1. 7132249a.01 analyzer system manual v1.0 (kiln inlet)

7/25/2019 1. 7132249A.01 Analyzer System Manual V1.0 (Kiln Inlet)

1/26

Analyzers and Process Instrumentation

SMC-9004H Gas Analyzer System

Operating Manual

Kiln inlet

SICK MAIHAK (Beijing) Co.,Ltd.

Version 1.0


2/26

SMC-9004H Gas Analyzer Systemkiln inlet

SICK MAIHAK(Beijing)Co.,Ltd. 2

Content

1 Safety Information ....................................................... 4

1.1 Application objective........................................................................................... 4

1.2 Authorized operator............................................................................................. 4

1.3 Safety rules and measuring protection.............................................................. 4

1.3.1 Power supply safety ................................................................................................. 5

1.3.2 Danger caused by hot, corrosive or over pressured gases ........................................ 5

1.3.3 Inspection and malfunction prevention .................................................................... 5

1.3.4 Switch off, pause and store....................................................................................... 5

1.4 Symbols used in this document......................................................................... 6

2 Product Description ..................................................... 8

2.1 Working principle................................................................................................. 8

2.2 System composition............................................................................................ 8

2.2.1 Automatic retraction device with probe ................................................................... 8

2.2.2 Heat exchanger equipment ....................................................................................... 9

2.2.3 Analysis and control unit .......................................................................................... 9

2.2.4 Compressed air system ............................................................................................. 9

2.3 System configuration ......................................................................................... 10

2.4 Technical data ..................................................................................................... 11

3 Installation ................................................................. 13

3.1 Probe retraction device..................................................................................... 13

3.1.1 Insertion tube installation ....................................................................................... 13

3.1.2 Automatic retraction device installation ................................................................. 13

3.2 heat exchanger equipment installation............................................................ 13

3.3 Analysis cabinet installation............................................................................. 13

3.3.1 Assembly of system cabinet ................................................................................... 13

3.3.2 Assembly of sample pipeline.................................................................................. 13

3.3.3 Installation of pneumatic pipe ................................................................................ 14

3.4 Installation of compressed air system ............................................................. 14

3.5 Electric installation ............................................................................................. 14

3.5.1 Installation of power supply wire ........................................................................... 14

3.5.2 Installation of signal wire ....................................................................................... 14

3.5.3 Part electrical wire .................................................................................................. 14

4 Commissioning and Parameterization ....................... 16

4.1 General................................................................................................................ 16

4.1.1 Prerequisite ............................................................................................................. 16

4.1.2 Basic procedures .................................................................................................... 16

4.2 System calibration.............................................................................................. 16

4.3 Running mode.................................................................................................... 17


3/26



5. Maintenance ............................................................. 20

5.1 General introduction .......................................................................................... 20

5.1.1 Patrol inspection ..................................................................................................... 20

5.1.2 Periodic draining and cleaning ............................................................................... 20

5.1.3 Heat preservation and heat tracing ......................................................................... 21

5.2 System daily maintenance................................................................................ 21

5.2.1 Daily check-up ....................................................................................................... 21

5.2.3 Analytical system maintenance list ........................................................................ 22

5.3 Infrared analyzer maintenance......................................................................... 22

5.3.1 Manual calibration zero point and span point of infrared analyzer ........................ 22

5.3.2 Zero point calibration ............................................................................................. 22

5.3.3 Span point calibration ............................................................................................ 22

6. Trouble shooting ....................................................... 24

6.1 Trouble-shooting for probe retraction device................................................. 24

6.2 Trouble-shooting for heat exchange device.................................................... 24

6.3 Trouble-shooting for heated sample pipe....................................................... 24

6.4 Trouble-shooting for analyzer cabinet............................................................. 25

Note

This document is the explanation document of SMC-9004H analyzer

system. The measuring location is kiln inlet.


