Smart Analyzer 90

Transcript

Smart Analyzer 90 Page 1 Smart Analyzer 90 Type SMA PRODUCT INSTRUCTION Page 2 WARNING notices as used in this manual apply to hazards or unsafe practices which couid result in personal injury or death. CAUTION notices apply to hazards or unsafe practices which could result in property damage. NOTES highlight procedures and contain information which assist the operator in understanding the information contained in this manual. - WARNING INSTRUCTION MANUALS DO NOT INSTALL MAINTAIN OR OPERATE THIS EQUIPMENT WITHOUT READING, UNDERSTANDING AND FOLLOWING THE PROPER Bailey Controls INSTRUCTIONS AND MANUALS, OTHERWISE IN- JURY OR DAMAGE MAY RESULT. RADIO FREQUENCY INTERFERENCE MOST ELECTRONIC EQUIPMENT IS INFLUENCED BY RADIO FREQUENCY INTERFERENCE (RFII. CAUTION SHOULD BE EXERCISED WITH REGARD TO THE USE OF PORTABLE COMMUNICATIONS EQUIPMENT IN THE AREA AROUND SUCH EQUIPMENT. PRUDENT PRACTICE DICTATES THAT SIGNS SHOULD BE POSTED IN THE VICINITY OF THE EQUIPMENT CAUTIONING AGAINST THE USE OF PORTABLE COMMUNICATIONS EQUIPMENT. POSSIBLE PROCESS UPSETS MAINTENANCE MUST BE PERFORMED ONLY BY QUALIFIED PERSONNEL AND ONLY AFTER SECUR- ING EQUIPMENT CONTROLLED BY THIS PRODUCT. ADJUSTING OR REMOVING THIS PRODUCT WHILE IT IS IN THE SYSTEM MAY UPSET THE PROCESS BEING CONTROLLED. SOME PROCESS UPSETS MAY CAUSE INJURY OR DAMAGE. _ AVERTISSEMENT MANUELS ITOPERATION NE PAS METTRE EN PLACE REPARER OU FAIRE FONCTIONNER CE MATERIEL SANS AVOIR LU, COMPRIS ET SUIVI LES INSTRUCTIONS REGLEMENTAIRES DE Bailey Controls TOUTE NEGLIGENCE A CET EGARD POURRAIT ETRE UNE CAUSE D'ACCIDENT OU DE DEFAILLANCE DU MATERIEL. PERTURBATIONS DE LA FREQUENCE RADIOPHONIQUE LA PLUPART DES EQUIPEMENTS ELECTRONIQUES SONT SENSIBLES AUX PERTURBATIONS DE LA FREQUENCE RADIO. DES PRECAUTIONS DEVRONT ETRE PRISES LORS DE L'UTILISAT|ON DE MATERIEL DE COMMUNICATION PORTATIF. LA PRUDENCE EXIGE QUE LES PRECAUTIONS A PREN- DRE DANS CE CAS SOIENT SIGNALEES AUX ENDROITS VOULUS DANS VOTRE USINE. PERTES ROCEDE RENVERSEMENTS L'ENTRETIEN DOIT ETRE ASSURE PAR UN PERSONNE QUALIFIE ET EN CONSIDERATION DE L'ASPECT SECURITAIRE DES EQUIPMENTS CONTROLES PAR CE PRODUIT. UADJUSTMENT ETIOU L'EXTRAT|ON DE CE PRODUIT LORSQU'IL EST INSERE A UN SYSTEME ACTIF PEUT OCCASIONNER DES A-COUPS AU PROCEDE CONTROLE. SUR CERTAINS PROCEDES, CES A-COUPS PEUVENT EGALEMENT OCCASIONNER DES DOMMAGES OU BLESSURES. NOTICE The information contained in this document is subject to change without notice. Bailey Controls Company, its affiliates, employees, and agents, and the authors of and contributors to this publication specifically disclaim all liabilities and warranties, express and implied {including warran- ties of merchantability and fitness for a particular purpose), for the accuracy, currency, completeness, and for reliability of the information contained herein and,-‘or for the fitness for any particuiar use andior for the performance of any material andfor equipment selected in whole or part with the user offer in reliance upon information contained herein. Selection of materials andfor equipment is at the sole risk of the user of this pubiication. This document contains proprietary information of Bailey Controls Company, Elsag Bailey, Inc. and is issued in strict confidence. its use, or reproduction for use, for the reverse engineering, development or manufacture of hardware or software described herein is prohibited. No part of this document may be photocopied or reproduced without the prior written consent of Bailey Controls Company. Page 3 Preface This publication is for the use of technical personnel respon- sible for the installation. configuration, calibration. operation and maintenance of the Bailey Type SMA Smart Analyzer 90. It is important for safety and operating reasons to read and understand this manual. Until doing so, do not install or complete any tasks or procedures related to configuration, calibration or operation. This product instruction applies to software revision B10. Page 4 List of Effective Pages Total number of pages in this manual is 213, consisting of the following: Page No. Preface List of Effective Pages iii When an update is received. insert the latest changed pages and dispose of the super- seded pages. NOTE: On an update page, the changed text or table is indicated by a vertical bar in the outer margin of the page adjacent to the changed area. A changed figure is indicated by a vertical bar in the outer margin next to the figure caption. The date the update was prepared will appear beside the page number. through through through through through through through through through through through through through through through xiii 1-14 2-8 3-3 4-37 5-13 6-15 7-4 8-31 9-7 10-43 1 1-14 A‘-4 C-2 Indcx4 Change Date Original Original Original Original Original Original Original Original Original Original Original Original Original Original Original Original Original Original Page 5 Table of Contents Page INTENDEDUSER EQUlPMENTDESCRIP'TION................................ FEATURES/BENEFITS. EQUIPMENTAPPLICATION.......................-........ INSTRUCTIONCONTENT................................ HOWTOUSETHISMANUAL............................... GLOSSARYOFTERMSANDABBREVIATIONS......-............... REFERENCEDOCUMENTS...-............................ ACCESSOR.IES............... SPECIFICATIONS SECTION ‘I -INTRODUCTION . . . . . . . . . SECTION2-DESCRIPTIONAND OPERATION . . . . . . . . . . . . . .. FUNCTIONAL OPERATION ProbewithFilterAssembly Sense:-Assemb1y..I.......‘..................