SICK SFU Series User manual

OPERATING INSTRUCTIONS
SFU
Gas Sampling Unit
with Weatherproof Enclosure

Described product
SFU (gas sampling unit) with higher protection class
These Operating Instructions refer to the gas sampling unit of the SFU-BF NI GL in the
weatherproof enclosure.
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 5
1.1 Function of this document....................................................................... 5
1.2 Target group.............................................................................................. 5
1.3 Symbols and document conventions...................................................... 5
1.3.1 Warning symbols...................................................................... 5
1.3.2 Warning levels / signal words................................................. 6
1.3.3 Information symbols................................................................ 6
2 Safety information............................................................................ 7
2.1 Basic safety information........................................................................... 7
2.2 Warnings on the device............................................................................ 7
2.3 Intended use............................................................................................. 8
2.4 Qualification of the operator.................................................................... 8
3 Product description........................................................................... 9
3.1 Product identification............................................................................... 9
3.2 Product description.................................................................................. 10
3.3 Design........................................................................................................ 11
3.3.1 Gas sampling tube................................................................... 11
4 Installation and start-up................................................................... 12
4.1 Important information.............................................................................. 12
4.2 Weatherproof enclosure........................................................................... 13
4.3 Preparing the connection bundle............................................................ 14
4.4 Mounting................................................................................................... 15
4.4.1 Installing the welding neck flange.......................................... 15
4.4.2 Connection of sample gas line............................................... 17
4.4.3 Connection of the pneumatic lines........................................ 18
4.5 Electrical installation................................................................................ 19
4.6 Installing the gas sampling tube on the gas sampling unit................... 20
4.7 Installing the SFU on the welding neck flange........................................ 20
5 Maintenance...................................................................................... 22
5.1 Important Information.............................................................................. 22
5.2 Maintenance plan..................................................................................... 22
5.3 Spare parts............................................................................................... 23
5.4 Replacing the sintered metal filter element........................................... 23
5.5 Replacing the glass fiber filter element.................................................. 26
5.6 Retrofitting the filter element................................................................... 29
5.7 Checking for correct operation................................................................ 32
6 Troubleshooting................................................................................. 33
6.1 Troubleshooting........................................................................................ 33
7 Disposal.............................................................................................. 34
CONTENTS
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8 Technical data.................................................................................... 35
8.1 Compliances and Standards.................................................................... 35
8.2 Dimensions............................................................................................... 35
8.3 Operating data.......................................................................................... 35
CONTENTS
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1 About this document
1.1 Function of this document
These Operating Instructions describe:
•Device components
•Installation
•Operation
•Maintenance work required for reliable operation
1.2 Target group
This document is addressed to technicians (persons with technical understanding)
installing, operating and maintaining the measuring system.
Responsibility of the operator
•Use the device only as described in these Operating Instructions. The manufac‐
turer assumes no responsibility for any other use.
•Maintenance work should be performed as prescribed in this Manual.
•Do not remove, add or change any components in or on the device unless such
changes are officially allowed and specified by the manufacturer.
°Otherwise the manufacturer's warranty becomes void.
°Otherwise the device can become dangerous.
•Observe special local conditions.
°Follow all local laws, regulations, and company policies applicable at the
installation location.
•Retain documents. These Operating Instructions:
°Must be kept available for reference.
°Must be passed on to new owners.
Requirements on the maintenance personnel
•The technician must be familiar with the exhaust gas technology of the operator's
plant (overpressure, toxic and hot flue gases) and be able to avoid hazards when
working on gas ducts.
•The technician must be familiar with handling compressed gas cylinders (span
gases).
•The technician must be able to avoid hazards caused by noxious span gases.
•The technician must be familiar with gas lines (PTFE lines) and their screw fittings
(be able to ensure gas-tight connections).
•Only electricians are permitted to work on the electrical system or electrical sub‐
assemblies.
1.3 Symbols and document conventions
1.3.1 Warning symbols
Symbol Significance
Hazard (general)
Hazard by voltage
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Symbol Significance
Hazard by acidic substances
Hazards by noxious substances
Hazard by high temperature
Hazard for the environment/nature/organic life
1.3.2 Warning levels / signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
Notice
Hazard which could result in property damage.
Note
Hints.
1.3.3 Information symbols
Symbol Significance
Important technical information for this product
Important information on electric or electronic functions
1 ABOUT THIS DOCUMENT
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2 Safety information
2.1 Basic safety information
WARNING
Health risk through dangerous sample gas
If dangerous sample gas is applied to the SFU:
bThe operator is responsible for safe handling of sample gas.