4/26



1 Safety Information

1.1 Application objective

SMC-9004H gas analyzer system is used merely on the special devices in cement

plant. Maintenance personnel should be trained by specialists before taking the role

and attentions should be paid on following points:

Operations and maintenance work should be done strictly following: 1) the

procedures mentioned in this manual; 2) the equipment parameters; 3) installation

specifications and work condition requirements (refer to drawings, nameplate,

other project documents).

Provide all the measuring data neededsuch as data for maintenance and

measurement.

1.2 Authorized operator

Comply to the regulations strictlymake sure the physical safety:

All the operations for measurement should be done by the authorized personnel

who were granted by specialists.

Operations should be performed by the authorized personnel. Operators should

be qualified by experts( training, education and experience) and should be

familiar with the criterion, accidents prevention regulations and system

characteristic. Moreoverhe could make a judgment and take an emergency

action to avoid potential risk in time. Operators should be familiar and passedindustry standard of DIN VDE0105, IEC 364 or other equivalent standard.

Operators should know the possible risk during operationsuch as hot, toxic

gases, overpressure gases, mixture of liquid and gases or other medium.

Thereforethe operators should receive some special training before starting to

work.

1.3 Safety rules and measuring protection

Incorrect operating could damage the equipment and threaten peoplelife

Read this chapter carefullycomply to SMC-9004M safety rules and pay moreattention on alarm signals in the operation introduction:

Following the safety rules and operation introductions before installation and

commission.

Be careful on Working condition/ environment during operation, try to prevent

potential risk.

Better understanding the operation introductions and other project documents,

strictly abide safety items in such documents to avoid any device damage and

physical injury..

Wearing suitable safety clothes to prevent from potential physical injury.


5/26



1.3.1 Power supply safety

Industry power supply is used for SMC-9004M system, system should be powered off

during power supply connecting and parts replacement.

1.3.2 Danger caused by hot, corrosive or over pressured gases

Sampling probe is installed directly on the sample point. Refer to operation instruction and

safety rules and ensure personnel safety during probe installation.

Warning

In order to eliminate potential risk, dangerous sources-such as toxic,

overpressure, overheat, or explosion gas-should be shut off before

replacing defective/failed parts.

1.3.3 Inspection and malfunction prevention

Important

During normal operation, any abnormality should be regarded as potential

problem, and special attention should be drawn on, which includes but

not limited- :

Over-range drift of measuring value

Power consumption increase sharply

Temperature rise increasingly for some components

Monitoring device be triggered somehow

Abnormal fierce vibration / fan noise becomes bigger

Smog and abnormal smell

1.3.4 Switch off, pause and store

SMC-9004H should retract the sample probe from the sample point, and then stop

running during the factory shutdown.

The whole system should be stored in a clean and dry location if power off is longer than 7

days.


6/26



1.4 Symbols used in this document

Note

Points out important information, which should be particularly noted.

Important

Warns of the risk to destroy the system or components or reducing its

function.

Warning

Warns of dangers, which emerge by inappropriate handing, and which can

result in death, bodily harm and/or substantial property damage.


7/26



SMC-9004HGas Analyzer System

2 Product description

Working principle

System composition

System configuration

Technical data


8/26



2 Product Description

2.1 Working principle

The rotary kiln is the core piece of a cement plant and is technologically characterized by

its extreme rough operating conditions. In it the transformation process takes place from

raw material to cement clinker. The concentration gradient of certain gas components

provides important information required to optimize the process.

The SMC-9004H gas analyzer system is especially designed for gas sampling and

analysis on the rotary kiln. This measuring gas is further purified in a heated dust filter and

fed to the analysis system. In regularly intervals or on request the dust filter and the

extraction pipe can be blown out by means of backpurging using compressed air. The

cooled gas extraction probe is mounted on a pneumatic-driven retraction unit. In case of

malfunction the probe is automatically withdrawn to prevent damage. A programmablelogic controller executes all control functions.