‘...... Cab1eAssernb1y...I..........................I...... Electronics Assembly OperatorInterface................................._ MicroprocessorcircuitBoard............................ ‘I‘erminationUnit{TU)CircuitBoard........................ Input/0utput[I/O)CircuitB0ard VaIveManifold.................................... 11111 INTRODUCTION.........I........................... INDICATORLIGI-YI‘S................................... KEYPAD INTRODUCTION-.......-......................‘...... UNPACKINGANDINSPECTION.............................. Unpacking Inspection STORAGE INSTRUCTIONS CUSTOMERSUPPLIEDITEMS . PREOPERATINGPROCEDURESOVERVIEW.................‘..... LOCATION CONSIDERATIONSAND SITE PREPARATION . . . . . . . . . . . . . . .. Sensor Assembly and Probe with Filter Assembly StandardProbewithFilterorDua1Filter...................... Optional High Temperature Probewith Filter CableAssembiyandTestGasTubing......................... BlectronicsAssemb1y TestGasCy1inders..........-.............-.......... Facilities.................................... Ele-ctricaIPower............-...................... SE'I‘UP/PHYSICALINSTALLATION ElectronicsAssemblyInstallation........................... SECTION 3 ~ OPERATOR INTERFACE . . . . . SECTION 4 - INSTALLATION Page 6 Table of Contents (continued) Page SECTION 4 - INSTALLATION (continued) Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Analog Outputs . . . . . I . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Inlet Thermocouple . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . 4-23 Preoperating Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Input 1 Output [1/ O] Circuit Board Switch Settings . . . . . . . . . . . . . . . . 4-24 Microprocessor Circuit Board Switch Settings . . . . . . . . . . . . . . . . . . 4-26 Termination Unit Circuit Board Switch Settings . . . . . . . . . . . . . . . . . 4-26 Test Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 4-28 Optional Blowback Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Test Gas Tubing and Flowmetcr . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Sensor Assembly and Probe with Filter Assembly . . . . . . . . . . . . . . . . . 4-30 Probe with Filter or Optional Dual Filter . . . . . . . . . . . . . . . . . . . . . 4-31 Optional High Temperature Probe with Filter . . . . . . . . . . . . . . . . . . 4-32 STARTING UP THE TYPE SMA ANALYZER . . . . . . . . . . . . . . . . . . . . . . . 4-34 OUTLET TI-IERMOCOUPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 SECTION 5 - CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-‘! INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 CONFIGURING THE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . - . 5- 1 SCREEN EXPLANATIONS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 5-I Setup Mode Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Setup Mode Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Installation Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Process Measurement Parameters [Analog Outputs] . . . . . . . . . . . . . . T . . 5-5 Alarm Low and High Limits [Digital Outputs) . . . . . . . . . . . . . . . . . . . . . 5-8 Thermocouples and Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . 5- 10 Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 12 RETURN TO OPERATE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . T . 5-12 SUMMARY TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 12 SECTION 6 - CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-‘I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 IN-SERVICE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 SCREEN EX‘.PLANA'I‘IONS AND PROCEDURES . . . . . . . T . . . . . . . . . . . . . . 6-1 Calibration Environment Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Sensor Assembly Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Sensor Assembly Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Sample Flow Rate Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Manually Initiated Calibration . . . . . . . . . . . . . . . . . . . . . _ . . . . . 6-9 Calibration Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-I0 Autocal Timer Initiated Calibration . . . . . . . . . . . . . . . . . . . . . . . . 6- 12 Blowback Solenoid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Manual Blowbaok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Automatic Blowback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 SUMMARY TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 14 SECTION 7- OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 7-‘! INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _. . . 7-l START-UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 I-E65-765 Page 7 Table of Contents (continued) Page SEC TION 7 - OPERATING PROCEDURES (continued) NORMAL OPERATIONS I I I I I I I I I I I . I I I I I I I I . . I . I I . I I I I . I I 7-1 SENSOR CALIBRATION I I I I I I I I . I I I I I I I I I I I I I I I I I I I I I I I I I 7~1 REMOTE INITIATED PROCEDURES [DIGITAL INPUTS} I I I . I I I I I I I I I I I I I 7-2 SCREEN EXPLANATIONS AND PROCEDURES I I I I I I I I I I I I I I . I I I I I I I 7-3. Operate Mode Access I I I . I . . I I I I I I I I I I I I I I I I I I . I I I I I I . I 7-3 Process Variables I I . I I I I I . I I I I I I . I I . I I I I I I I I I I I I . I I . . 