Buhler SCS 104 User manual

Gas Analysis
Installation and Operation Instructions
Original instructions
19" Sample Gas Conditioning System
SCS 104
BECS0031
02/2020
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2020
Document information
Document No.......................................................... BECS0031
Version........................................................................ 02/2020
Part No...............................................................998BECS0031

SCS 104
Contents
1 Introduction..................................................................................................................................................................................................................... 3
1.1 Intended Use......................................................................................................................................................................................................... 3
1.2 System Description ............................................................................................................................................................................................. 3
1.2.1 Sample conditioning section ............................................................................................................................................................3
1.2.2 Calibration gas section .......................................................................................................................................................................3
1.2.3 Blowback air section ............................................................................................................................................................................3
1.2.4 Manual control..................................................................................................................................................................................... 4
1.2.5 External control and monitoring.................................................................................................................................................... 4
1.3 Scope of delivery..................................................................................................................................................................................................4
2 Safety instructions......................................................................................................................................................................................................... 5
2.1 Important advice ................................................................................................................................................................................................. 5
2.2 General hazard warnings .................................................................................................................................................................................6
3 Transport and storage .................................................................................................................................................................................................. 7
4 Installation and connection ........................................................................................................................................................................................8
4.1 Installation site requirements.........................................................................................................................................................................8
4.2 Gas Line Connections .........................................................................................................................................................................................8
4.3 Electrical connections ........................................................................................................................................................................................8
5 Operation and control ................................................................................................................................................................................................ 10
5.1 Start up................................................................................................................................................................................................................. 10
5.2 Using the device menu .................................................................................................................................................................................... 10
5.2.1 Use of menu functions......................................................................................................................................................................10
5.2.2 Lock Menu..............................................................................................................................................................................................11
5.2.3 Overview of the menu items............................................................................................................................................................11
5.2.4 Description of menu functions ...................................................................................................................................................... 13
5.3 Manual operation of the SCS (front panel module CM0191)................................................................................................................ 16
5.4 Monitoring system operation on the controller module (front panel module CM0191) ............................................................. 16
5.5 External control ................................................................................................................................................................................................. 16
5.6 External monitoring......................................................................................................................................................................................... 16
5.7 Flow Meter Operation.......................................................................................................................................................................................17
5.8 Pressure regulators and gauges ....................................................................................................................................................................17
6 Maintenance.................................................................................................................................................................................................................. 18
7 Service and repair......................................................................................................................................................................................................... 19
7.1 Troubleshooting ................................................................................................................................................................................................ 19
7.1.1 Error messages on the display.......................................................................................................................................................20
7.2 Safety instructions............................................................................................................................................................................................ 21
7.3 Replacing the Fuse in the Front Panel.........................................................................................................................................................22
7.4 Replacing the fuse (F1) from the gaspumps ..............................................................................................................................................22
7.5 Replacing the fuse (F2) from the peristaltic pumps................................................................................................................................22
7.6 Replacing the Peristaltic Pump Hose...........................................................................................................................................................22
7.7 Replacing the filter element...........................................................................................................................................................................23
7.8 Replace Flowmeter module............................................................................................................................................................................23
7.9 Install Extension module gaspump.............................................................................................................................................................23
7.10 Drying the Moisture Detector........................................................................................................................................................................24
7.11 Calibration of the moisture detector...........................................................................................................................................................24
7.12 Spare parts and accessories ...........................................................................................................................................................................24
7.12.1 Spare parts and accessories............................................................................................................................................................ 24
8 Disposal........................................................................................................................................................................................................................... 25
9 Appendices.....................................................................................................................................................................................................................26
9.1 Technical Data....................................................................................................................................................................................................26
9.2 Legend................................................................................................................................................................................................................... 27
9.3 Drawing 1: Flow chart.......................................................................................................................................................................................28
9.4 Drawing 2: Wiring diagrams .........................................................................................................................................................................29
9.5 Drawing 3: Front view......................................................................................................................................................................................30
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9.6 Drawing 4: Back view.......................................................................................................................................................................................30
10 Attached documents....................................................................................................................................................................................................31
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1 Introduction
1.1 Intended Use
The SCS104 is a gas sample conditioning system. The specifications and their limits given in the appendices are to be main-
tained during installation. The device is not to be used in hazardous areas.
