7. 7132249b.03&04 analyzer system manual v1.0 (fine coal silo)

Analyzers and Process Instrumentation

SMC-9004D Gas Analyzer System

Operating Manual

（Fine coal silo）

SICK MAIHAK (Beijing) Co.,Ltd.

Version 1.0

SMC-9004D Gas Analyzer System（Fine coal silo）

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 ......................................................................... 5

2 Product Description ..................................................... 7

2.1 Working principle ................................................................................................. 7

2.2 System composition ............................................................................................ 7

2.2.1 Sampling unit ........................................................................................................... 7

2.2.2 Sampling gas transmission unit ................................................................................ 7

2.2.3 Sampling gas pre-treatment unit .............................................................................. 8

2.2.4 Sampling gas analysis unit ....................................................................................... 8

2.3 System configuration ........................................................................................... 8

2.4 Technical specification ........................................................................................ 9

3 Installation .................................................................. 11

3.1 System installation ............................................................................................. 11

3.1.1 Install flange with pipe ........................................................................................... 11

3.1.2 Assembly of sample pipeline.................................................................................. 11

3.1.3 Assembly of system cabinet ................................................................................... 11

3.1.3 Installation of pneumatic pipe ................................................................................ 12

3.2 Electric installation ............................................................................................. 12

3.2.1 Installation of power supply wire ........................................................................... 12

3.2.2 Installation of signal wire ....................................................................................... 12

3.3 Installation of Trace Heated Line ...................................................................... 12

4 Commissioning and Parameterization ....................... 14

4.1 General ................................................................................................................ 14

4.1.1 Prerequisite ............................................................................................................. 14

4.1.2 Basic procedures .................................................................................................... 14

4.2 System calibration.............................................................................................. 14

4.3 Manual mode ....................................................................................................... 15

4.3.1 Manual sampling .................................................................................................... 15

4.3.2 Manual back flushing ............................................................................................. 15

4.3.3 Manual drain .......................................................................................................... 15

4.4 Auto mode ........................................................................................................... 15



4.5 Parameter setting ............................................................................................... 16

5. Maintenance ............................................................. 18

5.1 General introduction .......................................................................................... 18

5.1.1 Patrol inspection ..................................................................................................... 18

5.1.2 Periodic draining and cleaning ............................................................................... 18

5.1.3 Heat preservation and heat tracing ......................................................................... 19

5.2 System daily maintenance ................................................................................ 19

5.2.1 Daily check-up ....................................................................................................... 19

5.2.2 Analyzer system maintenance list .......................................................................... 20

5.3 Infrared analyzer maintenance ......................................................................... 20

5.3.1 Manual calibration zero point and span point of infrared analyzer ........................ 20

5.3.2 Zero point calibration ............................................................................................. 20

5.3.3 Span point calibration ............................................................................................ 20

6. Trouble shooting ....................................................... 22

6.1 Trouble-shooting for sample probe .................................................................. 22

6.2 Trouble-shooting for analyzer cabinet ............................................................. 22

6.3 Trouble-shooting for analyzer cabinet ............................................................. 23

Note

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

system for fine coal silo (1 measurement point).



1 Safety Information

1.1 Application objective

SMC-9004D 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 needed，such as data for maintenance and

measurement.

1.2 Authorized operator

Comply to the regulations strictly，make 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. Moreover，he could make a judgment and take an emergency

action to avoid potential risk in time. Operators should be familiar and passed

industry standard of DIN VDE0105, IEC 364 or other equivalent standard.

Operators should know the possible risk during operation，such as hot, toxic

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

Therefore，the 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 people’ life

Read this chapter carefully，comply to SMC-9004D safety rules and pay more

attention 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.



1.3.1 Power supply safety

Industry power supply is used for SMC-9004D 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-9004D system will remain 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.

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.