7-4 SECTION 8 - TROUBLESHOOTING . . I I I . I I I I I I I . . . I I . I . I . I I I . I I 8-? INTRODUCTION I I I I I I . I I I I I I I I I I I I I . I I I I I I I I I I I I I I I I I 8-1 ERROR MESSAGES AND CORRECTIVE ACTION I I I I I I I I I I I I I I I I I I I I B-1 Alarm Signals [Digital Outputs] I I I I I I . I I I . I . I . I . I . I I I I I . I I I 8-2 Alarm Troubleshooting I I I I I . . . I I I I I I I I I I I I I I I I I I . I I I . I I 8-2 SECTION 9 - MAINTENANCE I I I I I I I I . I I I I I . I . I . . I . I I . . I I I I I I 9-‘! INTRODUCTION . I I I I I I I I I I I . I I . I I . I I I I I I I I I I I I I I I I I I I 9-1 MAINTENANCE SCHEDULE I I I I I I I I I I I I I I . I . I I I I I I I I I I . I I I I 9-1 PREVENTIVE MAINTENANCE I I I I I I I I I I I I I I I I I I I I I I I . I I I I I I I 9-1 Monthly I I I I I I I I I I I I . . I I I I I I I I I I I I I . . . I I . I I I I I I I I 9-2 Six Months or When the System is Out of Service I I I I I . . I I I I . . I I I I . 9-2 PROBE WITH FILTER ASSEMBLY BLOCKAGE CHECK I I I I I I I I I I I I I I I I I 9-2 SENSOR ASSEMBLY FLOW CHECK I I I I I I I I . I I I I I I I I I I I I I I I I I I 9-4 SENSOR ASSEMBLY LEAK CHECK I I I . I . I I I I I I I I I I I I I I . I . I . I . I 9-5 VALVE MANIFOLD BLOCK SOLENOID {V1 AND V2] CHECK I I I I I I I I I I I I I I 9-6 Valve Manifold Orifice Blockage Check I I I I I I I I I I I I . I I I I I . I . I I I 9-6 Solenoid Valves Check I . I . I I I I I I I I I I . I I . . I . I I I . . I I . I I I I 9-6 SECTION 10 - REPAIR/REPLACEMENT PROCEDURES I . I I I I I . I I I I I I I I I 10-1' INTRODUCTION I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 10-1 SENSOR ASSEMBLY INSTALLED ON THE PROCESS I I I I I I I I I . I I I I I I I I 10-2 Replacing the O2 Sensor I I I I I I I I I I I I I I I I I I I I I I I I I I I . I I I I 10-2 Replacing the CO: Sensor I I I I I I I I . I I . I I . I I I I I I I . I I I I I I I I 10-4 Replacing Flange Manifold Heaters HTR1 to I-ITR4 . I I I I I I I I I I I I I I I I 10-6 Replacing Flange Manifold Thermocouple T/C 2 I I I I I I . I I I I I I I I I I I I 10-7 Replacing COE Heaters HTR1 and HTR2 I I I I I I I I . . I I I . I I I I I I . I I 10-8 Replacing CO; Thermocouple T/C 1 I I I I I I I I . . I I I I . I I I I I I I I I I I 10-9 Replacing the Sensor Assembly Cold Junction Compensator [CJC) I . I . . I I I 10-10 Cleaning/Replacing the Sensor Assembly Orifices I . I I I I I I I I I I I I I I I 10-11 SENSOR ASSEMBLY REMOVED FROM THE PROCESS I I I I I I I I I . I I I I I 10- 12 Removing the Sensor Assembly I I I I I I I I I I I I I I I I I I I I . I . I I I I 10-12 Sensor Assembly Installation I I I I I I. I I I . I I I I I I I I I I I I I I . I I I 10-13 Repairing or Replacing the Standard Probe with Filter Assembly I I I I . I I I I 10-14 Cleaning or Replacing the Aspirator I I I I I I . I . I I I I I I I I I I I I . I I I 10-14 Replacing the Flow Disk I I I I I I I . I I I I I I I I I I I I I I I . I I I I I I I 10-15 Replacing the Internal Gaskets in the Type SMA2 Sensor Assembly I I I I I I I 10-17 Replacing the Cable Adapter I I I I I I I I . I I I I I I . I I . I . I I I I I I I I 10-19 Replacing the Cable Assembly I I I I I I I I I I I I I I I I . I I I . . I I I I I I 10-20 ELECTRONICS ASSEMBLY COMPONENTS I I I I I I I I I I I . I . . I I . I I I I 10-21 Replacing the Keypad . I I I I I I I I . I I I I I I I I I I . I I I I I I I I I I I 10-21 Replacing the Vacuum Fluorescent Display [VFD] I I I I I . I I I I I I I I I I I 10-23 Replacing the Microprocessor Circuit Board I I . I I I I I I . I I I I I I I I I I 10-24 Replacing the Input/Output [I/O) Circuit Board I . I I I I . . I I I I I I I I I I 10-25 Replacing Solenoid Valve V1 or V2 of the Valve Manifold Block I I I . I I I I I I 10-27 Replacing the Valve Manifold Block I I I I I I I I . I . I I I I I I I I I I I I I I 10-28 Replacing the Transformer I I I I I I I . I . I I I I I . I I I I I . . I I I I I I I 10-28 I-E65-765 V Page 8 Table of Contents (continued) Page SECTION ‘I0 - REPAIR/REPLA CEMENT PROCEDURES (continued) Replacing the Termination Unit [TU] Circuit Board . . . . . . . . . . . . . . . . 10-30 Replacing the RF] Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 NVRAM INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 ELECTRONICS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Setup Mode Calibration Environment . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Test Gas Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 AO1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 AO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 AO3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . . . 10-39 A04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 Electronics Assembly Cold Junction Cornpensator Calibration . . . . . . . . . . 10-41 Sensor Assembly Cold Junction Compensator Calibration . . . . . . . . . . . . . 10-42 SECTION ‘I1 - SUPPORT SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-? INTRODUCTION . . . . . . . . . . . . . . . . . . I . . . . . . . . . . . . . . I . . . 11-1 ORDERING REPLACEMENT PARTS AND KITS . . . . . . . . . . . . . . . . . . . . . 11-1 REPLACEMENT PARTS AND KITS . . . . . . . . . . . . . . . . . . . . . I . . . . . 11-1 Standard Parts and Kits . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . 11-1 Miscellaneous Parts and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 1- 12 APPENDIXA - OXYGEN SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 SENSOR VOLTAGE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Sensor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Partial Pressure of Oxygen on the Inside of the Sensor [Reference Air) . . . . . . . A-2 Partial Pressure of Oxygen on the Outside of the Sensor [Sample Gas] . . . . . . . A-2 OTHER ASPECTS OF OXYGEN MEASUREMENT . . . . . . . . . . . . . . . . . . . . . A-3 Net Versus Gross Oxygen Measurement . . . . . . . . . . . . . . . . . . . . . . . A-3 Wet Versus Dry Oxygen Measurement . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Comparing Oxygen Readings Between Analyzers . . . . . . . . . . . . . . . . . . . A-4 APPENDIX B - COe SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 CO¢ DEFINED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 WI-IY MEASURE COMBUSTIBLES AS COC . . . . . . . . . . . . . . . . I . . . . . . . B-1 ADDITION OF DILUTION AIR TO THE SAMPLE . . . . . . . . . . . . . . . . . . . . . B-l APPENDIX C - CALCULATING COMBUSION EFFICIENCY . . . . . . . . . . . . . . . . C-‘I INTRODUCTION . . . . . . . . . . . . . . . . . I . . . . . . . . . . . . . . . . . . . . C-1 Sensible 1-Ieat Loss in Dry Flue Gas . . . . . . . I . . . . . . . . . . . . . . . . . . C- I Sensible Heat Loss in the Moisture in the Air . . . . . . . . . . . . . . . . . . . . . C-1 Sensible Heat Loss in the H20 in the Fhel . . . . . . . . . . . . . . . . . . . . . . C-2 Latent Heat in the H20 in the Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Losses Due to Unburned Carbon in the Fuel [Ash] . . . . . . . . . . . . . . . . . . C-2 Losses Due to Cornbustibles in the Flue Gas . . . . . . . . . . . . . . . . . . . . . C-2 Other Losses (Radiation. Leakage of Outside Air, Blowdown, Soot Blowing, etc.) . . C-2 I-E65-768 Page 9 List of Tables No Title Page 1- 1. Glossary of Terms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . 1-8 1-2. Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1-3. Type SMA Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1-4. Accessory Part/Kit Number and Application . . . . . . . . . . . . . . . . . . . . 1- 10 1-5. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 3-1. Cursor Selection Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2. Zero and Span Gas Indicator Light {Yellow} . . . . . . . . . . . . . . . . . . . . 3-2 3-3. Alarm Indicator Light [Red] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-4. System Fault Indicator Light [Red] . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-5. Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 4-1. Digital Input Terminals and Descriptions . . . . . . . . . . . . . . . . . . . . . 4-20 4-2. Analog Output Terminals and Descriptions . . . . . . . . . . . . . . . . . . . . 4-21 4-3. Digital Output Terminals and Descriptions . . . . . . . . . . . . . . . . . . . . 4-22 4-4. Inlet Thermocouple Terminals and Location . . . . . . . . . . . . . . . . . . . . 4-23 4-5. Input/Output (1/ 0] Circuit Board Configuration Switches . . . . . . . . . . . . 4-25 4-6. Microprocessor Circuit Board Switches . . . . . . . . . . . . . . . . . . . . . . 4-26 4-7. Termination Unit Circuit Board Switches . . . . . . . . . . . . . . . . . . . . . 4-26 4-8. Test Gas Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 4-9. High Temperature Probe Length in Horizontal Applications Versus Process Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 4-10. Outlet Thermocouple Terminals and Location . . . . . . . . . . . . . . . . . . . 4-3'? 5-1. Sensor Assembly Cable Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5-2. Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . 5-12 6-1. Sensor Assembly Temperature Normal Operating Ranges and Alarm Limits . . . 6-4 6-2. Calibration Alarm Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 6-3. Sensor Assembly Pressure and Flow Data . . . . . . . . . . . . . . . . . . . . . 6- 14 6-4. Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 7-1. Remote Initiated Procedures [Digital Inputs] . . . . . . . . . . . . . . . . . . . 7-2 8-1. Alarm Signals [Digital Outputs] . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-2. Alarms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8-3. Suction Pressure and Sample Flow Rate Problems and Corrective Actions . 8-6 10-1. Resistance Check of Cable Adapter . . . . . . . . . . . . . . . . . . . . . . . 10-19 1 1-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1 11-2. CO Sensor Kit No. 258522_l . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 11-3. O2 Sensor Kit No. 258418_2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 11-4. Heater and Thermocouple Kit No. 258521_l . . . . . . . . . . . . . . . . . . . . 11-2 11-5. Seals Kit No. 258517_l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 11-6. Covers Kit No. 258523_1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 1 1-7 Sensor Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 1 1-8 Filter Assembly Part No. 6635398_1 . . . . . . . . . . . . . . . . . . . . . . . . 1 1-6 11-9. Secondary Filter Assembly Part No. 6639172_1 . . . . . . . . . . . . . . . . . . 11-7 1 1-10. High Temperature Probe Assembly and Seal Kit No. 25810l__1 . . . . . . . . . . 11-8 1 1- 1 1. Packing Gland and Seal Kit No. 258102_1 . . . . . . . . . . . . . . . . . . . . . 11-8 11-12. Filter and Wire Kit No. 258103_l . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 1 1-13. High Temperature Filter Housing Kit No. 25810-l_l . . . . . . . . . . . . . . . . 11-8 11-14. Keyboard Kit No. 258519_F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 11-15. VFD Display Kit No. 258518_1 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 1 1 - 16. Electronics Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 10 11-17. Probe Flange Kit No. 258536] . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 11-18. Panel Mount Kit No. 258524_1 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 1 1-19. Adapter Flange Kit No. 258-407__1 . . . . . . . . . . . . . . . . . . . . . . . . 11-12 1 1-20. Maintenance Kit No. 258432_1 . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 1 1-21. Calibration Kit No. 258539__1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-13 1 1-22. Standard Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ll-14 vii Page 10 Eiiiflliili List of Figures Page Title No. s_..,.~...:....3........H....n...._,........1..,...... 11111112“/.~nh~nh~.n_,.4.rJ..|_.1_..1_.. 444. TypeSMA1Sensor:A.ssemtily:::::::::::::::::::::::::::: 'I‘ypeSMA2SensorAssembly.....-...................... E1ectronicsAssembly[Externa11fievi'}--HiI:-:::::::::::::::: E1ectronicsAssembIy[IntemalView)........................ Cab1eAssembly................................... '1'ypeSMA1SensorAssemb1yFlowDiagram.................... TypeSMA2SensorAssemb1yF1owDiagram.................... AnalyzerlnstallationOvewiew........................... U H U s . . .nm 0:1 -‘Huang ...a . . .mm . . .®i ..._F-D . . .P Mb . . .5 . .s.w.w . .nbM ..emd ..men CS 1.rsa 3 ..mA.$ :1 qrn ..u.eMe 1.R..lm H Hm.m.m I .m M W W Ema m mom“ .0 d n a ..._ mmuem ..n w n r a b smeue m .w e n nam e rir s m s..m..m.n....w. A P eOOb s r v. c YV.m m M W. m R s msssm R .m .... fi....§ M M M Hrrmm n Pooofi . b S OSSHHC m m m 3?... M P S PSSOE. ._..U......._.....m...w_,.,.1...c..3.1...,.:.r...........,. 11111112222444.4444 Panel Mounted Electronics Assembly Clearance Requirements and MountingDirnensions.........................-..... 4-16 4-17 Directions for the TU Board Terminal Connections . . . . . . . . . . Electronics Assembly Termination Chamber and TU Board Wiring ConnectionDiagram 4-18 SensorAssembly Wiring Connection Diagram . . . . . . . . . . . . . . . . . . 4-18 Digital 1nputWiring Diagram {24 VDC} . . . . . . . . . . . . . . . . 4-20 Digital 1nputWiring Diagram[l20/240 VAC} . . . . . . . . . . 4-21 AnaIogOutputWiringDiagrarn.......................... 4-22 Digital Output Wiring Diagram [Non-Alarm State]. . . . - . . . . . . . . . . . 4--23 ThermocoupleInputWiringDiagram. . . . . . . . . . . . . . - . . . . . . .. 4-24 Input] Output Circuit Board Switch Locations and Functions . 4-25 Microprocessor Circuit Board Switch Locations . . . . . . . . . . . . . . . . . 4-26 OptionalBlowbackifitlnstallation. . . . . . . . . . . . . . . . . . . . . . . . 4-30 S9 4 4-10. 4-11 4-12. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4 19 234.235?89901234567890l234 333, . . . _ _ _l11111111122222 ...5668888.____..___-.___ 444. 8888888B8888888 W . .m . V . 4-L . H . B n - D - D; m 1 U . C . ."lv-J . ..D . h Three-Inch or Four-1nchAdapter Flange Kit. . . . . . . . . . . . . . . . . . . Reducing the High Temperature Probe Length. . . . . . . . . . . . . . . . . . Sensor Assembly and Cable Assembly Wiring Diagram . . E1ectronicsAssemb1yWiringDiagram . . . . . - . . . . . . . . . . . . . . . .. input/Output [I/O} Circuit Board Test Points . . . . . - . . . . . . . . . . . . . Electronics Assembly CJC Temtieratu-re 'I:oo lnletThermocoupleOpen....................-........ CO:PreheaterBlockTemperatureLow. . . . . . . CO: Preheater BlockThermocouple Open . . . . . . . . . . . . . . . . . . . . SensorAssernbly CJC Temperature Too High or Low . . . . . . . . . . . . . . Flange Manifold Block Thennocouple Open . . . . . . OutletThermocoupleOpen............................ O2HeaterCu1-rentTooL0w.......:::.:....:........... CO¢SpanGasConstantTooLow...........:.........-... OxygenSpanGasTool-IighorLow..-..................... w. ....|.._., mm. om fin mm.m H sena A mEG .-1 B .....m.m_m ow HDUS Foas mom m h mm .e..HP Ne TT mda H ee eocm c rr bMe.m r h u a .g OPM t rm 1 _nmMw m e e H CC M 6 PP h m ISE D P .65 T ueae . m ec 1 .1 IV U TT H t a.me0 a e r c T kk o m erpn M k cc 0 pews 0 mm T 5 me u n 10 as m m m a .1 B C Tmhw W r MM m mm? s m mm m M Hiomm @ w an r n MFFH M .m MM m a HDHZ E SE a P .oeeY. k .88 e S Wm mg a a. 3 m. a. 055m 0 C mm 0 C . L .0.L2.&4._&&?.&& viii Page 11 List Of Figures (continued) No. Title Page 8-20. COB Zero Gas Constant Too High or Low . . . . . . . . . . . . . . . . . . . . . . 8-25 8-21. Oxygen Zero Gas Constant Too High . . . . . . . . . . . . . . . . . . . . . . . . 8-26 8-22. Oxygen Zero Gas Constant Too Low . . . . . . . . . . . . . . . . . . . . . . . . 8-27 8-23. A/D Five or Zero Volt Reference Error . . . . . . . . . . . . . . . . . . . . . . . 8-28 8-24. System Fault Alarms [Not for A/' D Reference Errors] . . . . . . . . . . . . . . . 8-29 8-25. Sample Flow Rate Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 8-26. Sample Flow Rate Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 8-27. Suction Pressure Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31 8-28. Suction Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31 10- 1. Sensor Assembly and Cable Assembly Wiring Diagram . . . . . . . . . . . . . . 10-3 10-2. Type SMA2 Sensor Assembly Gaskets . . . . . . . . . . . . . . . . . . . . . . 10-16 10-3. Screen Flowchart [Setup Mode Calibration Environment] . . . . . . . . . . . . 10-34 11-1. Sensor Assembly Parts View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 1 1-2. Filter Assembly Parts View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-6 1 1-3. Secondary Filter Assembly Parts View . . . . . . . . . . . . . . . . . . . . . . . 1 1-7 1 1-4. High Temperature Filter Assembly Parts View . . . . . . . . . . . . . . . . . . . 