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 SystemFine coal silo
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
SICK MAIHAK(Beijing)Co.,Ltd.
SMC-9004D
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).
SMC-9004D
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 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-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.
SMC-9004D
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.
SMC-9004D
SMC-9004D
Gas Analyzer System
2 Product description
Working principle
System composition
System configuration
Technical data
SMC-9004D
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.
SMC-9004D
2.2.3 Sampling gas pre-treatment unit

SICKMAIHAK SMC-9004D system sampling gas pretreatment unit
Consists of:
Cabinet (the dimension is 2000700600 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
1Sampling probe SMC-205
1 set
2Sampling pipeline
1 set
3Pretreatment unit
Cabinet
Back flushing unit
Calibration unit
Control and data processing unit
1 set
4Analysis unit
1 set
SMC-9004D
2.4 Technical specification

Measured value acquisition
Parameters
measured
Gaseous contaminant
Measuring range
CO:0-2000ppm;
O2:0-10%
Measuring accuracy
1%
Response time
O2, CO,
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
Dry contact; 230VAC/5A
Power supply
sampling probe
230VAC/50Hz
500W/set
sampling pipeline
230VAC/50Hz
35W/m
SMC-9004D cabinet
230VAC/50Hz
1000W
Dimensionwidthheightthickness
sampling tube
SMC-9004D cabinet
external diameter 63 ; pipe diameter 2-6, 1- 8

2000700600mm
Remarks:
1)
Response time is related to the length of sample line.
SMC-9004D
SMC-9004D
Gas Analyzer System
Installation
System installation
Electrical installation
Installation of Trace Heated Line
10
SMC-9004D
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 pointrefer 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 itselfs 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.
11
SMC-9004D
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.
12
SMC-9004D
SMC-9004D
Gas Analyzer System
Commissioning and Parameterization
General
System calibration
Manual mode
Auto mode
Parameter setting
13
SMC-9004D
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 safety rules and earthing conductor before system power on!
4.1.2 Basic procedures
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.
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

The system should be calibrated regularly. The sampling or backflushing of system should
be stop before calibration (turn of PLC start button)
1Open 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
14
SMC-9004D
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
15
SMC-9004D
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
Auto sampling interval time
5min-30min
PLC potentiometer 0
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.
16
SMC-9004D
SMC-9004D
Gas Analyzer System
Maintenance
General introduction
System daily maintenance
Maintenance and Operation of infrared analyzer
17
SMC-9004D
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 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.
18
SMC-9004D
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.
19
SMC-9004D
5.2.2 Analyzer 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, 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 42input corresponding zero point number of standard
component, start 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, 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 inletopen the valvethen
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
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.
20
SMC-9004D
SMC-9004D
Gas Analyzer System
6 Trouble shooting
Trouble-shooting for sample probe

Trouble-shooting for heated sample line
Trouble-shooting for analyzer cabinet
21
SMC-9004D
6. Trouble shooting
6.1 Trouble-shooting for sample probe
Malfunction
phenomenon
do not heat up
Possible cause
Solution
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
filter
of
probe
Poor maintenance
Cleaning or
probe filter.
Block
staff
of
probe
Dust concentration is too high, effect

of Back Flushing is not good.
Cleaning
Random trip of air

switches
replacing
the
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
Block of pipe
Possible cause
Solution

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

pipe from system on both
sides,
connect
with
compressed instrument air,
carrying out back flushing
function.
22
SMC-9004D
6.3 Trouble-shooting for analyzer cabinet

Malfunction
phenomenon
Power supply lost
in cabinet
Possible cause
Solution
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
23
SMC-9004D
Malfunction
phenomenon
Measuring value
is incorrect:
Eg. SO2/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
magnetic valve
Clean or replace it when

necessary
obstruction of needle valvebulb wall Cleaning

float
24

7132249B.03&04 Analyzer System Manual V1.0 (Fine Coal Silo)

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Analyzers and Process Instrumentation

SMC-9004D Gas Analyzer System

SICK MAIHAK (Beijing) Co.,Ltd.

Gas Analyzer SystemFine coal silo

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

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

Gas Analyzer SystemFine coal silo

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

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

Gas Analyzer SystemFine coal silo

1.2 Authorized operator

1.3 Safety rules and measuring protection

Gas Analyzer SystemFine coal silo

1.3.1 Power supply safety

1.4 Symbols used in this document

Gas Analyzer SystemFine coal silo

Gas Analyzer SystemFine coal silo

Fig. 2.1 SMC-9004D gas analyzer system

2.2 System composition

Gas Analyzer SystemFine coal silo

2.2.3 Sampling gas pre-treatment unit

2.3 System configuration

Gas Analyzer SystemFine coal silo

2.4 Technical specification

60s while the length of sample line 30m

Isolated output 4-20mA; Maximum resistive load 750

Load capacity: 230VAC, 5A

Dry contact; 230VAC/5A

external diameter 63 ; pipe diameter 2-6, 1- 8

Gas Analyzer SystemFine coal silo

Gas Analyzer SystemFine coal silo

Gas Analyzer SystemFine coal silo

3.2 Electric installation

3.3 Installation of Trace Heated Line

Gas Analyzer SystemFine coal silo

Commissioning and Parameterization

Gas Analyzer SystemFine coal silo

4 Commissioning and Parameterization

4.2 System calibration

Gas Analyzer SystemFine coal silo

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

4.3 Manual mode

4.4 Auto mode

Gas Analyzer SystemFine coal silo

4.5 Parameter setting

Auto sampling interval time

Data update time

Gas Analyzer SystemFine coal silo

Gas Analyzer SystemFine coal silo

5.1.2 Periodic draining and cleaning

Gas Analyzer SystemFine coal silo

5.2 System daily maintenance

Gas Analyzer SystemFine coal silo

5.2.2 Analyzer system maintenance list

Check up leakage of pipeline

Replace /check up filter

5.3 Infrared analyzer maintenance

Gas Analyzer SystemFine coal silo

Trouble-shooting for sample probe

Gas Analyzer SystemFine coal silo

Power supply dose not switch on

Switch on power supply and fix

Heating strip damaged inside probe,