Fig. 2.1 SMC-9004H gas analyzer system

2.2 System composition

2.2.1 Automatic retraction device with probe

This device consists of a permanently fixed slide rail and a mobile carriage on which the

extraction probe and dust filter are mounted. The probe can be inserted or withdrawn by a

pneumatic drive either manually or automatically. In the case of power failure the probe is

withdrawn automatically to protect it. The probe pipe is made of steel that can withstand

high temperature. The gas extraction pipe can be blown out by means of backpurging

using compressed air. The dust filter is heated to prevent deposits forming. The purging of


9/26



the filter ensures long maintenance-free service life. The filter can be maintained or

exchange quickly and easily.

2.2.2 Heat exchanger equipment

This equipment is designed for cooling of the probe. It is connected to the gas sampling

probe unit through steel tubing. The unit consists of a stainless steel frame in which the

components of oil heat exchanger are placed. The cooling equipment contains oil with a

high boiling temperature. The equipment can controls the cooling liquid temperature

automatically by the heat exchanger fan.

T-07 is a liquid container. There is a level switch in it. When the liquid is not enough, an

alarm signal will be sent to PLC. By running pump PY-1, liquid in the system flows through

probe, filter F 11 and hand valve HV-13 by constant flow rate. The flow rate can be

adjusted a value between 1.5 and 3.5m3/h by throttle valve TV-12. Cooling liquid flows

into heat exchanger and hand valve HV-08 from probe and back to pump. Temperature

sensor TC-1 is used to measure temperature of cooling liquid in the back of probe and

send signal to temperature controller TK-1. The controller controls automatically the

speed of fan of heat exchanger by inverter BP-1 so as to adjust temperature of cooling

liquid. When system starts, valve HV-14 should usually open for a while so as to vent gas

in the pipe. Hand valve HV-09 is used to vent liquid in the system. When the pump PY-1 or

the filter F-11 is checked, valve HV-08 and Hv-13 should be closed.

2.2.3 Analysis and control unit

The analysis and control unit comprises a cabinet in which the preprocessing parts, the

controller and the analyzer are placed.

Consists of:

Cabinet

Filter, compressed condenser, sampling pump, flow meter

Calibration system(solenoid valve, pressure-adjusted filter, gas sources etc.

Drainage system (solenoid valve)

Back flushing system (solenoid valve)

Distribution and control system (PLC, 24V power supply, switches, wiring terminals)

2.2.4 Compressed air system

It is made up of air tank and filter parts. It is used to supply gas source for backflushingand pneumatic device.


10/26



2.3 System configuration

SMC-9004H system configuration

1Automatic retraction device with probe:

Sample probe

Automatic retraction device

A3 control box

1 set

2Heat exchanger unit

A2 control box

1 set

3Analysis and control unit:

Cabinet A3

Back flushing unit

Calibration unit

Control and data processing unit

Analyzer

1 set

4Compressed air system:

Gas holder with compressed air

Filter parts

1 set


11/26



2.4 Technical data

Measured value acquisition

Parameters

measured

Gaseous contaminant

O2, CO, NOx

Measuring range CO:0-2%;

O2:0-10%/0-21%;

NO:0-2000ppm;

Measuring precision 1%

Response time1)

60s while the length of sample line 30m

Connection

Analog output Isolated output 4-20mA Maximum resistive load750

Relay output Load capacity: 230VAC, 5A

Digital input Dry contact; 230VAC/5A

Power supply4)

sampling probe 220VAC/50Hz 500W/set

sampling pipeline 220VAC/50Hz 35W/m

SMC-9004H cabinet 380VAC/50Hz (3Ph+N+PE) 9000W

Dimension

Automatic retraction

device (LWH)400010001500mm

Heat exchanger unit

(WDH)11008102200mm

SMC-9004H cabinet

(WDH)12008002100mm

Gas holder 200L

Remarks1)

Response time is related to the length of sample pipeline.