1 1-9 11-5. Electronics Assembly Parts View . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 11 11-6. Probe Flange Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 ix Page 12 Safety Summary SPECIFIC WARNINGS Do not use the Type SMA2 analyzer to detect explosive levels (LEL) of any combustible gases. The 00.2 sensor is designed to respond to C0 and H2. it may not detect other combustible gases such as methane. (p. 1-7) Exercise care when installing or removing the sensor assembly on positively pressured processes. Wear suitable protective clothing to prevent personnel injury from any hot gases emitted from the process. (p. 4-9, 10-12, 10-13) Do not apply 1201240 VAC facility power to the electronics at this time because terminals may be live which have not been termi- nated yet. Apply power only after completing the installation of the cable onto the sensor. (p. 4-19) Use hand and eye protection when operating a grinding wheel or a welding torch. (p. 4-33) Maintenance must be performed only by qualified personnel and only after securing equipment controlled by this product. Adjusting or removing this product while it is in the system may upset the process being controlled. Some process upsets may cause injury or damage. (p. 8-1, 9-1, 10-1) Use protective hand covering when servicing this equipment. The sensor assembly cover temperature may exceed 121 °C (250°!-‘). The 00.; block may exceed 399°C (750°F). The llange tempera- ture may exceed 204°C (400°F). The probe with filter assembly may be at process gas temperature. (p. 10-1) When the apparatus is connected to its power supply, terminals may be energized. The openings of parts or removal of covers will expose energized components. Any adjustments, maintenance, or repairs of the energized apparatus must only be carried out by a skilled person who is aware of the hazard involved. (p. 10-1) Secure the equipment controlled by this product before calibrating the analog outputs. Adjusting the analog outputs while this product is in the system may upset the process being controlled. Some process upsets may cause injury or damage. (p. 10-36) Page 13 Safety Summary (continued) SPECIFIC CAUTIONS Do not modify the cable assembly in the field (i.e.. shorten the cable or remove the connectors for routing through conduit). Modi- fication of the cable voids the warranty and may damage the analyzer. (p. 2-6, 4-28) Do not locate the filter assembly where it will be directly exposed to, or within 3.1 meters (10 feet) of steam or liquids from process cleaning operations (soot blower or scrubber). The combinations of liquids and soot may plug the filter. (p. 4-9) Provide probe support within the duct when using a probe longer than 1.8 meters (6.0 feet). Failure to supply additional support may result in damage to the probe or sensor assembly. Tilt the probe and filter assembly upward during installation and removal to clear the probe support. (p. 4-10) Do not allow the duct gases to enter the filter assembly at a point higher than the entry point to the sensor assembly. Particles that pass through the filter assembly may eventually gravitate to the flange manifold assembly and cause blockage of the passages. (p. 4-10) Failure to add a two-stage filter system just before the regulator may cause blockage in the sensor assembly. (p. 4-15) All digital inputs must be either AC or DC- Do not mix AC and DC digital inputs as this will damage the analyzer. (p. 4-19) Connect the shielded wire to the green grounding screw. Do not connect the shielded wire to one of the TU board mounting screws as this will damage the analyzer. (p. 4-28) Use NEVER-SEEZ compound (or an equivalent graphite-based anti-seize compound) on all screw threads when installing sensor assembly components. Silicone or lead based compounds will con- taminate the CO9 and O2 sensors- Do not use teflon tape as small pieces may shear off and block or plug the orifices- (p. 10-2, 10-5) Do not touch the sensing elements with hands or tools. Do not allow the sensing elements to touch the sides of the 009 block when the sensor is inserted into the COe block. Contact with the elements may damage the sensor. (p. 10-4) Do not manually snap the flow disk. This will cause it to malfunc- tion. (p. 10-17) Page 14 Sommaire de Securite EIEJUUE ‘ AVERTISSEMENT D’ORDHE SPECIFIQUE N’utilisez pas Fanalyseur SMA pour détecter les niveaux explosifs (LEL) de gaz combustibles. L'anaIyseur SMA n'est pas destiné aux applications de sécurité. Le déteoteur de COB est concu en fonction de détecter les gaz CO et H2. 1| ne peut pas détecter d'autres gaz combustibles comma ie méthane. (p. 1-7) Soyez prudent tors de Pinstallation ou du retrait de Punité de détection dans les applications of: le procédé est sous pression. Portez de I'équipement et des vétements de protection pour éviter des blessures dues aux gaz chauds émanant du procédé. (p. 4-9, 10-12, 10-13) N'alirnentez pas Fassembiage électronique en 120!240 V c.a. a ce point-oi. Sinon, une tension de 120l240 V c.a. serait appliquée au cablage sans terminaisons. Ne branchez Palimentation qu’aprés avoir relié le cable a |‘unité de détection. (p. 4-19) Protégez les mains et les yeux an moyen de Féquipement protec- teur appeoprié lorsque vous utilisez d'une meuie ou d’un chalumeau de soudure. (p. 4-33) L’entrelien doit étre assuré par un personne qualifié et en considera- tion de I’aspect sécuritaire des équipements contrfales par ce produit. Uadjustment etfou Pextration de ce produit iorsqu'il est insére a un