WARNING
Risk of explosion in potentially explosive atmospheres
bDo not operate the SFU in potentially explosive atmospheres.
WARNING
Hazard through explosive or ignitable gases
bDo not use the SFU for measuring explosive or combustible gases.
2.2 Warnings on the device
Figure 1: Location of the warning signs on the device
1Warning sign "Caution!"
2Warning sign "Hot surface!"
DANGER
Hazard by voltage
bOnly authorized electricians may perform work on electrical components.
bDo not touch live components.
bDisconnect the device from the power supply before working on electrical compo‐
nents (e.g. by switching off the measuring system).
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WARNING
Risk of burns on hot surfaces
bAvoid contact with hot surfaces or wear protective clothing (e.g. protective gloves).
bLay hot parts on fireproof supports only.
2.3 Intended use
The gas sampling unit is used for extracting a partial stream of a gas mixture (usually
flue gas) from a line, stack or similar and for retaining particles that are contained in
the gas stream.
2.4 Qualification of the operator
The SFU may only be maintained by persons properly instructed on the tasks assigned,
possible risks and protective measures.
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3 Product description
3.1 Product identification
Product name SFU-BF NI GL
The exact type designation can be found on the type plate.
Accessories: •0.5 m unheated maritime gas sampling tube
•0.8 m unheated maritime gas sampling tube
•0.5 m heated gas sampling tube
•0.8 m heated gas sampling tube
•1.0 m heated gas sampling tube
•1.5 m heated gas sampling tube
•2.0 m heated gas sampling tube
•IP54 enclosure
Can already be ordered pre-assembled in combination
with the maritime gas sampling unit SFU-BF NI GL
Name of the pre-assembled set:
Consisting of:
SFU-BF NI GL in IP54 enclosure (PN 2098126)
•SFU-BF NI GL
•IP54 enclosure for SFU
Manufacturer SICK AG
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Type plate The type plate is located on the underside of the gas sam‐
pling unit.
NOTICE
It is possible that your SFU has a different configuration to that described in this Man‐
ual.
•Refer to the System Documentation delivered with your SFU for the individual con‐
figuration of your system.
PRODUCT DESCRIPTION 3
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3.2 Product description
Figure 2: Example configuration of a set consisting of weatherproof enclosure and SFU
1Weatherproof enclosure
2Gas sampling tube
3SFU filter housing
4Flange
5Silicone press ring seal (gas sampling tube seal)
The gas sampling unit consists of filter housing, gas sampling tube, weatherproof enclo‐
sure and optional pre-filter.
Application area
The gas sampling unit SFU is used for flue gas extraction and filtering for analysis in a
measuring system.
The flue gas is taken via a gas sampling tube and fed to a measuring system after filtra‐
tion.
The gas sampling tube is optionally available in various lengths.
As an option, the gas sampling tube contains a pre-filter at the probe tip.
For maritime applications, unheated gas sampling tubes without pre-filters are used.
Measuring system
The gas sampling unit is operated on a SICK measuring system. Thus, only this operat‐
ing mode is described in this Manual.
Applications with customer-owned peripheral devices are not planned.
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3.3 Design
Figure 3: SFU-BF NI GL
1Gas sampling tube
2Filter housing
33 pneumatic lines (backflush, activa‐
tion of main valve, zero gas)
4Output sample gas line
5Input connection bundle (electrical
and pneumatic lines)
6Filter element with rotary handle
The gas sampling unit consists of the following subassemblies:
•Gas sampling tube:
°Heated gas sampling tube:
°Unheated maritime gas sampling tube
°Optional: Pre-filter at the tip of the gas sampling tube
•SFU in IP54 enclosure:
°Heated filter housing with filter element
°Weatherproof enclosure
The electrically heated filter housing is made of coated aluminum. The filter housing is
insulated by an aluminum housing lined with polyimide.
The weatherproof enclosure is made of glass fiber reinforced plastic (GRP).
Thermostatic control
The gas sampling unit is thermostatically controlled.
•Heating control with Pt100 sensor and external heating control
•Limit value monitoring in the controller of the measuring system
3.3.1 Gas sampling tube
The length of the gas sampling tube depends on the conditions at the sampling point.
The gas sampling tube is available for maritime applications in an unheated version.
Type and length of the gas sampling tube are described in the supplied system docu‐
mentation.
NOTE
The gas sampling tube is supplied pre-assembled.
