7132249A.01 Analyzer System Manual V1.0 (Kiln Inlet)

Analyzers and Process Instrumentation
SMC-9004H Gas Analyzer System

Operating Manual
Kiln inlet
SICK MAIHAK (Beijing) Co.,Ltd.

Version 1.0
SMC-9004H
Gas Analyzer Systemkiln inlet
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
SICK MAIHAK(Beijing)Co.,Ltd.
SMC-9004H
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.
SMC-9004H
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 passed
industry 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 people life
Read this chapter carefullycomply to SMC-9004M 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.
SMC-9004H
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.
SMC-9004H
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.
SMC-9004H
SMC-9004H
Gas Analyzer System
2 Product description
Working principle
System composition
System configuration
Technical data
SMC-9004H
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 programmable
logic 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
SMC-9004H
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 backflushing
and pneumatic device.
SMC-9004H
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
10
SMC-9004H
2.4 Technical data

Measured value acquisition
Parameters
measured
Gaseous contaminant
Measuring range
CO:0-2%;
O2:0-10%/0-21%;
NO:0-2000ppm;
Measuring precision
1%
Response time
O2, CO, NOx
1)
60s while the length of sample line 30m
Connection
Analog output
Isolated output 4-20mA Maximum resistive load 750
Relay output
Load capacity: 230VAC, 5A
Digital input
Power supply
Dry contact; 230VAC/5A

4)
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
Remarks
1)
Response time is related to the length of sample pipeline.
11
SMC-9004H
SMC-9004H
Gas Analyzer System
Installation
System installation
Electrical installation
Installation of Trace Heated Line
12
SMC-9004H
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 steel channel supporting.
Gas outlet tubeGas outlet tube need to install on the top of analytical cabinet to make
sure 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 direction
and every 1.5m in vertical direction, the minimal bending radius is 0.5m. in order to extend
13
SMC-9004H
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 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 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 offered
by 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.
14
SMC-9004H
SMC-9004H
Gas Analyzer System
Commissioning and Parameterization
General
System calibration
Running mode
15
SMC-9004H
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 startup is 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. valve is 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 1 will 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 flowmeter and vent flowmeter to meet requirement.gas flow of analyzer
show normal, sample flow is 0.5L/minthen zero point calibration of analyzer can be
carried out.
Press the button Cal. gas 1 to Return to the original state after zero point calibration (the
lamp of Cal. gas 1 will be off. Then Gas Valve N2Y3 switch 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 2 will 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 3 will be light and the
calibration gas valve Y5 will switch on. Then the calibration of corresponding gas can be
16
SMC-9004H
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.
valve will be dark and the calibration is finished.
4.3 Running mode

When system is in normal state, switch on the PLC Startup and 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 out signal 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 in signal 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 out signal 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.
17
SMC-9004H
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.
18
SMC-9004H
SMC-9004H
Gas Analyzer System
5 Maintenance
General introduction
System daily maintenance
Maintenance and Operation of infrared analyzer
19
SMC-9004H
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 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 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.
20
SMC-9004H
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.
21
SMC-9004H
5.2.3 Analytical system maintenance list

Item
Maintenance Task
Check up running
analyzer system
manual calibration
point, span point
Check up leakage of pipeline
Remarks
state
1)
Replace /check up filter
1day
of
for zero
2)
30days
180days
Y
Y
Y
Y
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 valve then indicator light of Cal valve will 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 valve and 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.
22
SMC-9004H
SMC-9004H
Gas Analyzer System
6 Trouble shooting
Trouble-shooting for probe retraction device

Trouble-shooting for heat exchanger device
Trouble-shooting for heated sample line
Trouble-shooting for analyzer cabinet
23
SMC-9004H
6. Trouble shooting
6.1 Trouble-shooting for probe retraction device
Malfunction
phenomenon
Probe do not heat

up
Possible cause
Solution
Power supply dose not switch on
Switch 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
filter
of
probe
Poor maintenance
Cleaning or replace the probe

filter
Block
staff
of
probe
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
Probe
retract
The pressure of gas tank is low
Supply proper compressed air
There is leakage
Find and repair it
dont
6.2 Trouble-shooting for heat exchange device