systieme actif peut occasionner des a-coups au procédé contrc“>le. Sur certains procédés, ces a-coups peuvent également occasionner des dommages ou blessures. (p. 8-1, 9-1, 10-1) Utilisez des gants de protection lorsque vous effectuez Fentretien de cet équipement. La température du couvercle de l'unité cle détection peut atteindre ou dépasser 121°C (250°F). La tempera- ture du bloc C08 peut dépasser 399°C (750°F). Le température de la bride peut dépasser 204°C (400°F). Le sonde et Passemblage du filtre peuvent étre a la température du gaz du procédé. (p. 10-1) Quand Féquipement est relié a son bloc d‘a|imentation, des ter- minaux peuvent étres sous tension. Des cornposantes sous tension seront exposées si des couvercles sont retirés, ou si des assemblages sont ouverts. Tout ajustement, travail d’entretien ou de réparation au matériel alimenté doit etre accompti par une personne competente, consciente des dangers. (p. 10-1) II taut isoler Péquipement contr6|é par ce produit avant de procéder Fétalonnage des sorties analogiques. Si on ajuste les sorties analogiques tandis que le produit est reiié au systéme, le processus oontr6lé risque d‘étre perturbé, ce qui pourrait provo- quer des blessures ou des dommages. (p. 10-36) xii Page 15 Sommaire de Securite (continued) ATTENTION D'ORDRE SPECIFIQUE Ne modifiez pas l'assemb|age du cable en chantier (par exemple, en raccourcissant le cable ou en retirant Ies connecteurs a des fins d'inser1ion dans un conduit). Toute modification du cable annuie la garantie at risque d’e-ndommager Panaiyseur. (p. 2-6, 4-28) N‘instal|ez pas Fassembiage du iiltre la oi: il sera directement expose’ a de la vapeur ou a des iiquicles de nettoyage de procédé (souffleurs de suie ou brosseuses) ni e moins de 3.1 metres (10.0 pieds) de ceux-ci. Les iiquides et la suie bloqueraient le iiltre- (p. 4-9) Lorsque vous utilisez une sonde de plus de 1.8 metres (60 pieds), prévoyez un support a Finterieur de la canalisation. Sans suppor1 addi- iionnel, la sonde ou Funité de détection risqueraient d’étre endommagés. Lors de Pinstaliation cu du retraii, inclinez la sonde et Fassemblage du filtre vers i‘arriere pour dégager le support de la sonde. (p. 4-10) Ne permettez pas aux gaz du procédé d’entrer dans Passernblage du fiitre a un point plus haut que le point d'entrée de Passemblage de déteciion. Des particules passant au lravers ciu iiltre pourraient s_’accumu|er au niveau de Passemblage de la bride de collecteur at obstruer les passages. (p. 4-10) lnstallez un sysieme de filtre a deux étages immédiatement devant ie régulateur. Autrerneni, |'unilé de détection risque de se bloquer. (p. 4-15) Toutes les entrées numériques doivent étre de type c.a. cu c.c. L'ana|yseur serait endommagé par la combinaison de signaux c.a. et c.c. (p. 4-19) Reliez le fil blindlé e la vie verte de rnise e la terre. Ne reliez pas ie fil blinds‘: a une des vis de montage de la carte de raccordement; ceci endommagerait i‘analyseur. (p. 4-28) Lorsque vous installez des composantes de Passemblage du detec- teur, utiiisez du compose’: NEVER-SEEZ (ou un composé antigrippant équivalent a base de graphite) sur tous les filets de vis. Des composes ‘a base de silicone ou de plomb contamineraient Ies détecteurs de COe ei de Oz. N‘utilisez pas de ruban TEFLON; des particules pourraient s‘arracher et obstruer Ies orifices. (p. 1 0-2, 1 0-5) Ne touchez pas Ies éléments de détection avec les mains ou des outils. En Ies insérant dans le bloc CC-‘e, ne laissez pas les éléments de délection entrer en contact avec les parois du bloc CO.=_. Un contact avec les élérnents pourrait endornmager le détecteur. (p. 10-4) Une manipulation direcle du disque Fendommagera. (p. 10-17) xiii Page 16 SECTION 1 - INTRODUCTION 0 I/ER VIE W This instruction manual gives personnel a working knowl- edge of the Type SMA Smart Analyzer 90. The manual explains the analyzer operation and provides step-by~step procedures for specific tasks. The Type SMA Smart Analyzer 90 is a combustion analyzer. It continuously samples and analyzes industrial flue gases. The Type SMA1 Analyzer 90 monitors oxygen [02] only. The Type SMA2 Smart Analyzer 90 monitors both 02 and carbon mon- oxide equivalent {COC}. The 02 reading is a continuous percent by volume measurement of the net oxygen in the flue gas. The CO¢ reading indicates mostly carbon monoxide [CO]. but also responds to other combustibles present in the flue gas. The analyzer uses a close coupled sampling system which does not remove water vapor from the sample. The analyzer accepts thermocouple inputs for process tempera- ture measurement and calculates combustion efficiency. INTENDED USER Personnel requirements for installation, start-up. operation. maintenance and repair of the Type SMA Smart Analyzer 90 are: An electrician and a mechanic to install the Type SMA analyzer. - A combustion / start-up engineer familiar with the process and combustion in general to start up the Type SMA analyzer. A person trained in and familiar with the process to operate the Type SMA analyzer. - An electrical or service technician to maintain and perform repair] replacement procedures. EQUIPMENT DESCRIPTION The Type SMA analyzer has four main assemblies: the sensor assembly, the probe with filter assembly. the electronics as- sembly and the cable assembly [Figure 1-1]. The Type SMA1 analyzer uses an 02 only sensor assembly that contains the flange manifold. 