ABB SCC-K User manual

SCC-K NO2/NO Converter
Operator’s Manual 42/2352 EN Rev. 2

2 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Table of Contents
Page
Preface 3
General Safety Information 4
Safety Tips for Handling Electronic Measurement Devices 5
Chapter 1 Converter Installation and Start-Up
Instructions for Selecting a Location 6
Converter Unpacking 6
Dimensional Drawing 7
Sample Gas Line Connection 8
Status and Control Lead Connection 9
Power Supply Wiring Connection 10
Converter Start-Up 11
Chapter 2 Maintenance
Preface 12
Determining the Catalyst Service Life 12
Replacing the Catalyst Cartridge 13
Checking for Gas-Tightness 14
Troubleshooting 15
Chapter 3 Converter Shutdown and Packing
Converter Shutdown 16
Converter Packing 16
Annex
Description 17
Functional Schemes 18
Conversion Principle 19
Converter Construction 20
Operating Data 22

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter Operator’s Manual 3
Preface
Content of the
Operator’s Manual
This operator’s manual contains all the information you will need to safely and
efficiently install, start-up, operate and maintain the SCC-K NO2/NO Converter.
This operator’s manual contains information on all the functional units in the
converter. The delivered converter may differ from the version described.
Additional Document Data 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 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-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
General Safety Information
Requirements for
Safe Operation
In order to operate in a safe and efficient manner the instrument should be
properly handled and stored, correctly installed and started, properly operated
and correctly 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 instrument.
Special Information
and Precautions
These include
•The content of this operator’s manual.
•The safety information affixed to the instrument.
•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 instrument is used in other countries.
Instrument Safety
and Safe Operation
The instrument is designed and tested in accordance with EN 61010 Part 1,
“Safety Provisions for Electrical Measuring, Control, Regulation and Laboratory
Instruments” and has been shipped ready for safe operation.
To maintain this condition and to assure safe operation, read and follow the safety
information identified with the symbol in this manual. Failure to do so can put
persons at risk and can lead to instrument damage as well as damage to other
systems and instruments.
Additional
Information
If the information in this operator’s manual does not cover a particular situation,
ABB Automation Service is prepared to supply additional information as needed.
Contact your local ABB Automation service representative or
ABB Automation Service, Post Office Box 93 02 09, D-60457 Frankfurt
Telephone [phone], Fax [phone],
E-mail: callcenter[email protected]

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter 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 instrument can be hazardous if the protective lead is interrupted inside or
outside the instrument or if the protective lead is disconnected.
Proper Operating
Voltage
The instrument 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 Instrument
The instrument must be disconnected from all power sources before any mainte-
nance work is performed. Work on an instrument that is open and connected to
power should only be performed by trained personnel who are familiar with the
risks involved.
Charged Capacitors The instrument capacitors can retain their charge even when the instrument 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 fuseholder
contacts.
When Safe Operation
can no Longer be
Assured
If it is apparent that safe operation is no longer possible, the instrument should be
taken out of operation and secured against unauthorized use.
The possibility of safe operation is excluded:
•If the instrument is visibly damaged
•If the instrument is no longer operational
•After prolonged storage under adverse conditions
•After severe transport stresses

6 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Chapter 1 Converter Installation and Start-Up
Instructions for Selecting a Location
Short Gas Paths The converter should be installed as close as possible to the analyzer system in
order to avoid the re-oxidation of NO and NO2in long sample gas lines.
Adequate Air
Circulation
Provide for adequate natural air circulation around the cooler unit. Avoid heat
buildup.
Protection from
Adverse Conditions
Protect the converter from
•Cold
•Heat sources such as the sun, ovens and vats
•Large temperature variations
•Strong air currents
•Accumulations of dust and dust infiltration
•Corrosive atmospheres
•Vibration
Environmental
Conditions
Ambient temperature range +10 to +50 °C.
Average annual relative humidity ≤75 %, occasional and slight condensation
permitted.
Converter Unpacking
•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.
•Keep the shipping box and packaging material for future shipping needs.
Catalyst Cartridge The SCC-K NO2/NO converter is a completely pre-installed unit. The standard
catalyst cartridge supplied is already installed.