12/26




3 Installation

System installation

Electrical installation

Installation of Trace Heated Line


13/26



3 Installation

3.1 Probe retraction device

3.1.1 Insertion tube installation

Procedures:

Affirm and mark installing point

Remove the seal (if have)

Make a suitable hole in fluerefer to flange diameter

Insert insertion tube, pay attention to the position of fixed hole.

Weld insertion tube into sample point.

3.1.2 Automatic retraction device installation

The assemble retraction device should be placed closed to the measuring point (see

attached drawing of the system).

3.2 heat exchanger equipment installation

The heat exchanger equipment should be closed to the retraction device. By placing the

device it must be in consideration that there will be periodically service routines which

must be done. The location should be easy to maintenance and protected wind and rain.

It includes 4pcs. Hoses with DN25 PN1.6 flange, 1 meter length, for flexible connection

between the retraction device and the heat exchanger device.

3.3 Analysis cabinet installation

3.3.1 Assembly of system cabinet

System cabinet should located in analytical house where. There is no strong

electromagnetic interference and mechanical vibrationTry to keep closer to the sampling

point if possible. Analytical cabinet could locate by the weight of itselfor make use of the

4 mounting holes,aperture1630, at the bottom of the cabinet. The cabinet could fixed on

the steelchannel supporting.

Gas outlet tubeGas outlet tube need to install on the top of analytical cabinet to makesure measured gases safely flow out of the room.

Important

The system is not an explosion-proof system. Please do not operate the

system in explosion hazard.

3.3.2 Assembly of sample pipeline

Routing and mounting of sampling pipeline:

Sampling pipe can be laid out in the power cable tray, but need to separate from power

cables. Sampling pipe should be fastened with cable tray every 2m in horizontal directionand every 1.5m in vertical direction, the minimal bending radius is 0.5m. in order to extend


14/26



life time of sampling pipe please try to avoid the direct sunlight.

From sampling probe to Gas Analyzer, the incline degree of complex sampling pipe

should be higher than 1%,

Or

Binding sampling pipe with a steel rope, and fixing the steel rope on stack. Special

measures need to be taken to guarantee the sampling pipe will not be scratched by stack

wall.

Sampling pipe and span gas pipe need to be back flushed at least 2 or 3 times before

connecting into the system, a leakage test for the whole system must be conducted after

these back flushing.

3.3.3 Installation of pneumatic pipe

Calibration gases are lead to Cal gas 1, Cal gas 2and Cal gas 3respectively via

nylon pipes of 6 mm in diameter, which are provided by the manufacturer.

Vent, exhaust and drainage outlet are leaded outside with nylon pipes of 6 mm in diameter,

which are provided by the manufacturer.

Sampling point and sampling gas inlet of the cabinet are connected with pipe of 6 mm in

diameter.

3.4 Installation of compressed air system

The compressed air tank should be placed close to the probe retraction device.

The 200L tank ensures sufficient air for blowing back and retraction.

One pipe offered by factory which diameter is 12 mm is used to connect decompression

filter with sampling probe device (see attached flow chart).Galvanized steel pipe offeredby customer is employed and fixed to connect Compressor air pipe and entry of filter.

3.5 Electric installation

3.5.1 Installation of power supply wire

Through power wire bore at bottom of cabinet backboard, power supply wire is

supposed to be lead to air-break switch of power supply. The wire should be three-core

cable, which has a diameter no less than 4 mm2. Please make sure that the live wire,

neutral wire and ground wire are correctly connected respectively.

3.5.2 Installation of signal wire

The signal cable should be connected according to the system interface drawing.

