inspection..............................................................73
Cleaning hints...................................................................73
Status LEDs ......................................................................73
Calibrating the analyzer system.........................................74
Conversion of concentration values .............................74
Basics.................................................................................74
Calibration – Principles ...................................................74
Automatic calibration .....................................................75
Manual calibration ...........................................................76
Basic calibration...............................................................77
Measurement of calibration 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 air filter .....................................................................83
Emptying the condensate collection bottle .....................83
SCC-C – Replace peristaltic pump hose ........................... 84
SCC-C – Clean condenser fins.............................................85
When should the condenser fins be cleaned?............. 85
SCC-F – Replacing the diaphragm and valve plates ........ 86
Replacing the SCC-C............................................................ 88
Remove the old SCC-C.................................................... 88
Prepare the new SCC-C ..................................................89
Install the new SCC-C...................................................... 89
Replacing the SCC-F ............................................................90
Remove the old SCC-F ....................................................90
Prepare the new SCC-F....................................................91
Install the new SCC-F...................................................... 92
Replacing the AO2020 ......................................................... 92
Remove the old AO2020 ................................................. 92
Prepare the new AO2020................................................ 93
Install the new AO2020................................................... 93
14 Decommissioning .................................................. 94
Safety instructions ..............................................................94
Shutting Down the Analyzer System.................................94
Emptying the Condensate Collecting Bottle ................... 94
Transportation restraints activation ................................94
Sample Gas Feed Unit SCC-F.........................................94
Sample Gas Cooler SCC-C ..............................................94
Ambient conditions.............................................................94
15 Recycling and disposal ...........................................95
16 Specification ...........................................................95
17 Additional documents ............................................95
18 Appendix................................................................. 96
Fuses type 5×20mm ............................................................96
Location diagram................................................................. 97
Piping diagram .....................................................................98
Return form...........................................................................99

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 5
1Safety
General information and instructions
These instructions are an important part of the product and
must be retained for future reference.
Installation, commissioning, and maintenance of the product
may only be performed by trained specialist personnel who have
been authorized by the ship operator accordingly. The specialist
personnel must have read and understood the manual and must
comply with its instructions.
For additional information or if specific problems occur that are
not discussed in these instructions, contact the manufacturer.
The content of these instructions is neither part of nor an
amendment to any previous or existing agreement, promise or
legal relationship.
Modifications and repairs to the product may only be performed
if expressly permitted by these instructions.
Information and symbols on the product must be observed.
These may not be removed 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 death or
severe injury.
WARNING
The signal word ‘WARNING’ indicates an imminent danger.
Failure to observe this information may result in death or
severe injury.
CAUTION
The signal word ‘CAUTION’ indicates an imminent danger.
Failure to observe this information may result in minor or
moderate injury.
NOTICE
The signal word ‘NOTICE’ indicates possible material damage.
Note
‘Note’ indicates useful or important information about the
product.
Warranty provisions
Using the device in a manner that does not fall within the scope
of its intended use, disregarding this manual, using
underqualified personnel, or making unauthorized alterations
releases the manufacturer from liability for any resulting
damage. This renders the manufacturer's warranty null and void.

6 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
… 1 Safety
Intended use
The CEMcaptain GAA610-M analyzer system is designed for
continuous measurement of exhaust gases of marine diesel
engines. Measurement components are CO2and SO2which are
sampled downstream of the scrubber.
Any other use is not as specified. The specified use also includes
taking note of this operating instruction.
Improper use
The following are considered to be instances of especially
improper use of the device:
• For use as a climbing aid, for example for mounting
purposes.
• For use as a bracket for external loads, for example as a
support for piping, etc.
• Material application, for example by painting over the
housing, name plate or welding/soldering on parts.
• Material removal, for example by spot drilling the
housing.
The analyzer system must not be used to measure flammable
gases or combustible gas/air or gas/oxygen mixtures.
The analyzer system must not be installed in hazardous
locations.
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 operating instruction,
• 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 of the equipment and safe operation
The device was built and tested in accordance with
EN 61010 Part 1 ‘Safety regulations for electrical measuring,
control and laboratory equipment’ and it left the factory in
perfect condition.
To maintain this condition and to assure safe operation, read
and follow the safety instructions in this operating instruction as
well as applicable type approval standards of classification
societies.
Failure to do so can put persons at risk and can lead to device
damage as well as damage to other systems and devices.

