ABB SCC-E User manual

AnalyzeIT
Continuous Gas Analyzers – Sample Conditioning
SCC-E Sample Gas Feed Unit
Operator’s Manual 42/2358 EN Rev. 1
SCC-E

2 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1
Contents
Page
Preface 3
General Safety Information 4
Safety Tips for Handling Electronic Measurement Devices 5
Chapter 1 Preparing the Installation
Normal Operation 6
Requirements for the Installation Site 6
Power Supply 7
Sample Gas Inlet Conditions 7
Scope of Delivery 7
Dimensional Drawing 8
Chapter 2 Sample Gas Feed Unit Installation
Installing the Sample Gas Feed Unit 9
Connecting the Sample Gas Pipes 10
Connecting the Electrical Cables 11
Chapter 3 Sample Gas Feed Unit Start-Up
Power Supply and Sample Gas Activation 12
Sample Gas Pump Control 13
Cooler Control 13
Chapter 4 Maintenance
Replacing the Condensate Pump Hose 14
Replacing the Condensate Pump Pressure Rollers and Springs 16
Replacing the Diaphragm and Valve Plates in the Diaphragm Pump 18
Checking the Gas Paths for Leaks 21
Troubleshooting 22
Chapter 5 Shutting Down and Packing the Feed Unit
Shutting Down the Feed Unit 23
Packing the Feed Unit 23
Appendix
Description 24
Circuit Diagrams 25

42/23-58 EN Rev. 1 SCC-E Sample Gas Feed Unit Operator’s Manual 3
Preface
Contents of this
Operator’s Manual
This operator’s manual contains all the information you need to install, commission,
operate and maintain the SCC-E sample gas feed unit safely and in accordance
with the regulations.
This operator’s manual contains information on all the function units of the sample
gas feed unit. It is possible that the sample gas feed unit that you have been
supplied with could differ from the model described here.
Additional Document Specification Sheet “System Components and Accessories for Sample Gas
Conditioning”, Document No. 10/23-5.20 EN
This publication can be ordered from your authorized ABB representative or from
ABB Automation Products GmbH, Analytical Division, Marketing Communication,
Fax: [phone], E-mail: [email protected]
Further Details
on the Internet
You can find further information on ABB Analytical products and services on the
internet: “http://www.abb.com/analytical”.
Identifies safety information to be heeded during unit operation
in order to avoid risks to the operator.
Identifies specific information on operation of the unit as well as
on the use of this manual.
Symbols and
Typefaces
1, 2, 3, ... Identifies reference numbers in the figures.
This operator’s manual is protected by copyright. The translation, duplication and distribution in any form,
even in a revised edition or in extracts, in particular as a reprint, by photomechanical or electronic repro-
duction or in the form of storage in data processing systems or data networks are prohibited without the
consent of the copyright holder and will be prosecuted under civil and criminal law.

4 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1
General Safety Information
Requirements for
Safe Operation
In order to operate in a safe and efficient manner the unit should be properly
handled and stored, correctly installed and started, properly operated and
carefully maintained.
Personnel
Qualifications
Only persons familiar with the installation, set-up, operation and maintenance of
comparable equipment and certified as being capable of such work should work
on the unit.
Important Notes and
Regulations
It is important to comply with:
•The content of this operator’s manual
•The safety information affixed to the unit
•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 unit is used in other countries.
Unit Safety and
Safe Operation
The unit is designed and tested in accordance with EN 61010 Part 1, “Safety
Provisions for Electrical Measuring, Control, and Laboratory Instruments” and has
been shipped ready for safe operation.
To maintain this condition and to assure safe operation, read and follow the safety
information identified with the symbol in this manual. Failure to do so can put
persons at risk and can lead to unit damage as well as damage to other systems
and instruments.
Additional
Information
If the information in this manual does not cover a particular situation, ABB Service
is prepared to supply additional information as needed.
Contact your local ABB service representative or
ABB Service, Telephone: [phone], Fax: [phone],
E-mail: callcenter[email protected]

42/23-58 EN Rev. 1 SCC-E Sample Gas Feed Unit Operator’s Manual 5
Safety Tips for Handling Electronic Measurement Devices
Protective Lead
Connection
The protective lead should be attached to the protective lead connector before
any other connection is made.
Risks of Loss of
Protective Lead
Continuity
The unit can be hazardous if the protective lead is interrupted inside or outside the
unit or if the protective lead is disconnected.
Proper Operating
Voltage
The unit voltage must be set to match the line voltage before the power supply is
activated.
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 Unit
The unit must be disconnected from all power sources before any maintenance
work is performed. Work on a unit that is open and connected to power should
only be performed by trained personnel who are familiar with the risks involved.
Charged Capacitors The unit capacitors can retain their charge even when the unit is disconnected
from all power sources.
Use of Proper Fuses Only fuses of the specified type and rated current should be used as replacements.
Never use patched fuses. Do not short-circuit the fuse holder contacts.
When Safe Operation
can no Longer be
Assured
If it is apparent that safe operation is no longer possible, the unit should be taken
out of operation and secured against unauthorized use.
The possibility of safe operation is excluded:
•If the unit is visibly damaged
•If the unit is no longer operational
•After prolonged storage under adverse conditions
•After severe transport stresses.

