SICK SFU Series, SFU-BF NI GL Operating Instructions Manual
SFU
Gas Sampling Unit
with Weatherproof Enclosure
O P E R A T I N G I N S T R U C T I O N S
Described product
SFU (gas sampling unit) with higher protection class
These Operating Instructions refer to the gas sampling unit of the SFU-BF NI GL in the
weatherproof enclosure.
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
CONTENTS
1 About this document........................................................................ 5
1.1 Function of this document....................................................................... 5
1.2 Target group.............................................................................................. 5
1.3 Symbols and document conventions...................................................... 5
1.3.1 Warning symbols...................................................................... 5
1.3.2 Warning levels / signal words................................................. 6
1.3.3 Information symbols................................................................ 6
2 Safety information............................................................................ 7
2.1 Basic safety information........................................................................... 7
2.2 Warnings on the device............................................................................ 7
2.3 Intended use............................................................................................. 8
2.4 Qualification of the operator.................................................................... 8
3 Product description........................................................................... 9
3.1 Product identification............................................................................... 9
3.2 Product description.................................................................................. 10
3.3 Design........................................................................................................ 11
3.3.1 Gas sampling tube................................................................... 11
4 Installation and start-up................................................................... 12
4.1 Important information.............................................................................. 12
4.2 Weatherproof enclosure........................................................................... 13
4.3 Preparing the connection bundle............................................................ 14
4.4 Mounting................................................................................................... 15
4.4.1 Installing the welding neck flange.......................................... 15
4.4.2 Connection of sample gas line............................................... 17
4.4.3 Connection of the pneumatic lines........................................ 18
4.5 Electrical installation................................................................................ 19
4.6 Installing the gas sampling tube on the gas sampling unit................... 20
4.7 Installing the SFU on the welding neck flange........................................ 20
5 Maintenance...................................................................................... 22
5.1 Important Information.............................................................................. 22
5.2 Maintenance plan..................................................................................... 22
5.3 Spare parts............................................................................................... 23
5.4 Replacing the sintered metal filter element........................................... 23
5.5 Replacing the glass fiber filter element.................................................. 26
5.6 Retrofitting the filter element................................................................... 29
5.7 Checking for correct operation................................................................ 32
6 Troubleshooting................................................................................. 33
6.1 Troubleshooting........................................................................................ 33
7 Disposal.............................................................................................. 34
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CONTENTS
8 Technical data.................................................................................... 35
8.1 Compliances and Standards.................................................................... 35
8.2 Dimensions............................................................................................... 35
8.3 Operating data.......................................................................................... 35
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1 About this document
1.1 Function of this document
These Operating Instructions describe:
Device components
•
Installation
•
Operation
•
Maintenance work required for reliable operation
•
1.2 Target group
This document is addressed to technicians (persons with technical understanding)
installing, operating and maintaining the measuring system.
Responsibility of the operator
Use the device only as described in these Operating Instructions. The manufac‐
•
turer assumes no responsibility for any other use.
Maintenance work should be performed as prescribed in this Manual.
•
Do not remove, add or change any components in or on the device unless such
•
changes are officially allowed and specified by the manufacturer.
Otherwise the manufacturer's warranty becomes void.
°
Otherwise the device can become dangerous.
°
Observe special local conditions.
•
Follow all local laws, regulations, and company policies applicable at the
°
installation location.
Retain documents. These Operating Instructions:
•
Must be kept available for reference.
°
Must be passed on to new owners.
°
ABOUT THIS DOCUMENT 1
Requirements on the maintenance personnel
The technician must be familiar with the exhaust gas technology of the operator's
•
plant (overpressure, toxic and hot flue gases) and be able to avoid hazards when
working on gas ducts.
The technician must be familiar with handling compressed gas cylinders (span
•
gases).
The technician must be able to avoid hazards caused by noxious span gases.
•
The technician must be familiar with gas lines (PTFE lines) and their screw fittings
•
(be able to ensure gas-tight connections).
Only electricians are permitted to work on the electrical system or electrical sub‐
•
assemblies.
1.3 Symbols and document conventions
1.3.1 Warning symbols
Symbol Significance
Hazard (general)
Hazard by voltage
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1 ABOUT THIS DOCUMENT
Symbol Significance
1.3.2 Warning levels / signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
Hazard by acidic substances
Hazards by noxious substances
Hazard by high temperature
Hazard for the environment/nature/organic life
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
Notice
Hazard which could result in property damage.
Note
Hints.
1.3.3 Information symbols
Symbol Significance
Important technical information for this product
Important information on electric or electronic functions
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2 Safety information
2.1 Basic safety information
WARNING
Health risk through dangerous sample gas
If dangerous sample gas is applied to the SFU:
The operator is responsible for safe handling of sample gas.
b
WARNING
Risk of explosion in potentially explosive atmospheres
Do not operate the SFU in potentially explosive atmospheres.
b
WARNING
Hazard through explosive or ignitable gases
Do not use the SFU for measuring explosive or combustible gases.
b
SAFETY INFORMATION 2
2.2 Warnings on the device
Figure 1: Location of the warning signs on the device
Warning sign "Caution!"