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 7
Working with hazardous gases
Some gas components whose concentration is measured with
the analyzer system are hazardous to health.
For this reason, the sample gas must under no circumstances be
allowed to escape uncontrolled from the sample gas path in
either the measurement mode or when performing maintenance.
• The analyzer system must be checked for leaks regularly.
• The measured stack gas must be returned to the process or
discharged in a suitable exhaust duct.
• Ensure adequate ventilation of the room in which the
analyzer system is installed.
• The legal requirements for the maximum work place limit
values of the measurement and test gases must be observed.
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.
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.
Risks involved in opening the gas paths
Do not open any gas paths in the analyzer 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 responsibility to provide and continuously
ensure a secure connection between the product and your
network or any other network (as the case may be).
Operator shall establish and maintain any appropriate measures
(such as but not limited to the installation of firewalls,
application of authentication measures, encryption of data,
installation of anti-virus programs, etc.) to protect the product,
the network, its system and the interface against any kind of
security breaches, unauthorized access, interference, intrusion,
leakage and / or theft of data or information.
ABB Ltd and its affiliates are not liable for damages and / or
losses related to such security breaches, any unauthorized
access, interference, intrusion, leakage and / or theft of data or
information.
Services and ports on the Ethernet interface
Port
Description
22/tcp
Used only for software updates.
No direct access to the device.
502/tcp
Used for Modbus/TCP.
The device allows connection to any Modbus client. The port
must be activated via ECT, the port is delivered in a deactivated
state.
8100/tcp
Used for test and calibration software Optima TCT Light.
Binary proprietary protocol.
The port is deactivated. It can be activated for TCT access via a
secure connection, and deactivated when the TCT access is
terminated
Access authorizations
Access to the calibration and to the menus used to change the
configuration of the instrument is restricted by password
protection.
It is recommended that the factory-set passwords be changed
by the operator, see Password protection on page 53.

8 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
… 1 Safety
Manufacturer’s address
ABB Automation GmbH
Measurement & Analytics
Stierstädter Str. 5
60488 Frankfurt am Main
Germany
Tel: [phone]
Email: [e-mail]
ABB Engineering (Shanghai) Ltd.
Measurement & Analytics
No. 4528, Kangxin Highway, Pudong New District
Shanghai, 201319,
P.R. China
Tel: [phone]
Fax: [phone]
Email: [e-mail]
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.
For emergencies, please contact:
Contact Center
www.abb.com/contacts

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 9
2Design and function
Measuring principle
The GAA610-M is based on ABB’s proven NDIR (Non-Dispersive
Infrared) measurement technology.
The analyzer module Uras26 allows for reliable measuring and
monitoring of the limit values for SO2and CO2and reports the
ratio as specified by the IMO (International Maritime
Organization), and it can be employed for continuous monitoring
of CO if required.
Device description
The GAA610-M is a multi-component analyzer system
continuously providing real-time data of relevant pollutants like
SO2/CO2ratio.
It proves compliance of vessels to low emission limits of
emission control areas (ECA zones) and global limits.
The measurement can be used to control the exhaust gas
cleaning system on board, so called scrubber as well.
The GAA610-M is proven for use on board by all major
classification societies and complies with Marpol Annex IV
requirements and NOxTechnical Code2008.
Reducing maintenance hassles during ship operation has been
the guiding principle for development. An increased uptime is
provided with the GAA610-M by its robust and simple design as
well as its innovative digital features allowing for tailored
services according your needs.
The GAA610-M analyzer system extracts the sample gas from the
exhaust gas stream.
The gas analyzer 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 filters ensure
that the sample gas entry conditions of the connected gas
analyzer are met, and a proper measurement result is obtained
regardless of the process and the local conditions.
The sample handling system is specific for the applied
measuring principle.
The GAA610-M analyzer system is a complete turn-key solution
with the following components:
• Probe and filter unit for proper gas sampling
• Heated sample gas line for feeding the sample to the gas
analyzer
• Sample conditioning components like sample gas cooler,
filters and pump to ensure the gas conditions for reliable
measurement results
• AO2020-Uras26 gas analyzer (Advance Optima – AO2000
series) for measuring SO2and CO2
The sample conditioning components and the gas analyzer are
integrated into the analyzer cabinet of the analyzer system.
Available options are:
• Air conditioning unit for operation at ambient
temperature 5 to 55 °C (41 to 131 °F). Higher ambient
temperature during operation on request.
• Dual sampling for simultaneous measurement at two
different sampling locations (on request)
Type approvals
• DNV GL
• Lloyd's Register
• Bureau Veritas
• ABS Group
• Korean Register of Shipping (KR)
• ClassNK