2 Product description

Working principle

System composition

System configuration

Technical data



2 Product Description

2.1 Working principle

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

analysis of cement plant. The analyzing system includes back-purgable sampling probe,

heated sample gas line, gas cooler, special powerful sample gas pump, filters, valves and

analyzer S710 (SIDOR). The sample pump draws the process gas from sample point,

through the sampling unit, transmission unit and pretreatment unit, and then into the

infrared analyzer. Thus, it can fulfill difficult measuring tasks with high dust loads or high

water content. If multiply sample points are required, the system can also be modified to

switch between several measuring points. In regularly intervals or on request the dust

filter and the probe can be blown out by means of backpurging using compressed gas. A

programmable logic controller executes all control functions. Thus, it can be adapted to a

wide variety of measuring tasks. This system is an elementary and economic solution for

standard applications.

Fig. 2.1 SMC-9004D gas analyzer system

2.2 System composition

2.2.1 Sampling unit

The sampling probe of SMC-9004D system is SMC-205 sampling probe.

2.2.2 Sampling gas transmission unit

We take heated sample pipeline made by SICKMAIHAK as sampling gas transmission

unit.



2.2.3 Sampling gas pre-treatment unit

SICKMAIHAK SMC-9004D system sampling gas pretreatment unit

Consists of:

Cabinet (the dimension is 2000×700×600 mm)

Filter, compressed condenser, sampling pump, flowmeter

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

Drainage system (solenoid valve)

Back flushing system (solenoid valve)

Distribution and control system (PLC, switches, wiring terminals)

2.2.4 Sampling gas analysis unit

S700 series infrared gases analyzer of SICKMAIHAK have been put to use in many

places with its newly modular design. Different parameters could be measured (such as:

CH4, NOX, CO, O2 etc.)

2.3 System configuration

SMC-9004D system configuration

（1）Sampling probe SMC-205 1 set

（2）Sampling pipeline 1 set

（3）Pretreatment unit

Cabinet

Back flushing unit

Calibration unit

Control and data processing unit

1 set

（4）Analysis unit 1 set



2.4 Technical specification

Measured value acquisition

Parameters

measured

Gaseous contaminant

O2, CO,

Measuring range CO:0-2000ppm;

O2:0-10%

Measuring accuracy ±1%

Response time 1)

＜60s while the length of sample line ≤30m

Connection

Analog output Isolated output 4-20mA; Maximum resistive load 750Ω

Relay output Load capacity: 230VAC, 5A

Digital input Dry contact; 230VAC/5A

Power supply

sampling probe 230VAC/50Hz 500W/set

sampling pipeline 230VAC/50Hz 35W/m

SMC-9004D cabinet 230VAC/50Hz 1000W

Dimension（width×height×thickness）

sampling tube external diameter Ø63 ; pipe diameter 2-Ø6, 1- Ø8

SMC-9004D cabinet 2000×700×600（mm）

Remarks: 1)

Response time is related to the length of sample line.




3 Installation

System installation

Electrical installation

Installation of Trace Heated Line



3 Installation

3.1 System installation

3.1.1 Install flange with pipe

Procedures:

Affirm and mark installing point

Remove the seal (if have)

Make a suitable hole on sample point（refer to flange diameter）

Insert flange (with pipe), pay attention to the position of fixed hole.

Weld flange into sample point.

Note

Seal flange holes quickly to prevent leakage once installation completed.

If possible, heat preservation measures can be taken for parts exposed in

air.

After the flange is installed, the probe can be installed.

3.1.2 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 direction

and every 1.5m in vertical direction, the minimal bending radius is 0.5m. in order to extend

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.

3.1.3 Assembly of system cabinet

System cabinet is recommended to locate inside shelter where there is no strong

electromagnetic and no mechanical vibration.

In order to shorten response time system cabinet location should be as close as possible

to the sampling point. The cabinet can be located by itself‟s weight or by 4 bolts (M14)

fixing on steel supporting baseplate.

Ventilation pipe needs to be installed on the top of cabinet to ensure exhaust gas flow out

into air.



Important

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

system in explosion hazard.

3.1.3 Installation of pneumatic pipe

Calibration gases are lead to “Cal. gas 1”, “Cal. gas 2” and “Cal. gas 3” respectively 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 8 mm in

diameter. The port “Backflush gas 1” and “Backflush gas 2” are lead to the decompressors

with filter via nylon pipe of 8 mm in diameter. The compressed air line is connected to inlet

of the filter. The pipe for compressed gas is supposed to be prepared by the customer.