02 sensor. heaters and the termination chamber [Figure 1-2]. The 'l}rpe SMA2 analyzer uses a combination O2 and CO: sensor assembly that con- tains the COC sensor and all of the components in the 02 only sensor assembly [Figure 1-3]. OVERVIEW 1 - 1 Page 17 amuse ‘ INTRODUCTION The probe with filter assembly comes in one of three types: the standard probe with filter, the standard probe with op- tional dual filter and the optional high temperature probe with filter [Figure 1-4]. The electronics assembly consists of the operator interface, input] output (1/ 0] board, microprocessor board, valve mani- fold and the termination unit board [Figures 1-5 and 1-6]. The cable assembly comes in a standard 15-meter [50-foot] length. Optional 30-meter [100-foot} and 46-meter [150—foot] lengths are available [Figure 1-7). ELECTRONICS ASSEMBLY i senson ASSEMBLY E I i E1 % PROBE wm-1 FILTER asssmszx .~ Ii W - i I I I “ I ‘ l ' 3. I ; “ii Z 5 =5 “Fl: CABLE ASSEMBLY 1 \\__——/’ Figure 1-1. Main Assemblies TERMINATION CHAMB ' FLANGE |‘\ MANIFOLD Figure 1-2. Type SMAI SensorAssembly EQUiF-‘MENTI DESCRIPTION 1-2 Page 18 INTRODUCTION Figure L3. Type SMA2 Sensor Assembly FLOPPY FILTER E w mm PT om wnn_._.. um mw T S SECONDARY FILTER 1% STANDARD PFIOBE WITHOPTIONALDUALFILTEH r‘_________________~______F__________J FLOPPY FILTER OPTIONAL HIGH TEMPERATURE PROBE WITH FILTEFI FLOPPY FILTEFI CERAMIC PROBE Figure 1-4. Probe with Filter Assemblies EQUIPMENT DESCRIPTION Page 19 INTRODUCTION I .-' W_1E I / YWTA Figure 1-7. Cable Assembly FEA TURES/BENEFITS New Rugged Indtwtriul Design. The stainless steel heater block, extrusion honed metals and corrosion resistant plas- tics have hardened this rugged design. The Type SMA Smart Analyzer 90 is built to withstand demanding utility. petro- chemical and other industrial applications. Highly Accurate Sensors. The patented O2 sensor is a reli- able zirconium oxide design. It has built-in contaminant protection and an integral self-controlled heater for longer life expectancies. A catalytic type. RTD based sensor is used for the CO6 measurement. The high sensitivity of the RTD com- bined with the poison resistant catalyst provides improved performance. The accuracy of both 02 and C0: measure- ments is not affected by flue gas temperature. particulates or variations in either water vapor or carbon dioxide. Self-Diagnostics and Alarming. The microprocessor based electronics continuously analyzes and monitors the opera- tion of the sensors. analyzer and combustion process. Sensor calibration data is normalized against known test gas con- centrations to warn of an impending sensor failure. Analyzer alarm messages display on the screen in English. Form C relay contacts are provided for alarms. Patented Close Coupled Sctmple System. The close coupled sample system saves maintenance time and increases the life of the sensor when compared with typical measurement tech- niques. The floppy filter removes flue gas particulates before analysis while the patented self-cleaning action eliminates filter buildup and plugging. The industry proven hot gas sample system uses heated passages to keep the process FEATUHESIBENEFITS 1 - 5 Page 20 INTRODUCTION 1% sample at a temperature above dew point to insure trouble- free operation. High Temperature Operating Range. The analyzer assem- bly with the standard stainless steel probe and floppy filter assembly handles flue gas temperatures up to 649 degrees Centigrade {1200 degrees Fahrenheit]. Other optional probe with filter assemblies are available for temperatures up to 1649 degrees Centigrade [3000 degrees Fahrenheit]. Easy Installation and Start-Up. Flange mounting, plug-in cable connectors and menu-driven start-up procedures sig- nificantly reduce installation. commissioning and operator training times. Simplified In-House Maintenance. The sensors are field re- placeable without having to remove the sensor assembly. Easy access is provided to all sensor assembly components and electrical connections. Extensive self-diagnostics and optional filter blowback further reduce maintenance requirements. Automatic Sensor Calibration [Standard]. The automatic calibration permits unattended operation and eliminates la- bor intensive calibration checks required by other analyzers. Calibrations can be programmed to start automatically at specific intervals. manually via the operator interface or re- motely by digital inputs. Contact outputs indicating calibration alarms and calibration in progress signal external control systems of the analyzer calibration status. Low Cost Integrated Solution. No other combustion ana- lyzer provides both 02 and low range C05 measurements and automatic calibration in a single. low cost package. Remote Blowback (Optional). The analyzer may be fitted with an optional dual filter and remote blowback solenoid to offer added protection in applications with abnormally high levels of fine particulate. Distinctive Operator Interface. A ten-key keypad and a two-line 80-character vacuum fluorescent display provide a highly visible. menu-driven operator interface. Front panel mounted LEDs readily indicate the status of the analyzer. Process Temperature Measurement. The analyzer accepts thermocouple inputs for inlet air and outlet flue gas tempera- ture measurements. Combustion E_fl'iciency Calculation (Standard). Combus- tion efficiency is calculated based on the inlet and outlet temperature measurements and the flue gas composition [02 and C0¢ content}. It is available for natural gas. light oil, heavy oil, anthracite. bituminous and lignite. FEATURESIBENEFITS

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