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter Operator’s Manual 7
Dimensional Drawing
Housing Version The converter is designed as a 19-inch unit and is suitable for wall-mounting using
a special mounting bracket.
Figure 1
Dimensional Drawing
(dimensions in mm)
NOx
NO
360
360
1234
5
435
465.6
57
120
44260
325
483
132,5(3HE)
1Power supply input X1
2Status signal output X2 (9-pin Sub-D female connector)
3Heated sample gas inlet 6 mm
4Sample gas outlet G1/4 inch
5Sample gas inlet G1/4 inch
Distance above the converter at least 1 height unit

8 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Sample Gas Line Connection
Sample Gas
Connections
The gas inlet and outlet hoses/tubes are connected on the rear of the converter.
Standard G1/4-inch threaded joints are available for the connection of the gas
sample lines.
•Do not confuse hose/tube connections for sample gas inlet and outlet; the
connections are labeled accordingly.
•The tightness of the connections can only be guaranteed if the end section of
the connection hose/tube is flat (use a hose-cutter).
Step Action
Loosen the sleeve nut of the clamping-ring threaded joint by turning
to the left.
1
Take care that the nut is removed carefully from the body of the
threaded joint to avoid losing the clamping ring which is
mounted loose in the nut.
2 Push the sleeve nut over the connection hose/tube.
3 Push the clamping ring onto the connection hose/tube with the
thicker bulge pointing to nut.
4 Push the hose/tube onto the supporting nipple in the threaded joint.
5 Tighten the sleeve nut by hand. The hose/tube is now mounted in
such a way that it cannot slip and is resistant to pressure.
Sample Gas Line
Connection
6 Check for tightness of all sample lines after connection (see page 14).
Note
for CO Measurement
For simultaneous measurement of NOx and CO (ppm concentrations) the
CO measurement must be carried out in a separate gas path (see Fig. 2) due to
CO formation in the carbon-molybdenum catalyst.
Figure 2
Location of the
Converter for
Simultaneous
Measurement of
NOx and CO
NO
CO, SO2O2
P
Feed Unit
SCC-F
Cooler
SCC-C
NO /NO
Converter
SCC-K
2
Condensate Trap
Uras14
NO
CO,SO2
O2

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter Operator’s Manual 9
Status and Control Lead Connection
CAUTION!
Follow local regulations on installing and connecting electrical wiring.
Status and Control
Lead Connections
The general status alarm for signaling temperatures outside the permitted range
and the facility for connecting the solenoid valves externally are provided at the
9-pin sub-D plug on the rear side of the converter housing (see Fig. 3).
Correct functioning of the converter is only guaranteed when the sub-D plug X2 is
mounted.
Figure 3
Pin-out of
Sub-D Plug X2
1 2 3 4 5
6 7 8 9
General status alarm:
Make-contact element,
potential-free
Switch ratin
g
: 24 V, 1
A
Catalyzer
Bypass
Internal control
External control
Temperature Alarm Contacts 5 and 9 are provided in the sub-D plug to ensure sure signaling of tem-
peratures outside the permitted range. This involves a potential-free make-contact
element with a switch rating of 24 V, 1 A. The alarm is signaled if temperatures
exceed the permitted temperature range by ±5 °C.
Version with Two
Solenoid Valves
As an option the converter has two solenoid valves for switching between sample
gas paths. The valves can be controlled either internally or externally by the
customer.
Internal Control If the converter is controlled internally, the bridge between contacts 1 and 6 in the
sub-D plug is absolutely necessary.
External Control External switching is carried out by the customer using potential-free contacts. If
the converter is controlled externally, the bridge between contacts 1 and 6 in the
sub-D plug must be removed
With external control the switch on the front plate is out of function. The chosen
gas way is indicated by the two LED’s.
Catalyst

10 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Power Supply Wiring Connection
CAUTION!
Follow all applicable national safety regulations for the preparation and
operation of electrical devices as well as the following safety precautions.
The converter voltage must be set to match the line voltage before the power
supply is connected.
The protective lead should be attached to the protective lead connector
before any other connection is made.
The converter can be hazardous if the protective lead is interrupted inside or
outside the cooler unit or if the protective lead is disconnect
An external mains switch is required.
Mains Connection The converter is connected to the mains at the rear of the converter housing via a
cold-device plug (X1) with a 2-meter connecting cable.
Fuses The main circuit is equipped with a fuse corresponding to the nominal current
(over current protection).
The both main fuses F1 and F2 (2 A) are located below the connector plug X1, on
the back panel of the converter housing.