3.2 Electric installation

3.2.1 Installation of power supply wire

Through power wire bore at side 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.

3.2.2 Installation of signal wire

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

3.3 Installation of Trace Heated Line

When the sampling line is in environment of subzero degree Centigrade, the trace heated

line is needed to prevent the sampling line from clog by frozen water. One end of the trace

heated line is connected with the connection box of the filter, the other end is connected

with point 3 and 4 of the restrictor in the cabinet.




4 Commissioning and Parameterization

General

System calibration

Manual mode

Auto mode

Parameter setting



4 Commissioning and Parameterization

4.1 General

4.1.1 Prerequisite

① Make sure electronics components are connected properly before start-up.

② Make sure pneumatic circuit are properly connected before start-up.

Important

Check safety rules and earthing conductor before system power on!

4.1.2 Basic procedures

① Switch on the main power supply; the indicating lamp should be on. Power on the

compressor cooler and PLC in sequence, then check if they can work normally.

② Power on S710（SIDOR）analyzer. Wait few minutes for preheating and initiation.

③ Waiting few minutes for compressor cooler until targeted cooling temperature Is reach

(normally 2-5 degree C).

④ Operation can be carry out if everything is normal（no alarm）.

4.2 System calibration

The system should be calibrated regularly. The sampling or backflushing of system should

be stop before calibration (turn of PLC start button)

1）Open disconnection valves of zero gas cylinder and span gas cylinder. Adjust pressure

regulators of zero gas cylinder and span gas cylinder to regulate the outlet pressure to 0.2

MPa-0.4 MPa.

2) Switch 5-way valve to “Cal. gas 1” position; Open the shutoff valve of the pressure

regulator to feed zero gas; Adjust sample gas flow meter to 0.5 L/min; then zero point

calibration of analyzer can be carried out. After the zero point calibration is finished, shut

disconnecting valve of zero gas cylinder, let out reminder gas in the gas line, shut the

pressure regulator, shut disconnecting valve in the pressure regulator, shut the shutoff

valve of the pressure regulator. Zero calibration is done.


regulator to feed span gas 1; Adjust sample gas flow meter to 0.5 L/min; then span gas 1

calibration of analyzer can be carried out. After the span gas calibration is finished, shut

disconnecting valve of span gas 1 cylinder, let out reminder gas in the gas line, shut the


valve of the pressure regulator. Span gas 1 calibration is done.


regulator to feed span gas 1; Adjust sample gas flow meter to 0.5 L/min; then span gas 2

calibration of analyzer can be carried out. After the span gas calibration is finished, shut

disconnecting valve of span gas 2 cylinder, let out reminder gas in the gas line, shut the




valve of the pressure regulator. Span gas 2 calibration is done.

4) Switch 5-way valve to “Sample gas” position, the system is exited from calibration

status, the other function can be operated.

※ Attention! In the case of output pressure of gas cylinder exceeds 0.4 MPa, remainder

gas in the line should be let out and feeding pressure should be readjusted. Shut the

pressure regulator. Loosen the nut to let out reminder gas and then retighten it (Attention:

The gas is toxic).(To adjust the S710(SIDOR) according to the operating instruction).

4.3 Manual mode

There are manual buttons on the cabinet panel, which can complete many debugging or

testing operations. When the system starts up, the buttons “Cal. valve”, “maintenance”

and “PLC start” are in the up state (the corresponding lamps are dark). In this state, the

system is in manual mode. You can do the following operation in this mode.

4.3.1 Manual sampling

Press the button “Sample pump” and “Sample gas”. Then the manual sampling starts. You

can test if the sampling is normal in this state. Adjust the flowmeter “Sampling flowmeter”,

“Bypass flowmeter” and “Vent flowmeter” to meet the requirement. Normally, the flow of

sampling flowmeter should be 0.5L/min, the spare gas is vented by vent flowmeter. When

the manual sampling is running continuously for some time, the system will backflush the

sampling line automatically for clean it.

4.3.2 Manual back flushing

If press the button “Backflush”, the system will carry out the function of manual back

flushing to purge the pipeline and probe filter element. The backflush valve Y3 and Y4 will

open. The flush gas can flush through the filter element and over the filter surface. When

flush starts, the system will flush for 15S, and pause for 4S. The flush and pause will be

done continuously for 3 times.