PRODUCT DESCRIPTION 3
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4 Installation and start-up
4.1 Important information
WARNING
Risk of injury by a heavy load
The weatherproof enclosure including the sampling system with flange weighs
approx. 30 kg.
bUse proper lifting techniques to lift or move the device.
bLift the unit by the enclosure. If necessary, remove the cover in order to grip the
device better and reduce the weight.
bAlways work in pairs.
WARNING
Health risk through dangerous sample gas
If dangerous sample gas is applied to the SFU: The operator is responsible for safe han‐
dling of sample gas.
bIn addition to these Operating Instructions, observe all local laws, technical rules,
and company-internal instructions valid at the site where the SFU is installed.
bOperate the SFU only in rooms with adequate installation OR install suitable gas
monitoring equipment.
bChannel sample gas off safely.
WARNING
Hazard through sample gas pressure
The stacks can have underpressure or overpressure.
bObserve information from the plant operator.
WARNING
Risk of burns on hot surfaces
Filter housing, flanges and sample gas line can be hot.
bAllow the surface of the device parts to cool down to body temperature or wear
suitable protective gloves.
WARNING
Danger to life by electric voltage
bOnly allow an authorized electrician to work on the electric system.
The assembly of the gas sampling unit contains the following work steps:
Step Work step Special features Side
1 Install the welding neck flange Has to be performed by the
operator beforehand
page 15
2 Connect the sample gas line page 17
3 Connect the hoses for valves page 18
4 Connect the electrical connec‐
tions
page 19
5 Install the gas sampling tube page 20
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Step Work step Special features Side
6 Attach the SFU to the welding
neck flange
Observe preheating period page 20
4.2 Weatherproof enclosure
Figure 4: SFU-BF NI GL in weatherproof enclosure (closed left and open right)
1Enclosure cover
2Enclosure base
3Tension locks
4Filter housing
5Gas sampling tube
6Ventilation membrane
DANGER
Hazard by voltage
Live parts are accessible after the weatherproof enclosure has been opened.
bDisconnect the gas sampling unit from the power supply before opening the enclo‐
sure (for example by switching off the measuring system).
CAUTION
Risk of burns on hot surfaces
You can perform the work while the filter is hot.
bWear suitable gloves.
Removing the enclosure cover
1 Unlock the tension locks.
2 Pull the enclosure cover away from the gas sampling tube and lift.
Fitting the enclosure cover
1 Fit the enclosure cover in the direction of the gas sampling tube.
2 Lock the tension locks.
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4.3 Preparing the connection bundle
Figure 5: Standard connection bundle
Standard hose bundle cable (system-
specific example) with:
- Power supply
- Grounding conductor yellow/green
- Signal lines
- Tube, gray: Zero gas/span gas
- Tube, black: Main valve
- Tube, blue: Backflush
Figure 6: DNV GL approved connection bundle:
DNV GL approved connection bundle:
- Power supply
- Grounding conductor yellow/green
- Signal lines
- Tube, gray: Zero gas/span gas
- Tube, black: Main valve
- Tube, blue: Backflush
Halogen-reduced for use on passenger
ships
Additionally improved protection against
fire
The connection bundle (option) connects the SFU with the measuring system.
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Preparation of the connection bundle
NOTE
Leave a sufficient length for pulling the gas sampling unit out of the stack (approx. 2
m).
1 Strip the connection bundle and shorten the hoses and lines to the required
length.
Cut the hoses at right angles. Avoid damaging the lines and hose lines.
2 Cut the flexible wires to the required length. Press the crimp lead end sleeves onto
the ends of the flexible wires.
4.4 Mounting
4.4.1 Installing the welding neck flange
WARNING
Risk of burns by hot flanges.
The flanges can reach high temperatures.
bBefore starting any work on the flanges, allow the flanges to cool down to body
temperature or wear appropriate protective gloves.
DANGER
Health risk through hot or toxic gases/dusts in the measuring duct
The measuring duct can contain hot or toxic gases or dust deposits which can escape
when opening the duct-side flange. Even if the measuring duct is out of operation dur‐
ing the installation, escaping gases can lead to severe damage to health.
bAlways put the measuring duct out of operation for the duration of the installation.
bIf required, purge the measuring duct with ambient air before starting installation
work.
bDuring installation work, always wear protective clothing which is suitable or speci‐
fied by the operating company.
The operator is responsible for installing the welding neck flange.
The specifications of the flange connection are described in the System Documentation
delivered.
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min.70
10°
~
~30
123 4
a
Figure 7: Installation requirements for welding neck flange
1Gas sampling tube
2Stack wall
3Welding neck flange
4Probe filter
bAttach the flange with a tilt of approx. 10°.
bThe minimum distance a behind welding neck flange must be min. the length
specified in the following table in order to maintain and dismantle the gas sam‐
pling unit.