10 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
… 2 Design and function
Measurement ranges
Sample components and measuring ranges
Sample component
Standard measuring ranges
CO2
0 to 20 Vol.-%
SO
20 to 250 ppm
0 to 500 ppm
SO2
/CO
2
ratio Calculated
O2
(option) 0 to 25 Vol.-%
CO (option)
0 to 500 ppm
Inputs and outputs
Analog output
The measured concentrations of CO2and SO2as well as the ratio
SO2/CO2are 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
• SO2meas. range feeback
Further digital signals can be added

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 11
System structure
System cabinet
1
Main switch
2
Gas analyzer AO2020
3
Status indicators for measuring, back purge, general alarm, condensate
level
4
Heated sample gas line temperature controller
5
Ethernet port
6
Sample Gas Cooler SCC-C
7
Sample Gas Feed Unit SCC-F
8
Cabinet air conditioner
Figure 1: GAA610-M system cabinet
Front Door
The front door can be opened without any risks.
Behind the front door is the front panel, the Sample Gas Feed
Unit SCC-F and the 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 alarm.
Below the alarm signals is an ethernet socket for maintenance
purpose.
Cabinet interior
The cabinet contains the sample conditioning components,
pump, valves, filters and gas analyzer.
It also contains the main switch, the power supply and the fuses
for all components, as well as the connection terminals for
analog and digital signals.

12 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
… 2 Design and function
… System structure
System schematic
A
Exhaust gas stream
B
Compressed instrument air inlet
C
Calibration gas inlet
D
Ambient air / zero gas inlet
E
Sample gas outlet
F
Condensate outlet
1
Exhaust pipe
2
Heated sample probe with probe tube and filter unit
3
Backpurging solenoid valves
4
Backpurging air panel
5
Heated sample gas line
6
Sample gas solenoid valve
7
Sample gas cooler SCC-C
8
Oil/Soot removal filter
9
Sample gas feed unit SCC-F
0
Aqua stop filter
k
AO2020 gas analyzer with Uras26
l
Cooling unit for analyzer cabinet
m
10 l condensate bottle with condensate alarm switch
Figure 2: System schematic
Sample gas flow
The sample gas is extracted from the exhaust duct after the
scrubber by a heated sample probe.
The heated sample 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 entrance of the analyzer cabinet there is a 3/2-way
solenoid valve. The gas flow goes to the gas cooler and via filter,
flow meter, pump and aqua stop filter to the gas analyzer.
See also Piping diagram on page 98.
Sample probe
The sample probe is connected gas tight to the process with a
flange. The probe tube extracts the gas in the middle of the
exhaust duct.
An external heated filter separates the dust from the sample
gas. The Filter is heated by a self-limiting PTC heater to 180 °C
(356 °F). The filter is equipped with a ceramic filter element.
To clean the filters in the sample probe a back purging system
via the filter can be integrated.

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 13
Heated sample gas line
The heated sample gas line is directly connected to the filter at
the probe. The core is a PTFE hose. The line is heated to 180 °C
(356 °F).
The temperature is controlled with a Pt100 resistance
thermometer and the power/temperature is adjusted with a
temperature controller installed in the cabinet. In case of a
deviation from the set value a message is generated and
displayed on the AO2020-Display.
Temperature controller
A Temperature controller is used to control the temperature of
the heated sample gas line.
An alarm signal is output as soon as the temperature drops
below the minimum temperature limit.
Solenoid valve
A solenoid valve is installed to switch between measuring gas
and ambient air during calibration and standby mode.
Aqua stop filter
The aqua stop filter is the final protection for the analyzer. The
aqua stop filter holds back any humidity.
AO2020-Uras26 gas analyzer
The AO2020-Uras26 gas analyzer is integrated into the analyzer
system for measuring CO2and SO2.
The main components are an 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 content of the sample
at a certain dew point (typically 3 °C). Therefore, the temperature
of the sample falls from approx. 180 °C to the set point of the
sample gas cooler and condensation will occur. The condensate
is removed with a hose pump and collected in a separate bottle.
The sample gas cooler is controlled by the system and the
following signals can be output:
• Condensate level:
The level of the condensate collecting bottle is monitored
and a signal will output (displayed via a red lamp on the
front panel) when maintenance / emptying the bottle is
required.
• Fault cooler:
A status signal "fault cooler" is set if the cooler
temperature is too high. The signal is also provided as
"Failure" status signal.
• Failure alarm:
If a failure of the cooler is detected, the feed pump is
switched off and the system is set to system failure
mode. The system failure mode is displayed on the panel
and provided as a status signal.

