ABB GAA330-M User manual

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ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION
GAA330-M
Emission monitoring system for marine applications
Measurement made easy

GAA330-M EMISSION MONITORING SYSTEM | OI/GAA330-M-EN REV. C 3
Contents
Preface ....................................................................................................................................................................5
Safety information.................................................................................................................................................7
Intended application...................................................................................................7
Safety information ......................................................................................................7
System overview ..................................................................................................................................................10
System description .................................................................................................. 10
System design............................................................................................................12
Installation preparation ......................................................................................................................................16
Installing the analyzer system .................................................................................16
Analyzer system: Installation site requirements..................................................17
Back-purging unit: Installation site and air supply requirements ................... 20
Items delivered...........................................................................................................21
Materials needed for installation (not supplied) .................................................22
Installation........................................................................................................................................................... 24
Type 40 probe tube and filter unit installation ................................................... 24
Type 42 probe tube and filter unit installation.................................................... 25
PFE2 Filter unit installation..................................................................................... 26
PFE2 Filter unit gas connection ..............................................................................27
PFE3 Filter unit installation..................................................................................... 29
PFE3 Filter unit gas connection ............................................................................. 30
Sample gas line installation .....................................................................................31
Back-purging unit installation................................................................................ 34
Analyzer cabinet installation................................................................................... 35
Electrical connection ...........................................................................................................................................36
Safety information ................................................................................................... 36
Notes........................................................................................................................... 36
Type 42 probe tube and filter unit electrical connection ...................................37
PFE2 Filter unit electrical connection.................................................................... 38
PFE3 Filter unit electrical connection.................................................................... 40
Analyzer cabinet electrical connection ..................................................................41
Gas sampling with automatic back-purging .................................................................................................... 45
In general.................................................................................................................... 45
Components for automatic back-purging procedure ....................................... 46
Start of the back-purging procedure.................................................................... 46
Program sequence.................................................................................................... 47
Cycle time................................................................................................................... 49
Post-purge time ........................................................................................................ 50
Start-up and operation........................................................................................................................................51
Start-up .......................................................................................................................51
Warm-up phase ......................................................................................................... 52

4 GAA330-M EMISSION MONITORING SYSTEM | OI/GAA330-M-EN REV. C
Operation..............................................................................................................................................................53
Display and control unit........................................................................................... 53
Screen ......................................................................................................................... 54
Status LEDs................................................................................................................ 55
Numeric keypad ........................................................................................................ 55
Cancel keys................................................................................................................. 56
Softkeys...................................................................................................................... 56
Password protection................................................................................................ 58
Menu tree ................................................................................................................... 59
Setting the time zone, date and time ................................................................... 60
Selecting user interface language ..........................................................................61
Maintenance .........................................................................................................................................................62
Safety information ................................................................................................... 62
Regular maintenance tasks..................................................................................... 63
Analyzer cabinet: Visual inspection ....................................................................... 65
Calibrating the analyzer system............................................................................. 67
Checking the seal integrity ..................................................................................... 70
Replacing the filter element in the filter unit........................................................71
Replacing the cooling unit / fan outlet filter mesh ............................................ 75
Replacing the suction filter in the diaphragm pump ......................................... 75
Emptying the condensate collection bottle ........................................................ 75
Troubleshooting...................................................................................................................................................76
Dynamic QR code...................................................................................................... 76
Status messages....................................................................................................... 78
Sample gas cooler problems .................................................................................. 78
Gas analyzer problems............................................................................................. 79
Gas pump problems ................................................................................................. 79
Analyzer cabinet problems...................................................................................... 80
Notify service..............................................................................................................81
Disposal ...................................................................................................................... 82
Index ......................................................................................................................................................................83

GAA330-M EMISSION MONITORING SYSTEM | OI/GAA330-M-EN REV. C 5
Preface
Content of this operating instruction
This operating instruction contains all the information necessary for the
safe and compliant installation, start-up, operation and maintenance of the
analyzer system.
Further information
System documentation
The system documentation includes the following material:
•Analyzer data sheet
•Operating instruction
•Certificates
•CD-ROM with
•Drawings set (layout plan, piping plan, interface plan) and
•Information about function block configuration if applicable
•DVD-ROM "Software tools and technical documentation"
Analyzer data sheet
The version of the delivered analyzer system is described in the "Analyzer
data sheet" supplied with the analyzer system.
DVD-ROM "Software tools and technical documentation"
The DVD-ROM "Software tools and technical documentation" with the fol-
lowing contents is included in the scope of supply of the analyzer system:
•Software tools
•Operating instructions
•Data sheets
•Technical information
•Certificates
Internet
You will find information on ABB Analytical products and services on the
Internet at "http://www.abb.com/analytical".
Service contact
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
ABB Service,
Telephone: [phone], Telefax: [phone] 29031,
E-mail: [e-mail]