3.5.3 Part electrical wire

The system includes analysis cabinet (A1), heat exchanger control box (A2)probe

retraction control box (A3) and probe retraction heat tracing distribution box. The attached

electrical connection should follow the electrical drawings of the system.
http://dict.cnki.net/dict_result.aspx?searchword=%e9%95%80%e9%94%8c%e9%92%a2%e7%ae%a1&tjType=sentence&style=&t=galvanized+steel+pipehttp://dict.cnki.net/dict_result.aspx?searchword=%e9%95%80%e9%94%8c%e9%92%a2%e7%ae%a1&tjType=sentence&style=&t=galvanized+steel+pipe


15/26




4 Commissioning and Parameterization

General

System calibration

Running mode


16/26



4 Commissioning and Parameterization

4.1 General

4.1.1 Prerequisite

Make sure electronics components are connected properly before start-up.

Make sure pneumatic circuit are properly connected before start-up.

Important

Check-up safety measures before electricity switch on.

4.1.2 Basic procedures

Turn on the switch F1~F14 respectively after turning on main power switch F100 and

then check if system works well. Turn on the switch F101 of oil pump 10 minutes after

switch F103 is on. Turn on the switch F102 of heat exchanger and check the inverter

works well. Be sure the circuit breaker F101 for circulation pump and the circuit breaker

F102 for heat exchange fan cannot be switch on until the oil circuit is filled with oil.

Power on S710SIDORanalyzer. Wait few minutes for preheating and initiation.

Waiting few minutes for compressor cooler until targeted cooling temperature Is reach

(normally 2-5 degree C).

Operation can be carry out if everything is normalno alarm.

4.2 System calibration

When the button PLC startupis in up state, the calibration or manual operation can be

carried out. When press the button Cal. valve, the system will be into calibration mode

(the lamp of Cal. valveis light. Choose the component need to be calibrated by pressing

the corresponding button of calibration gas.

Normally, the first step is to calibrate the zero point of standard gas in the analyzerPress

the button Cal. gas 1, the lamp of Cal. gas 1will be light. ValveY3will switch on so

that zero gas N2 can be supplied to gas analyzer. In this case, gas flow can be adjusted

by Sample flowmeterand vent flowmeter to meet requirement.gas flow of analyzer

show normal, sample flow is 0.5L/minthen zero point calibration of analyzer can becarried out.

Press the button Cal. gas 1to Return to the original state after zero point calibration (the

lamp of Cal. gas 1will be off. Then Gas Valve N2Y3switch off.

But the job of calibration has not been finished at the moment yet.

Step 2Press the button of Cal. gas 2, the lamp of Cal. gas 2will be light and the

calibration gas valve Y4 will switch on. Then adjust the flowmeter to meet the requirement.

After that, the span calibration can be carried out. After the calibration, press the button of

Cal. gas 2, the corresponding lamp and valve will switch off.

Step 3Press the button of Cal. gas 3, the lamp of Cal. gas 3will be light and the

calibration gas valve Y5 will switch on. Then the calibration of corresponding gas can be


17/26



carried out. The gas flow requirement also should be met in the process.

Warning

The port of calibration gas is on the side of the cabinet. The calibration gas

cylinder should be correctly connected with the corresponding port

according the drawing. The adjusted valve should be open before the

calibration. The calibration gas is harmful to body so that the adjusted

valve should be close after the calibration is done.

When the foregoing things are done, press the button Cal. valve. The lamp of Cal.

valvewill be dark and the calibration is finished.

4.3 Running mode

When system is in normal state, switch on the PLC Startupand the system is ready for

sampling.

When the S20 handle switch on the sampling probe device is switched to auto position,

system will be in auto-sample auto-run mode. Open the baffler in the furnace mouth and

then click the S21 button, the probe will get into the sampling point. When the probe get to

the sampling point, a probe in signal will be sent to PLC and then system will start

sampling. When you click the S22 button, the probe will be back from sampling point.

When the probe has got back completely, a probe outsignal will be sent to PLC and then

close the baffler in the furnace mouth.