4.3.3 Manual drain

Press the button “Drain”, then the drain valve2 Y1 and Y2 will open to drain the water.

4.4 Auto mode

When the system starts up and the buttons “Cal. valve” and “Maintenance” are up status

(the lamp of “Cal. valve” and “Maintenance” are dark.), press down the button “PLC start”

and then the system will be into the auto mode.

In auto mode, the system can accept the remote running signal. When the signal is on, the

system will automatically carry out the auto running function such as auto backflushing,

auto sampling, auto drain. When system starts sampling, firstly the corresponding line will

be backflushed automatically. Then the auto sampling will start. The sampling time are

calculated in the sampling process. When the sample time is gone, system will start



flushing automatically.

When the remote signal is off, you can execute the auto operation by the button “Sample

gas”.

When the backflushing is done in auto mode, the drain valves Y1 and Y2 will open

automatically to drain the water.

4.5 Parameter setting

The time for auto sampling interval and data update can be adjusted by the potentiometer

of PLC.

Parameter Set value Adjusted way

1 Auto sampling interval time 5min-30min PLC potentiometer 0

2 Data update time 0S-357S PLC potentiometer 1

In the initial set of the program, the data update time is set to 90S, and the auto sampling

interval time is set to 15 minutes approximately. When the parameter need be adjusted,

adjust the potentiometer.




5 Maintenance

General introduction

System daily maintenance

Maintenance and Operation of infrared analyzer



5. Maintenance

5.1 General introduction

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

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 by

operators. 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 record（keeping 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.



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 cooler’s 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.



5.2.2 Analyzer 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 S700（SIDOR）is in menu 42, refer to S700

（SIDOR）

Calibration parameter settings of Infrared analyzer S700（SIDOR）is in menu 632, refer to

S700（SIDOR）instruction 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, switch 5-way valve to calibration gas 1 position, system will be into zero gas

calibration status (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 42，input corresponding zero point number of standard

component, 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”.

5.3.3 Span point calibration

First, switch 5-way valve to calibration gas 2/3 position, system will be into span gas

calibration status. Connect the calibration gas to calibration gas inlet，open the valve，then

adjust reducing valve to make gas flow stay at 0.5L/min; enter analyzer S710 menu 42,

input 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”.




6 Trouble shooting

Trouble-shooting for sample probe

Trouble-shooting for heated sample line

Trouble-shooting for analyzer cabinet



6. Trouble shooting

6.1 Trouble-shooting for sample probe

Malfunction

phenomenon

Possible cause Solution

do not heat up

Power supply dose not switch on Switch on power supply and fix

correctly.

Heating strip damaged inside probe,

or short-circuit occurred inside probe

Examining the short circuit or

open circuit by multi-meter.

Replacing the heating strip.

Block of probe

filter

Poor maintenance Cleaning or replacing 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 probe Checking by multi-meter,

replace it if necessary.

Air switch broken Replace it

6.2 Trouble-shooting for analyzer cabinet

Malfunction

phenomenon


do not heat up

Power supply dose not switch on Switch on power supply and fix

correctly

Heating strip damaged inside

sampling pipe.

Examining 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.



6.3 Trouble-shooting for analyzer cabinet

Malfunction

phenomenon


Power supply lost

in cabinet Power 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 input

modules 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 occurred Identifying and eliminating

alarm

Button (on front

panel of cabinet)

function does not

work

And

Some channel

indicator of PLC

input module and

output module is

light

Devices controlled by PLC are

damage Replace damaged devices

power of devices controlled by PLC is

lost Check wiring



Malfunction

phenomenon

Possible cause Treatment

Measuring value

is incorrect:

Eg. SO2/NO

value looks 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 ring

Leakage 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 up，tighten or replace it

3. Gas line obstructed，possible part

·sampling probe element Clean or replace

·condensing cylinder Cleaning

·magnetic valve Clean or replace it when

necessary

·obstruction of needle valve，bulb wall、

float

Cleaning

7. 7132249b.03&04 analyzer system manual v1.0 (fine coal silo)

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