Malfunction
phenomenon
Oil pump
run
cant
thermometer, flow
meter dont work
Possible cause
Treatment
Power on and fix correctly
The pump is broken
Repair it
Power on and fix correctly
It is broken
Repair it
6.3 Trouble-shooting for heated sample pipe

Malfunction
phenomenon
Possible cause

correctly
Heating strip damaged
Examining it by multi-meter,
replace it if necessary.
Poor maintenance
Cleaning: disconnect sampling

pipe from system on both
sides,
connect
with
compressed instrument air,
carrying out back flushing
function.
Do not heat up
Block of pipe
Treatment
24
SMC-9004H
6.4 Trouble-shooting for analyzer cabinet

Malfunction
phenomenon
Power supply lost
in cabinet
Possible cause
Treatment
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
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
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
damage
controlled
by
PLC
are
power of devices controlled by PLC is

lost
24VDC
and
power
eliminating
Replace damaged devices
Check wiring
25
SMC-9004H
Malfunction
phenomenon
Measuring value
is incorrect:
Eg. CO/NO value
looks lower but
O2 looks higher.
Possible cause
Treatment
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
solenoid valve
on
sampling
Pump diaphragm damaged
Connector of negative pressure loose

or damaged
Check up, tighten or replace
1. Sample pump malfunction
Sampling
flow is low
gas
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 Cleaning

float
26

7132249A.01 Analyzer System Manual V1.0 (Kiln Inlet)

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

7132249A.01 Analyzer System Manual V1.0 (Kiln Inlet)

Enviado por

Direitos autorais:

Formatos disponíveis

Analyzers and Process Instrumentation

SMC-9004H Gas Analyzer System

SICK MAIHAK (Beijing) Co.,Ltd.

Gas Analyzer Systemkiln inlet

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

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

Gas Analyzer Systemkiln inlet

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

Gas Analyzer Systemkiln inlet

1.2 Authorized operator

1.3 Safety rules and measuring protection

Gas Analyzer Systemkiln inlet

1.3.1 Power supply safety

Gas Analyzer Systemkiln inlet

1.4 Symbols used in this document

Gas Analyzer Systemkiln inlet

Gas Analyzer Systemkiln inlet

Fig. 2.1 SMC-9004H gas analyzer system

2.2 System composition

Gas Analyzer Systemkiln inlet

Gas Analyzer Systemkiln inlet

2.3 System configuration

2Heat exchanger unit

3Analysis and control unit:

4Compressed air system:

Gas Analyzer Systemkiln inlet

2.4 Technical data

O2, CO, NOx

60s while the length of sample line 30m

Isolated output 4-20mA Maximum resistive load 750

Load capacity: 230VAC, 5A

Dry contact; 230VAC/5A

Heat exchanger unit

Gas Analyzer Systemkiln inlet

Gas Analyzer Systemkiln inlet

3.2 heat exchanger equipment installation

3.3 Analysis cabinet installation

Gas Analyzer Systemkiln inlet

3.4 Installation of compressed air system

3.5 Electric installation

Gas Analyzer Systemkiln inlet

Commissioning and Parameterization

Gas Analyzer Systemkiln inlet

4 Commissioning and Parameterization

4.2 System calibration

Gas Analyzer Systemkiln inlet

4.3 Running mode

Gas Analyzer Systemkiln inlet

Gas Analyzer Systemkiln inlet

Gas Analyzer Systemkiln inlet

5.1.2 Periodic draining and cleaning

Gas Analyzer Systemkiln inlet

5.2 System daily maintenance

Gas Analyzer Systemkiln inlet

5.2.3 Analytical system maintenance list

Check up leakage of pipeline

Replace /check up filter

5.3 Infrared analyzer maintenance

Gas Analyzer Systemkiln inlet

Trouble-shooting for probe retraction device

Gas Analyzer Systemkiln inlet

Probe do not heat

Power supply dose not switch on