When the S20 handle switch on the sampling probe device is switched to manual position,

system will be in manual-sample auto-run mode. Open the baffler in the furnace mouth

and then press the S21 button, the probe will get into sampling point. When you release

the S21 button, probe will stop entering and system will start sampling. When the probe

get to the sampling point, a probe insignal will be sent to PLC. When you press the S22

button, the probe will get back from sampling point. When you release the S22 button,

probe will stop exiting. When the probe has got back completely, a probe outsignal will

be sent to PLC and then close the baffler in the furnace mouth.

When system is in run mode, sampling gas flow should be adjusted to 0.5L/min, venting

flow should be adjusted to 0-1L/min. Bypass flow should be adjusted to maximum, after

there are sampling gas flow and venting flow.

When the switch PLC START-UP is off, system will be into manual mode. You can

calibrate analysis instruments and do some manual functions.


18/26



In an emergency, e.g. cooling oil circuit fails or in case of a cooler fault, the gas sampling

probe is retracted from the sample point by the emergency retraction function to protect

the probe. The emergency retraction command has the highest priority (higher than

commands issued from on-site control box). In the control analysis cabinet, the alarm is

indicated by the red indicator lamp H17. The red indicator lamp H19 on the on-site control

box also indicates that an alarm is present.

The reason for the emergency retraction should be checked from the cabinet and onsite.

Emergency retraction is carried out in the following situations: Cooling oil over-heat alarm,

Oil level low alarm from Liquid storage tank, Cooling oil flow low ,Frequency inverter alarm

for cooling fan, Sample gas cooler alarm, Circuit breaker alarm, Power failure, When

EMERGENCY STOP is actuated.

To clear the alarm, carry out the following steps: Identify the reason for the emergency

retraction. Rectify the fault. Press the button S19 (Reset alarm) on the on-site control box.

If faults are still present, the system returns to 'fault'. Once you have rectified all the faults

and acknowledged them by pressing S19 on the on-site control box, the probe can be

inserted into the inlet chamber again via the control of the button S21 (probe in).

Emergency retraction can also be triggered by actuating the EMERGENCY STOP switch

in the control cabinet or on-site control panel.


19/26




Maintenance

General introduction

System daily maintenance

Maintenance and Operation of infrared analyzer


20/26



5. Maintenance

5.1 General introduction

Daily maintenance is a crucial job which insures safety and stable running of SMC-9004M

gas analyzer system.From maintenance point of view, preventive maintenance is always

better than corrective action when issue happened.

System daily maintenance contains:

patrol inspection periodic draining and cleaning

heat preservation and heat tracing troubleshooting

Interval of daily maintenance

Interval time of maintenance - which is affected by dust concentration, type of dust,

sampling gas temperature, programs developed and field environment - is set up byoperators. Hence, this parameter setting should follow experts advice. Generally

speaking, system maintenance should be carried out every 2-6weeks, and maintenance

results should be documented.

Maintenance protocol

Periodic maintenance should be carried out by experienced operators, or this

maintenance work can be contracted to SICKMAIHAK service team, SICKMAIHAK can

provide out customer with professional maintenance services.

5.1.1 Patrol inspection

Check system apparatus display and recordkeeping in touch with operators to know

system working status.

Check power supply, gas source (including compressed air, calibration gas).

Check heat strip inside sampling pipe.

Check corrosion situation for components and connectors of pretreatment part, repair

or replace defective parts.

Check leakage for joint parts of between system and flue.

5.1.2 Periodic draining and cleaning

Periodic draining and cleaning is not necessary for all parts. Maintenance period can be

decided upon actual conditions.

This task is mainly targets on sampling probe, sampling pipe, dust filter and so on. The

measuring values will be affected directly or indirectly since dust particulate, oil droplets

will deposit in measuring pipe of these devices.


21/26



Warning

(1) Before maintenance, related technologists and operators should be

informed and certain permission should be gotten.

(2) System should be put into manual mode.