1.2 System Description
Please consult the illustrations and the legend at the end of the operating manual. The components are numbered. The num-
bers are referenced in the text.
1.2.1 Sample conditioning section
The sample gas is pulled in at the sample inlet (1) and through the cooler (2) by the sample pump (6). The cooler (2) operates at
approximately 5°C (41°F). The moisture in the sample gas drops out inside the heat exchanger (integral to the cooler) and is de-
livered to the condensate outlet (10) by the condensate pump (3). The condensate pump is often referred to as a peristaltic
pump.
The heat exchanger temperature is shown in the display (30). In the event of a cooler (2) overload and temperature increase of
3K the sample pump (6) will turn off to avoid downstream moisture damage, and the temperature alarm LED (25) will turn red.
Additionally, a highly sensitive moisture sensor (4) is located downstream from the cooler (2) and before the filter (5). If the mois-
ture sensor (4) detects even the slightest amount of moisture in the sample gas stream, the pump will turn off, and the moisture
alarm (26) will illuminate and the display shows “h20.1”.
Downstream from the moisture sensor (4) the sample gas passes through the filter (5) to remove particulates. The filter element
is visible and accessible at the front panel.
From the outlet of the filter the sample gas is directed to a manual three way valve (7) located on the front panel that allows
either sample gas or calibration gas to enter the inlet of the sample pump (6). The manual valve provides calibration gas directly
to the analyzers, bypassing the probe when in the calibration position.
The sample pump output passes through an adjustable flowmeter with needle valve (8a) to the analyzer(s). The portion of the
sample gas or calibration gas not required by the analyzer(s) flows through a second flowmeter without needle valve (8b). The
amount of sample gas being used by the analyzer(s) is the difference between the two flowmeters. Both flowmeters are visible
and accessible from the front panel. If flow decreases the set limit at flowmeter (8a), the flow alarm LED (27) on the front panel
will turn red.
Condensate pump (3) and gas pump (6) are redundant. Switches (3c and 6c) on relay board RB0291 (23) can be used to change
the active pumps.
Whenever the SCS is powered up the sample conditioning system is operating.
1.2.2 Calibration gas section
Up to 6 calibration gases and 1 zero gas (span 1 – span 6 + zero gas) can be connected to the bulkhead fittings (11a..g + zero gas)
on the rear panel of the SCS. The flow of each calibration gas is controlled by an independent solenoid valve (12a..g) into a com-
mon, adjustable flowmeter with needle valve (13) located on the front panel. From the flowmeter (13) the selected calibration gas
flows to the span outlet bulkhead fitting (14) located on the rear panel and to the manual three way valve (7). A specific calibra-
tion gas is selected using the mode switch (28) and indicated by the system mode LEDs (29), all located on the front panel. Calib-
ration gases can also be controlled by an external controller when the mode switch (28) is in the sample (external control) posi-
tion.
1.2.3 Blowback air section
Instrument air for blowback is connected to the inlet bulkhead fitting (15) on the rear panel. The blowback air pressure is adjus-
ted with a regulator (16), displayed on a pressure gauge (19) and controlled by a solenoid valve (17). The blowback air passes
through the outlet bulkhead fitting (18) located on the rear panel. Operation of the blowback solenoid is selected with the mode
switch (28) and indicated by a system mode LED on the front panel. Blowback air can also be controlled by an external controller
(40) when the mode switch (28) is in the sample (external control) position.
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1.2.4 Manual control
Manual control is exercised using the rotary (mode) switch (28). The selectable system modes are: "Blow-back", “Zero Air”,
“Sample (external control)”, "Span 1", "Span 2", "Span 3", "Span 4", "Span 5", and "Span 6". The selected mode is indicated by the
system mode LEDs (29). Rotating the mode switch to any position other than sample (external control), will direct the selected
calibration gas or air to the corresponding outlet.