6 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1
Chapter 1 Preparing the Installation
Normal Operation
Normal Operation The SCC-E sample gas feed unit is designed for continuous dosed sample gas
feeding.
The SCC-E sample gas feed unit with Peltier cooler is additionally designed for
cooling the sample gas and separating and removing the condensate.
The SCC-E 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 can combine with air or oxygen to form an
ignition-capable mixture, or
•in a potentially explosive atmosphere or in hazardous areas.
Requirements for the Installation Site
Short Gas Feed 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 accumulation.
Protection against
Adverse
Environmental
Conditions
The sample gas feed unit should be protected from
•Cold,
•Radiated heat, e.g. from the sun, kilns or boilers,
•Temperature fluctuations,
•Strong air movement,
•Dust deposits and dust penetration,
•Corrosive atmosphere,
•Vibration.
Climatic Conditions Ambient temperature In operation: +10 to +45 °C
During Storage and transport: –25 to +60 °C
Relative humidity ≤75 % year-round average, ≤95 % on 30 days per
year, occasional light condensation permissible

42/23-58 EN Rev. 1 SCC-E Sample Gas Feed Unit Operator’s Manual 7
Power Supply
Power Supply Input voltage 230 VAC, 50 Hz or 115 V AC, 60 Hz
Power consumption 230 V AC, 50 Hz: 1.05 A, 240 VA
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 7 to 70 l/h
Sample gas inlet temperature +10 to +50 °C
Sample gas inlet dew point Version without cooler: The dew point of the sample
gas must be at least 5 °C lower than the lowest
ambient temperature anywhere in the sample gas
feed 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
Scope of Delivery
Quantity Description
1 SCC-E Sample Gas Feed Unit
2 Operator’s Manuals (1 copy in German, 1 in English)
Scope of Delivery
1 Diaphragm Pump Spare Parts Set
The mounting brackets are fitted in the factory.

8 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1
Dimensional Drawing
Fig. 1
Dimensional Drawing
(Dimensions in mm)
3.0
SCC-E
Te s t G a s
Sample Gas
Alarm Pump
248 36
17,5 185
220
372,5
30025 47,5
37,75 101,5
10
7
246
1
7
7
263
220
89
10
5
7
11
6
1
2
3
4
12
13
1Sample gas inlet
2Test gas inlet
3Sample gas outlet
4Power supply and status signal cables
5Flow meter with needle valve
6Peristaltic pump 1)
7Condensate monitor 1) /diaphragm filter
8Red LED indicator “condensate alarm” 1)
9Pump switch
10 Temperature controller for cooler 1)
11 3-way cock “sample gas/test gas”
12 Condensate outlet 1)
13 4 x M5 threaded holes in ground plate
1) only in version with Peltier cooler and condensate pump
•You should allow for the additional space required for the cooling air inlet on the
left side of and above the unit.
•The mounting brackets are fitted in the factory, with about 2.5 cm projection to
the rear wall.
•Slope max. 5°.

42/23-58 EN Rev. 1 SCC-E Sample Gas Feed Unit Operator’s Manual 9
Chapter 2 Sample Gas Feed Unit Installation
•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 that none of the enclosed accessories are lost during unpacking (see
section “Scope of Delivery”, page 7).
•Keep the shipping box and packaging material for future shipping needs.
Installing the Sample Gas Feed Unit
Step Action
Mount the sample gas feed unit on the wall using 4 M6 screws (not
supplied). The mounting brackets required for this purpose are
mounted on the rear of the side panels in the factory.
1
To enable the cooling air to pass unobstructed out of the
sample gas feed unit to the rear, the projection of the mounting
brackets of around 2.5 cm to the rear wall, which is set up in
the factory, must not be reduced.
2 If necessary, remove the condensate outlet hose from the peristaltic
pump and pull it out backwards.
Install the
Sample Gas Feed Unit
on the Wall
3 If necessary, remove the handle and close the threaded holes.
Step Action
1 Unscrew the mounting brackets from the rear of the side panels and
screw them securely at the front of the side panels, flush with the front
panel, using the threaded holes provided for this purpose.
Exchange the fittings flange on the case cover with the blank flange
on the rear wall.
2
Take care not to bend or squash any hoses.
3 If necessary, remove the handle and close the threaded holes.
4 If necessary, remove the adhesive pads from the bottom.
Install the
Sample Gas Feed Unit
in a 19-inch
Cabinet/Rack
5 Mount the feed unit in a 19-inch cabinet/rack using 4 M5 screws.
Step Action
1 Unscrew the mounting brackets from the rear of the side panels.
If necessary, exchange the fittings flange on the case cover with the
blank flange on the rear wall.
Desktop Installation
2
Take care not to bend or squash any hoses.

10 SCC-E Sample Gas Feed Unit Operator’s Manual 42/23-58 EN Rev. 1
Connecting the Sample Gas Pipes
Fig. 2
Gas Connections
(View from above)
Sample
Gas In
Sample
Gas Out
Tes t
Gas In
Gas Connections The gas connections are PPH screw connections for DN 4/6 mm hose.
Connect Gas Pipes Connect the gas pipes to the gas inlets and outlet. The gas pipes should be made
from material that is suited to the measuring task.