(3) Be careful for electric shock and high temperature during maintenance.

(4) Seal all parts tightly after cleaning.

5.1.3 Heat preservation and heat tracing

Check heat preservation, heat tracing of system is an important task of daily maintenance

which related to correctness of measured data and normal running of system.

5.2 System daily maintenance

Periodic system maintenance is necessary to make sure proper running of our system.

5.2.1 Daily check-up

The main task of daily check-up is patrol checking to find out systematic abnormity and

solve it.

5.2.1.1 Check up sampling gas flow volume before flowing into gas analyzer.

Sampling gas flow volume should be between 0.5 and 0.8L/min, and can be adjusted by

flow meters. It shows that sampling pipe has been blocked if adjusting flow meters still

cannot drop back into the range, the common blockage cause is probe filter, if this is the

case probe filter needs to be replaced.

5.2.1.2 Check up coolers temperature display

Working temperature should be between 2-5, if temperature exceeds this range,

system shall be stopped immediately for trouble-shooting, otherwise gas analyzer may be

damaged.

5.2.1.3 Inspection measuring value of Analyzer

A leakage is believed on gas line if the SO2 measurements show that measuring value is

very low (or high oxygen content), suitable leak detection methods need to find a leak

point. If the system has no leak point and the measuring value is still abnormal that

Analyzer needs to be calibrated using the standard span gas

5.2.1.4 Check up pressure of compressed air.

System may not work properly if the pressure is lower than 0.4 MPa.5.2.1.5 The condition of heat exchanger unit should usually be checked to ensure that

there is no oil leakage. Check the flow of oil cooling system and make sure it is more than

3.2m3/h. Check the temperature of the cooling oil. Check the oil level switch signal. If the

oil level in the oil tank is very low, oil should be filled in the tank.

5.2.1.6 The condition of sampling probe device should usually be checked to ensure that

there are no broken parts. The dust on the probe tube should be usually clean.


22/26



5.2.3 Analytical system maintenance list

Item Maintenance Task 1day 30days 180days

1 Check up running state of

analyzer system

Y

2 manual calibration 1) for zero

point, span point

Y

3 Check up leakage of pipeline Y

4 Replace /check up filter2)

Y

Remarks

Calibration gas buying: Preparing to buy when gas pressure lower than

10bar, and stop using when gas pressure is lower than 1bar.

Concentration of Calibration gas should be between 80% and 100% of

full measuring range.

Note 1): increase /reducing times if necessary

Note 2): according to actual condition

5.3 Infrared analyzer maintenance

5.3.1 Manual calibration zero point and span point of infrared analyzer

Manual calibration of Infrared analyzer S700SIDORis in menu 42, refer to S700

SIDOR

Calibration parameter settings of Infrared analyzer S700SIDORis in menu 632, refer to

S700SIDORinstruction in paragraph 7.5.4.

5.3.2 Zero point calibration

Zero point calibration gas N2 from cylinder can calibrate zero point of all the

component.

First of all, press the button Cal valvethen indicator light of Cal valvewill be light,

system will be into calibration mode(refer to chapter 4.2 system calibration).

Adjust reducing valve of the calibration gas cylinder to make gas flow stay at 0.5L/min

enter S710 analyzer menu 42input corresponding zero point number of standard

componentstart up zero point calibration by pressing button Enterthen operate

according to the clue on the screen. Save the calibration result if done well or cancel the

operation by pressing the button Esc.

5.3.3 Span point calibration

First, press the button Cal valveand the indicator light will on, system will into calibration

mode. Connect the calibration gas to calibration gas inletopen the valvethen adjust

reducing valve to make gas flow stay at 0.5L/minenter analyzer S710 menu 42input the

calibration component number. Start up zero point calibration by pressing button Enter

then operate according to the clue on the screen. Save the calibration result if done well or

cancel the operation by pressing the button Esc.