Table 1: Minimum distance behind welding neck flange
Length of gas sampling tube Minimum distance a
0.5 m 915 mm
0.8 m 1215 mm
1.0 m 1415 mm
1.5 m 1915 mm
2.0 m 2415 mm
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4.4.2 Connection of sample gas line
Figure 8: Sample gas connection SFU-BF NI
GL in weatherproof enclosure
1Insulating shell
2Clamping ring screw connection
3Sample gas line
4Cable gland with cap nut, small
5Cable gland with cap nut, large
NOTE
If you lay the heated sample gas line before installing the gas sampling unit: Observe
the installation of the sample gas line:
bStart laying at the measuring system:
°The end with electrical connection is connected to the measuring system.
°The end without electrical connection is connected to the gas sampling unit.
Roll up excess length at the gas sampling unit.
Leave enough length for pulling out the gas sampling unit (approx. 2 m).
bProtect the line from damage (chafing through vibration, mechanical and thermal
load).
bObserve a minimum bending radius of 300 mm.
1. Remove the enclosure cover (see "Weatherproof enclosure", page 13).
2. Unscrew the large cap nut and slide it onto the sample gas line.
3. Unscrew the insulation half-shell.
4. Feed the sample gas line through the large cable gland of the weatherproof enclo‐
sure and then through the installation plate and the hose clamp.
5. Screw the sample gas line tight on the clamping ring screw connection.
°For first screwing (clamping ring still loose): 1¼ turn to "hand-tight".
°For further screwing: (clamping ring tight) ¼ turn to "hand-tight".
6. Fasten the sample gas line using a hose clamp. The screw head can be reached
via an opening in the chamfer of the installation plate.
7. Screw the insulation half-shell back on again.
8. Tighten the cap nut hand-tight.
9. Check hose connections for leaks:
The leak tightness check is performed via the connected measuring system: See
the Operating Instructions of the measuring system.
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4.4.3 Connection of the pneumatic lines
NOTICE
Risk of damaging the measuring system.
•Ensure correct assignment of the pneumatic connections.
•Ensure leak tightness of the system.
Connection for SFU-BF NI GL
Figure 9: Connection of SFU-BF NI GL pneu‐
matic lines
1Backflush
2Main valve
3Zero gas
4Installation plate
1. Push the cap nut onto the connection bundle.
2. Feed the connection bundle through the cable gland of the weatherproof enclo‐
sure and then through the installation plate.
3. Connect the 3 hoses with the 3 hose fittings on the filter housing and ensure cor‐
rect layout.
4. Push the hoses flush over the hose connections of the hose fitting.
5. Hose for the zero gas: Use clamping ring screw connection with support sleeve.
6. Tighten the cap nut by hand.
7. Screw the cable gland tight.
4.4.3.1 Adapter for inch thread (option)
If you want to connect pneumatic lines with inch thread: There is an adapter set with 4
clamping ring screw fittings.
Part No. "Adapter set inch thread": 2083838
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Figure 10: Adapter set
Installation
1. Wrap the thread with 2 - 2.5 layers of Teflon tape.
2. Tighten the adapter with an open-end wrench until a distinct increase in strength
is felt.
Then tighten by approx. 1/8 to 1/4 turn.
4.5 Electrical installation
WARNING
Danger to life by electric voltage
bOnly allow an authorized electrician to work on the electric system.
WARNING
Risk of short-circuit due to condensate.
bAllow the electronics to acclimatize sufficiently before connecting.
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Figure 11: Terminal diagram for 230 V and 115 V
The electrical connection of the gas sampling unit is made via the connection terminals
on the installation plate.
Observe the terminal diagram on the SFU.
The temperature sensors and the heating cartridges are wired ex factory.
bRemove the enclosure.
bPerform electrical connections.
4.6 Installing the gas sampling tube on the gas sampling unit
Installing the gas sampling tube
The gas sampling unit with gas sampling tube is supplied pre-assembled.
Installing the pre-filter
The pre-filter can be screwed to the gas sampling tube.
1 Wrap the thread with Teflon tape.
2 Screw the pre-filter onto the tip of the gas sampling tube. Tighten by hand with a
wrench.
4.7 Installing the SFU on the welding neck flange
NOTICE
Risk of contamination of the gas sampling unit
Do not install a cold gas sampling unit on the stack.
bAllow the gas sampling unit to warm up before installing it on the welding neck
flange.
bWarm-up time: Approx. 1.5 h at 25 °C ambient temperature
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