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter Operator’s Manual 11
Converter Start-Up
Safety Measures Before using the converter for the first time, check that the safety measures
specific to the installation and process are complied with!
Step Action
1 Connect converter to the mains; compare the mains voltage with the
information on the identification plate before starting up.
2 If necessary, connect general alarm-contact to the measurement
control station.
3 Switch sample gas path to “NO”/ “Bypass”.
4 Insert catalyst cartridge into the mounting adapter.
5 Introduce cartridge into the tube furnace and lock into place by
turning the adapter handle. Moisten the outer O-rings helps placing
the cartridge into the tube furnace.
6 Set the desired catalyst temperature depending on the sample gas
flow using the temperature controller:
30 l/h: 320 °C – 60 l/h: 320 °C – 90 l/h: 340 °C – 150 l/h: 360 °C
1. Press PGM key; the set point is displayed.
2. Set the set point using the arrow keys.
3. Press PGM key; the changed set point is saved.
4. Press PGM key again.
The warm-up time is approximately 30 minutes.
Initial Start-Up
7 When the desired temperature is reached, switch sample gas path
over to catalyst operation internally or externally.
When using a new catalyst cartridge for the first time or after longer periods of
storage at room temperature, the response time T90 can be substantially longer!

12 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Chapter 2 Maintenance
Preface
CAUTION!
Before carrying out maintenance work, make sure that safety measures
specific to the installation and process are complied with!
CAUTION!
Dangerous voltage. Remove mains plug before opening the converter’s
housing!
Maintenance Periods The SCC-K converter does not need special maintenance periods.
Determining the Catalyst Service Life
Catalyst Service Life The catalyst service life depends essentially on the following factors:
•Sample gas flow rate
•Temperature
•NO2concentration in the sample gas
•O
2concentration in the sample gas
The catalyst service life is > 6 months for 30 l/h, 320 °C, 10 ppm NO2and
5 Vol.-% O2.
During the stated service life, conversion is over 95 %. If the degree of efficiency
falls notably below 95 %, the used catalyst cartridge should be replaced (see
page 13).
Adverse conditions in the installation can lead to a substantially shorter catalyst
service life!

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter Operator’s Manual 13
Replacing the Catalyst Cartridge
CAUTION!
The catalyst cartridge is hot! Touching the cartridge can lead to very severe
burns. Wear protective gloves and safeguard cartridge against unauthorized
access!
Step Action
1 Switch the converter’s sample gas path either internally or externally
to bypass.
Removing the catalyst cartridge:
Unlock the adapter of the catalyst cartridge by turning the handle. and
pull it out of the tube furnace.
2
The catalyst cartridge is hot!
3 Pull the catalyst cartridge out of the adapter by twisting gently.
4 Remove the two outside and the
two inside O-ring seals from the
adapter.
Mounting the catalyst cartridge:
Insert new O-ring seals into the outside and inside seal grooves of the
adapter.
5
Do not damage the O-ring seals.
Introduce the new catalyst cartridge into the adapter with gentle
twisting movements.
6
In order to obtain the required gas tightness, take care that the
cartridge is always inserted into the adapter right up to the
stop!
Insert the catalyst cartridge into the tube furnace.
7
Moisten the outer O-rings helps placing the cartridge into the
tube furnace. Do not use grease for O-rings because it could
affect the efficiency of the catalyst!
Replacing the
Catalyst Cartridge
8 Lock the adapter of the catalyst cartridge in place by turning the
handle.

14 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Checking for Gas-Tightness
The converter must be cooled down to room temperature in order to check for
gas-tightness!
Step Action
1 Connect device to mains supply.
2 Set temperature controller to room temperature.
3 Switch sample gas path to catalyst operation (lower green LED lights
up).
4 Seal sample gas outlet tightly.
5 Connect sample gas outlet with U-tube manometer or similar and
upstream stopcock.
Release air using the stopcock until the manometer displays a
pressure of approximately pe= 50 hPa.
6
Do not exceed the maximum operating pressure of pabs =
200 kPa!
7 Close stopcock.
Checking for Gas-
Tightness
8 A leak is shown by a marked fall in pressure after several minutes.