23/26




6Trouble shooting

Trouble-shooting for probe retraction device

Trouble-shooting for heat exchanger device

Trouble-shooting for heated sample line

Trouble-shooting for analyzer cabinet


24/26



6. Trouble shooting

6.1 Trouble-shooting for probe retraction device

Malfunction

phenomenon

Possible cause Solution

Probe do not heat

up

Power supply dose not switch onSwitch on power supply and fix

correctly

Heating part damage inside probe or

short circuit occurred inside probe

Examining the short circuit or

open circuit by multi-meter

Contact supplier

Block of probe

filter

Poor maintenance Cleaning or replace the probe

filter

Block of probe

staff

Dust concentration is too high, effect

of Back Flushing is not good.

Cleaning

Random trip of air

switches

Short-circuit inside probeChecking by multi-meter,

replace it if necessary.

Air switch broken Replace it

Probe dont

retract

The pressure of gas tank is low Supply proper compressed air

There is leakage Find and repair it

6.2 Trouble-shooting for heat exchange device

Malfunction

phenomenon

Possible cause Treatment

Oil pump cant

run

Power supply dose not switch on Power on and fix correctly

The pump is broken Repair it

thermometer, flow

meter dont work

Power supply dose not switch on Power on and fix correctly

It is broken Repair it

6.3 Trouble-shooting for heated sample pipe

Malfunction

phenomenon


Do not heat up

Power supply dose not switch onSwitch on power supply and fix

correctly

Heating strip damagedExamining it by multi-meter,

replace it if necessary.

Block of pipe Poor maintenance

Cleaning: disconnect sampling

pipe from system on both

sides, connect with

compressed instrument air,

carrying out back flushing

function.


25/26



6.4 Trouble-shooting for analyzer cabinet

Malfunction

phenomenon


Power supply lost

in cabinetPower supply dose not switch on

Switch on power supply and fix

correctly

Check ON/OFF position for

power supply switches

Button (on front

panel of cabinet)

function does not

work

And

Channel indicator

of all PLC inputmodules is blind.

Push button broken Replacing push button

PLC 24 VDC power supply damaged Replacing 24VDC power

supply

24 VDC power supply disconnected Check wiring

Button (on front

panel of cabinet)

function does not

work

And

Some channel

indicator of PLC

input module is

light, but channel

indicator of all

PLC output

modules is blind

PLC damage Replace PLC

PLC program lost Download PLC program

Alarm occurredIdentifying and eliminating

alarm

Button (on front

panel of cabinet)

function does not

work

And

Some channelindicator of PLC

input module and

output module is

light

Devices controlled by PLC are

damageReplace damaged devices

power of devices controlled by PLC islost

Check wiring


26/26


Malfunction

phenomenon


Measuring value

is incorrect:

Eg. CO/NO valuelooks lower but

O2 looks higher.

Leakage happened in sampling line, possible leaking point:

components before sampling pump, intake connector

Seal ring of sampling probe damaged Replace seal ringLeakage happened on back flushing

connector

Reseal

Sampling solenoid valve damaged Replace with new one

Leakage happened on sampling

solenoid valve

Replace with new one

Pump diaphragm damaged Replace with new one

Connector of negative pressure loose

or damaged

Check up, tighten or replace

Sampling gas

flow is low

1. Sample pump malfunction

Sample pump diaphragm damaged Replace diaphragm

Sample pump damage Replace sample pump

Inlet diaphragm of sample pump

damage

Replace inlet diaphragm

2. Leakage happened on Sampling line, possible leaking point: components

behind air pump, connectors

Connector flexible or damage Check uptighten or replace it

3. Gas line obstructedpossible part

sampling probe element Clean or replace

condensing cylinder Cleaning

three-way magnetic valve Clean or replace it when

necessary

obstruction of needle valvebulb wall

float

Cleaning

1. 7132249a.01 analyzer system manual v1.0 (kiln inlet)

Documents