6 GAA330-M EMISSION MONITORING SYSTEM | OI/GAA330-M-EN REV. C
Symbols and typefaces in this operating instruction
CAUTION identifies safety information to be heeded during analyzer sys-
tem operation, in order to avoid risks to the user.
NOTE identifies specific information on the operation of the analyzer system
as well as on the use of this operating instruction.
1, 2, 3, … Identifies reference numbers in figures.
Display Identifies a display on the screen.
Input Identifies a user entry
•either by pressing a soft key
•or by selecting a menu item
•or via the numeric keypad
peGauge pressure
pabs Absolute pressure
pamb Atmospheric pressure

GAA330-M EMISSION MONITORING SYSTEM | OI/GAA330-M-EN REV. C 7
Safety information
Intended application
Intended application
The analyzer system is designed for continuous measurement of concentra-
tions of specific components in gases or vapor.
Any other use is not as specified. The specified use also includes taking note
of this operating instruction.
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.
The analyzer system interior remains free of explosive atmosphere during
normal operation. Therefore, the integration of explosion protection
measures inside the analyzer system is not required.
Safety information
Requirements for safe operation
In order to operate in a safe and efficient manner the analyzer system should
be properly handled and stored, correctly installed and set-up, properly op-
erated and correctly maintained.
Personnel qualifications
Only persons familiar with the installation, set-up, operation and mainte-
nance 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 analyzer system,
•The applicable safety precautions for installing and operating electrical
devices,
•Safety precautions for working with gases, acids, condensates, etc.

8 GAA330-M EMISSION MONITORING SYSTEM | OI/GAA330-M-EN REV. C
Safety labels affixed to the analyzer system
Observe the safety labels affixed to the analyzer system or to the individual
components:
Consult documentation!
Hot surface! (Temperature > 60 °C)
Corrosive material!
Risk of electric shock!
National regulations
The regulations, standards and guidelines cited in this operating instruction
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 safety standard
EN 61010 Part 1 "Safety requirements for electrical equipment for measure-
ment, control, and laboratory use" and is shipped ready for safe operation.
To maintain this condition and to assure safe operation, read and follow the
safety information in this operating instruction and use the described ac-
cessories as specified in this operating instruction. Failure to do so can put
persons at risk and can lead to device damage as well as damage to other
systems and devices.
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 from the sample gas path in either
the measurement mode or when performing maintenance. The analyzer
system must be checked for leaks regularly. The diluted stack gas must be
discharged outside the room where the analyzer cabinet is installed. 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 con-
nector before any other connection is made.

GAA330-M EMISSION MONITORING SYSTEM | OI/GAA330-M-EN REV. C 9
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.
Correct operating voltage
Be sure the analyzer system voltage setting matches the line voltage before
connecting the power supply.
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.
Charged capacitors
The capacitors in the analyzer system can retain their charge even when it is
disconnected from all power sources.
Use of proper fuses
Only fuses of the specified type and rated current should be used as re-
placements. Never use patched fuses. Do not short-circuit the fuse holder
contacts.
Risks involved in opening the gas paths
Do not open any gas paths in the analyzer system or in the integrated ana-
lyzers. Doing so will damage gas path seal integrity.
If system-internal gas paths are opened, a seal integrity check must be per-
formed with a leak detector (thermal conductivity) when the device is reas-
sembled.
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.

10 GAA330-M EMISSION MONITORING SYSTEM | OI/GAA330-M-EN REV. C
System overview
System description
Intended use
The GAA330-M analyzer system is designed for continuous measurement of
exhaust gases of marine diesel engines. Measurement components are CO2
and SO2which are sampled downstream of the scrubber.
Measuring principle
The 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 con-
ditions. The sample handling system is specific for the applied measuring
principle. The analyzer system uses the NDIR photometer AO2000-Uras26
for detecting SO2and CO2.
System design
The GAA330-M analyzer system is a complete turn-key solution with the
following components:
•Probe and filer 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 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:
•Heated probe for measuring low temperature samples
•Filter unit (with protection box, IP54, anti-freeze heating) for installation
locations at −20 °C to +45 °C
•Air conditioning unit for operation at ambient temperature +5 °C to
+45 °C
•Dual sampling for simultaneous measurement at two different sampling
locations
•Dual switching for measurement at two sampling locations or for unin-
terrupted measurement at one sample location