The valves are switched with a short time delay, so the correct mode can be selected before any change in gas flow takes effect.
1.2.5 External control and monitoring
The SCS can be externally controlled only if the mode switch (28) is in the exernal control (sample) position. Each mode is selec-
ted using the corresponding dry contacts at the external control terminal block (40) located on the rear panel. When no external
contact is closed the SCS is in the sample mode. The externally selected mode is shown by the system mode display LEDs on the
front panel (29) and can be monitored at the mode output terminal board (41) on the rear panel. LED and status output for ex-
ternal control (sample) position are also active.
Alarms for moisture, flow and temperature can be monitored at the status output terminal block (42) on the rear panel. An open
contact indicates status OK. A closed contact indicates an alarm. The normal status of the contacts may be changed on the con-
troller module from normally open to normally closed.
1.3 Scope of delivery
– SCS analysis gas conditioning system
– Product Documentation
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2 Safety instructions
2.1 Important advice
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
In this manual, the following warning signs are used:
Warning against hazardous situations General notice
Warning against electrical voltage Disconnect from mains
Warning against respiration of toxic gases Wear respirator
Warning against acid and corrosive substances Wear eye/face protection
Warning against potentially explosive atmospheres Wear protection gloves
Warning against hot surface
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2.2 General hazard warnings
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal,
– compliance with national installation regulations.
– the device is protected from mechanical loads.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
– Do not install damaged or defective spare part. If necessary, visually inspect prior to installation to determine any obvious
damage to the spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic, corrosive gas/condensate
Sample gas/condensate may be hazardous to health.
a) If necessary, ensure a safe gas/condensate discharge.
b) Always disconnect the gas supply when performing maintenance or repairs.
c) Protect yourself from toxic/corrosive gasses/condensate when performing mainten-
ance. Wear appropriate protective equipment.
DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
Do not expose the device to combustible or explosive gas mixtures.
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3 Transport and storage
The device should be only transported in the original case or in appropriate packing.
If the device is not used for some time, protect it against heat and humidity. Store the device in a roofed, dry, and dust free
room. Temperature should be between –5 °C and 40 °C (23 °F and 104 °F).
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4 Installation and connection
4.1 Installation site requirements
The unit mounts in a 19 inch rack. Due to the weight the housing requires rails. These are available from the cabinet/rack manu-
facturer.
Please note, cooling generates waste heat inside the SCS. Adequate ventilation is therefore required (e.g. fan slot inside the cab-
inet).
The following requirements must be met during installation:
– Never install the system near sources of heat or vibration, in direct sunlight, or around high frequencies or magnetic fields.
The operator must install a lightning arrester.
– The system must be permanently installed in a location which can support the weight of the system.
– It must be protected from shock and impact.
– Never expose the display components to external forces.
– Never install the system outdoors.
4.2 Gas Line Connections
DANGER Toxic, acidic gasses
Sample gas can be harmful.
a) The gas lines and electric cables must be connected by a professional. Observe local
laws and regulations.
b) If necessary, ensure a safe gas discharge.
c) Switch off the gas supply before performing maintenance and secure against acci-
dental opening.
d) Protect yourself from toxic/corrosive gases. Wear suitable protective equipment.
The gas connections are 1/4” bulkhead fittings. Ensure the connections are tight.
4.3 Electrical connections
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
Use the included M3 plug to connect to power. The plug insert can be installed turned to your liking. Please refer to the wiring
diagram in the appendix for the assignment.
The supply line diameters must be aligned with the rated current. Use a maximum line cross-section of 1.5mm2 and a cable dia-
meter of 8-10mm (0.31 – 0.39 inch).
CAUTION Same Voltage
The voltage at the clamps for the status must always be the same. Do not mix different
voltages at the clamps.
All other signals connect with the included connector.
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