14 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
… 2 Design and function
… System structure
Sample Gas Feed Unit SCC-F
1
Condensate monitor
2
LED display and reset switch for
condensate and flow alarm
3
Flow monitor with needle valve
Figure 4: Sample Gas Feed Unit SCC-F
The sample gas feed 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 a limit value an alarm is displayed on the front
panel. In addition, the sample probe is automatically
backpurged.

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 15
3Product identification
Name plate
Note
The name plates displayed are examples. The device
identification plates affixed to the device can differ from this
representation.
Note
Products that are marked with the adjacent symbol
may
not be disposed of as unsorted municipal waste
(domestic waste).
They should be disposed of through separate
collection of electric and electronic devices.
The type plate is located at the top right of the right-hand side
panel of the analyzer cabinet near the cable glands.
1
Manufacturer, address
2
Serial number
3
CE marking
4
Disposal 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
Consult documentation, i.e. consult this
operating instruction.
Risk of electric shock!
Corrosive material!
Hot surface!
(Temperature > 60 °C)
Scope of delivery
Quantity
Description
Standard equipment
1
×
Analyzer cabinet
1
× set
System documentation
Additional items delivered per order
1
×
Gas sampling probe tube type
40 (unheated)
1
×
Filter unit and 2
-stage back-purging unit
1
×
Sample gas line, heated
1
×
Condensate collection bottle
1
×
Wear
parts set (optional)

16 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
4Transport 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.

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 17
Storing the device
Bear the following points in mind when storing devices:
• Store the device in its original packaging in a dry and
dust-free location.
• Observe the permitted ambient conditions for transport
and storage.
• Avoid storing the device in direct sunlight.
• In principle, the devices may be stored for an unlimited
period. However, the warranty conditions stipulated in
the order confirmation of the supplier apply.
Ambient conditions
Ambient temperature during transport / storage
• 2 to 60 °C (35.6 to 140 °F);
• −20 to 70 °C (−4 to 158 °F) after draining and drying parts
in contact with condensate.
Max. permissible humidity
Year-round average max. 75%, short-term max. 95%,
occasional slight condensation is permitted.
Packaging
1. If the original packing material is no longer available, wrap
the device in bubble foil or corrugated cardboard.
When shipping overseas, also heat-seal the device 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 of shipping. The box should also be
lined with a double layer of bitumen paper for overseas
shipping.
3. Mark the box ‘Fragile! Handle with care!’.
Returning devices
Use the original packaging or a secure transport container of an
appropriate type if you need to return the device for repair or
recalibration purposes.
Fill out the return form (see Return form on page 99) and include
this with the device.
In accordance with the EU Directive governing hazardous
materials, the owner of hazardous waste is responsible for its
disposal or must observe the following regulations for shipping
purposes:
All devices delivered to ABB must be free from any hazardous
materials (acids, alkalis, solvents, etc.).
Address for the return:
Contact Center
www.abb.com/contacts

18 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
5Preparation for Installation
Safety instructions
CAUTION
Injury hazard due to heavy weight
Depending on the version, the gas analyzer cabinet weighs
approx. 240 kg (529 lb)!
• A suitable lifting device (crane, block and tackle, lifting
truck, etc.) is required for transport, setting upright and
installation!
• Only use the handling lugs provided to connect any lift
cables to the analyzer cabinet.
Note
• The system must be installed by ABB or by personnel trained
by ABB.
• When installing the analyzer system, in addition to this
operating instruction, comply with the information
contained in the drawings set.
• If there is shipping damage which points to improper
handling file a damage claim with the shipper (railway, mail
or freight carrier) within seven days.
• Make sure the enclosed accessories are not lost.
• Keep the packaging material for future shipping needs.
Installation – Overview
1. Prepare the gas sampling probe installation site, see
Choosing the extraction point on page 18.
2. Prepare the analyzer cabinet installation site, see
Requirements for the installation site on page 18.
3. Install the gas sampling probe and filter unit, see Probe tube
and filter unit installation on page 25.
4. Install the sample gas line, see Sample gas line installation
on page 27.
5. Install the back-purging unit (if applicable), see Back-purging
unit installation on page 29.
6. Install the analyzer cabinet, see Analyzer cabinet installation
on page 30.
7. Install the instrument air and test gas supply
(if applicable), see Gas connections on page 31.
8. Connect the gas lines to the analyzer cabinet, see
Connecting the gas lines on page 32.
9. Connect the electrical leads to the analyzer cabinet, see
Electrical connections on page 33.
Requirements for the installation site
DANGER
Risk of explosion
The analyzer system must not be installed in hazardous
locations.
Choosing the extraction point
The extraction point must be suitable for extracting a
representative specimen flow.
In case of emission monitoring of exhaust gases, the extraction
point is specified in accordance with responsible technical
inspection authority, e.g. classification society.
Wall tube installation
1
Wall tube
2
Wall tube mounting flange
3
Gasket
4
Sample probe tube flange
5
Flow direction
Figure 7: Wall tube installation, Dimensions in mm (inch)
Install the wall tube with mounting flange (DN 65, PN 6, facing
type A to EN 1092-1; not supplied) at the extraction point in such
a way that the sampling probe tube can be easily installed and
removed.
The sampling probe tube must be easily accessible to allow
maintenance work to be performed. Align the boreholes of the
mounting flange in relation to the flow direction 5of the
process gas.

GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B 19
Short gas paths
The analyzer cabinet should be installed as close as possible to
the sampling site. A short sample gas line results in short T90
times.
The sample gas line length is limited to 30 meters with 230 VAC
power on account of pressure drop build-up in the line and the
required electrical fusing.
The test gas cylinders should be installed as close as possible to
the analyzer system. Test gas cylinders are only required for
regular adjustment during operation if CEMS is not equipped
with internal gas filled cells.
Protection from adverse ambient conditions
Protect the gas analyzer cabinet from the following influences:
• Water spray
• Contact with chemicals
• Strong sunlight and heat radiation
• Strong air currents
• Heavy dust load
• Corrosive atmospheres
Installation indoors
The analyzer system is intended for 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 cabinets weight.
Climatic Conditions
Ambient temperature
In operation: 5 to 55 °C* (41 to 131 °F)*
* Higher ambient temperature during operation on request.
Ambient temperature during transport / storage
• 2 to 60 °C (35.6 to 140 °F);
• −20 to 70 °C (−4 to 158 °F) after draining and drying parts
in contact with condensate.
Max. permissible humidity
Year-round average max. 75%, short-term max. 95%,
occasional slight condensation is permitted.
IP rating
IP 54
Vibration resistance in accordance with IEC 60068-2-6
Vibrations according the below tested conditions showed
negligible influence on measurement value.
Test Fc:
±1.0 mm, 2−0
+3 Hz up to 13.2 Hz;
0.7 g at 13.2 Hz up to 100 Hz
Overvoltage category
II
Pollution degree
2

20 GAA610-M ADVANCED EMISSION GAS MONITORING SYSTEM | OI/GAA610-M-EN REV. B
… 5 Preparation for Installation
Backpurging Unit
Design of the back-purging unit
The back-purging unit consists of a protective cabinet with shut-
off valve, 6 bar pressure reduction valve, solenoid valves for
back-purging, pressure regulator and 2 l compressed air receiver
(pressure buffer tank) for effective pressure pulses also with
lower airflow rate.
Distance to sampling probe
The distance between the back-purging unit and the sampling
probe should be as short as possible and must not exceed 2 m
(6.6 ft).
Protection from adverse ambient conditions
Protect the back-purging unit against:
• Water spray
• Contact with chemicals
• Strong sunlight and heat radiation
• Strong air currents
• Heavy dust load
• Corrosive atmospheres
• Vibration
Instrument air supply
Compressed air for back-purging
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 Nm
3
/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 gas analyzer.
• Only use dry and clean compressed air.
Power supply
Power supply
Terminals
-X60
: L, N, PE or L1, L2, PE
Operating voltage
230 V AC, ±10
%
Frequency
50 / 60 Hz, ±3 Hz
External fuse
25
A
Power consumption
System cabinet
500
w
Air conditioner
1600
W
Sampling probe
300 W
Heated sample gas line
Approx. 90
W/m
Sample gas inlet conditions
DANGER
Explosion hazard
Explosion hazard when measuring ignitable gas / air or
gas / oxygen mixtures
• The gas analyzer may not be used for the measurement of
ignitable gas / air or gas / oxygen mixtures
GAA610-M – Sample gas inlet conditions
Temperature
Max. 500 °C (932 °F)
Pressure
850
to 1100 hPa (0.85 to 1.1 bar), (12.3 to 16 psi)