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter Operator’s Manual 15
Troubleshooting
Problem Cause Corrective Action
No mains power Check that mains cable fits properly (X1);
ok?
Sub-D plug not inserted in
socket X2
Check whether sub-D plug is present and is properly
plugged in;
ok?
LEDs do not light
up
Valves do not
switch over
Temperature
controller out of
order
Fuses F1, F2 defective Check fuses and replace if necessary.
Heater defective Measure voltage at terminals X4/2 and 3;
ok?
Replace heater;
not ok?
Temperature controller
defective
Measure voltage at terminal X4/6 and 7;
Voltage < 8 V DC?
Check controller according to operator’s manual;
Voltage > 8 V DC?
Converter does
not heat up
Solid-state relay defective Replace solid-state relay.
No mains supply (see
above)
Sub-D plug not inserted
into socket X2 (see above)
See above
Internal circuit:
No solder link 1-6 in sub-
D plug
Check sub-D plug and if necessary solder link
Valves do not
switch over
LEDs do not light
up
External circuit:
Error in external control
Check external control
Valves do not
switch over
LEDs light up
Valves defective Check that valves function
Valves defective (see
above)
See aboveNo sample gas
flow
Gas sample lines blocked
or leaking
Check gas sample lines;
Check for gas-tightness (see page 14)
Cartridge does not heat
up (see above)
See aboveNo conversion
No sample gas flow (see
above)
See above

16 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Chapter 3 Converter Shutdown and Packing
Converter Shutdown
Short-term Shutdown No special measures need to be taken when the converter is taken out of
operation for a short period.
In order to avoid unnecessary consumption of the catalyst and to ensure that the
catalyst is ready for use at short notice, the catalyst temperature should be
reduced to approximately 100 °C in the “stand-by” during brief operational
pauses.
Long-term Shutdown When the converter is taken out of operation for more protracted periods, we
recommend rinsing the converter with inert gas or air at room temperature.
Ambient Temperature The location at which the converter is mounted must remain frost-free even when
the device is switched off.
Converter Packing
Step Action
1 Whenever possible use the original packaging and padding materials.
If the original packaging is not available, cover the converter with
bubble paper or corrugated cardboard.
Place the converter in an adequately sized box lined with shock-
absorbing material (e.g. foam).
2
The cushioning material’s thickness should be adequate for the
converter’s weight.
Packing
3 Mark the box “Fragile Item” and “Transport Upright”.
Step Action
Add a drying agent (e.g. silica gel) and wrap the converter air-tight in
an additional 0.2-mm thick polyethylene sheet.
1
The amount of drying agent used should be adequate for the
package volume and the planned shipping time (at least 3
months).
Overseas Shipment
2 Wrap the box in a layer of kraft paper.
Ambient Temperature Ambient temperature during storage and transport: –25 to +60 °C

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter Operator’s Manual 17
Annex
Description
Legal Requirements In combustion processes – such as, for example, in large furnaces – in which the
nitrogen dioxide content amount to more than 5 % of the nitrogen oxide emission,
continuous measurement of total nitrogen oxide NOx consisting of nitrogen
monoxide NO and nitrogen dioxide NO2is prescribed by law in Germany.
Functional Principle The SCC-K NO2/NO Converter converts the NO2content of the sample gas by
catalysis into NO (see also section “Conversion Principle”, page 19). To do this the
sample gas is conducted through a special stainless steel cartridge with a
catalyst-filling based on carbon-molybdenum. This conversion makes it possible
to measure nitrogen oxides indirectly using all commercially available NO-selective
measurement instruments.
Construction The converter is designed as compact, user-friendly and easy to service 19-inch
plug-in unit for mounting in 19-inch cabinet systems or with a mounting bracket
for wall-mounting (see also section “Converter Construction”, page 20).
Catalyst Cartridge The catalyst is filled and formatted at the works and is ready for use immediately.
The ability to select the appropriate catalyst filling and the possibility of adjusting
the cartridge temperature optimally to the catalytic reaction by way of an electro-
nic temperature controller means that the converter can be used in a wide range
of applications.

18 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Functional Schemes
Figure 4
Standard Version with
4-Way Ball Valve
1
2
360
E1
4
5
Y1
1Power supply
2Status signal
4Sample gas outlet
5Sample gas inlet
E1 Tube furnace
Y1 4-way ball valve
Catalog numbers:
23093-4-0801974 (230 VAC)
23093-4-0801977 (115 VAC)
Figure 5
Option with
2 Solenoid Valves
1
2
360
E1
4
5
Y1
Y2
1Power supply
2Status signal
4Sample gas outlet
5Sample gas inlet
E1 Tube furnace
Y1 3/2-way solenoid valve
Y2 3/2-way solenoid valve
Catalog numbers:
23093-4-0801975 (230 VAC)
23093-4-0801978 (115 VAC)
Figure 6
Option with Heated
Sample Gas Inlet
1
2
360
E1
3
4
Y1
NO NOx
Bypass
1Power supply
2Status signal
3Heated sample gas inlet
4Sample gas outlet
E1 Tube furnace
Y1 3/2-way solenoid valve
Catalog numbers:
23093-4-0801976 (230 VAC)
23093-4-0801979 (115 VAC)

42/23-52 EN Rev. 2 SCC-K NO2/NO Converter Operator’s Manual 19
Conversion Principle
Reaction Equation The conversion of nitrogen dioxide NO2into nitrogen monoxide NO occurs
according to the following gross reaction equation:
2 NO2<–> 2 NO + O2
Reaction Equilibrium The reaction equilibrium is shifted entirely onto the side of the original material
NO2. A shift of the equilibrium towards the products and the resultant high product
yield can only be achieved subject to a high expenditure of energy, i.e. temperature
(100% conversion at temperatures over 600 °C).
Using a Catalyst By using a catalyst the activation energy of the above reaction is reduced
considerably so that conversion rates of 99% are possible at temperatures below
400 °C.
Catalyst A carbon-molybdenum mixture is used as catalyst. The carbon supporting
material guarantees optimal contact between the gas to be converted and the
surface of the catalyst combined with a simultaneously low flow resistance.
Catalyst
Temperatures
The catalyst temperature can be adjusted continuously using the temperature
controller on the front of the converter.
The recommended settings for catalyst temperatures depending on the gas flow-
rate for a conversion rate above 95% are:
30 l/h: 320 °C – 60 l/h: 320 °C – 90 l/h: 340 °C – 150 l/h: 360 °C
Gas Conditioning For reasons associated with the filter effect of the catalyst filling an appropriate
gas conditioning system is to be mounted upstream of the converter in order to
separate out suspended particles and to dry the sample gas!
Cross-Sensitivities Ammonia NH3in the sample gas converts a part of the NO2into dinitrogen oxide
N2O and elementary N2. Depending on the ammonia concentration, this can cause
a substantial reduction in the conversion rate.

20 SCC-K NO2/NO Converter Operator’s Manual 42/23-52 EN Rev. 2
Converter Construction
Figure 7
Views from Front
and Back
NOx
NO
360
360
67 8
1234
5
Mounting The SCC-K NO2/NO-Konverter is designed as compact, user-friendly and easy to
service 19-inch plug-in unit for mounting in 19-inch cabinet systems. When fitted
with a mounting bracket with a vertical swivel-holder, the converters can also be
wall-mounted.
Operating Elements All operating elements are mounted on the front panel of the converter for easy
access. These are (see Fig. 7):
6Selector switch for bypassing the catalyst cartridge,
7Mounting adapter with handle for the catalyst cartridge,
8Temperature controller with digital temperature display.
Catalyst Cartridge The catalyst cartridge is mounted in a heat-insulated tube furnace. The special
mounting adapter with handle allows the hot catalyst cartridge to be released and
removed without tools being needed.
Temperature
Controller
The converter temperature is electronically controlled and can be set continuously
at the temperature controller on the converter’s front panel in a range between
+50 °C and +700 °C depending on the catalytic reaction.
Status Signals One alarm for excessively high and low temperatures is provided as a status
contact output at the 9-pin sub-D-plug on the rear side of the converter.
Continued on next page