1
Warning sign "Hot surface!"
2
DANGER
Hazard by voltage
Only authorized electricians may perform work on electrical components.
b
Do not touch live components.
b
Disconnect the device from the power supply before working on electrical compo‐
b
nents (e.g. by switching off the measuring system).
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2 SAFETY INFORMATION
WARNING
Risk of burns on hot surfaces
Avoid contact with hot surfaces or wear protective clothing (e.g. protective gloves).
b
Lay hot parts on fireproof supports only.
b
2.3 Intended use
The gas sampling unit is used for extracting a partial stream of a gas mixture (usually
flue gas) from a line, stack or similar and for retaining particles that are contained in
the gas stream.
2.4 Qualification of the operator
The SFU may only be maintained by persons properly instructed on the tasks assigned,
possible risks and protective measures.
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3 Product description
3.1 Product identification
Product name SFU-BF NI GL
Accessories:
Name of the pre-assembled set:
Consisting of:
Manufacturer SICK AG
Type plate The type plate is located on the underside of the gas sam‐
PRODUCT DESCRIPTION 3
The exact type designation can be found on the type plate.
0.5 m unheated maritime gas sampling tube
•
0.8 m unheated maritime gas sampling tube
•
0.5 m heated gas sampling tube
•
0.8 m heated gas sampling tube
•
1.0 m heated gas sampling tube
•
1.5 m heated gas sampling tube
•
2.0 m heated gas sampling tube
•
IP54 enclosure
•
Can already be ordered pre-assembled in combination
with the maritime gas sampling unit SFU-BF NI GL
SFU-BF NI GL in IP54 enclosure (PN 2098126)
SFU-BF NI GL
•
IP54 enclosure for SFU
•
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
pling unit.
NOTICE
It is possible that your SFU has a different configuration to that described in this Man‐
ual.
Refer to the System Documentation delivered with your SFU for the individual con‐
•
figuration of your system.
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3 PRODUCT DESCRIPTION
3.2 Product description
Figure 2: Example configuration of a set consisting of weatherproof enclosure and SFU
Weatherproof enclosure
1
Gas sampling tube
2
SFU filter housing
3
Flange
4
Silicone press ring seal (gas sampling tube seal)
5
The gas sampling unit consists of filter housing, gas sampling tube, weatherproof enclo‐
sure and optional pre-filter.
Application area
The gas sampling unit SFU is used for flue gas extraction and filtering for analysis in a
measuring system.
The flue gas is taken via a gas sampling tube and fed to a measuring system after filtra‐
tion.
The gas sampling tube is optionally available in various lengths.
As an option, the gas sampling tube contains a pre-filter at the probe tip.
For maritime applications, unheated gas sampling tubes without pre-filters are used.
Measuring system
The gas sampling unit is operated on a SICK measuring system. Thus, only this operat‐
ing mode is described in this Manual.
Applications with customer-owned peripheral devices are not planned.
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3.3 Design
Figure 3: SFU-BF NI GL
Gas sampling tube
1
Filter housing
2
3 pneumatic lines (backflush, activa‐
3
tion of main valve, zero gas)
Output sample gas line
4
Input connection bundle (electrical
5
and pneumatic lines)
Filter element with rotary handle
6
PRODUCT DESCRIPTION 3
The gas sampling unit consists of the following subassemblies:
•
•
The electrically heated filter housing is made of coated aluminum. The filter housing is
insulated by an aluminum housing lined with polyimide.
The weatherproof enclosure is made of glass fiber reinforced plastic (GRP).
Thermostatic control
The gas sampling unit is thermostatically controlled.
•
•
3.3.1 Gas sampling tube
The length of the gas sampling tube depends on the conditions at the sampling point.
The gas sampling tube is available for maritime applications in an unheated version.
Type and length of the gas sampling tube are described in the supplied system docu‐
mentation.
Gas sampling tube:
Heated gas sampling tube:
°
Unheated maritime gas sampling tube
°
Optional: Pre-filter at the tip of the gas sampling tube
°
SFU in IP54 enclosure:
Heated filter housing with filter element
°
Weatherproof enclosure
°
Heating control with Pt100 sensor and external heating control
Limit value monitoring in the controller of the measuring system
NOTE
The gas sampling tube is supplied pre-assembled.
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4 INSTALLATION AND START-UP
4 Installation and start-up
4.1 Important information
WARNING
Risk of injury by a heavy load
The weatherproof enclosure including the sampling system with flange weighs
approx. 30 kg.
Use proper lifting techniques to lift or move the device.
b
Lift the unit by the enclosure. If necessary, remove the cover in order to grip the
b
device better and reduce the weight.
Always work in pairs.
b
WARNING
Health risk through dangerous sample gas
If dangerous sample gas is applied to the SFU: The operator is responsible for safe han‐
dling of sample gas.
In addition to these Operating Instructions, observe all local laws, technical rules,
b
and company-internal instructions valid at the site where the SFU is installed.
Operate the SFU only in rooms with adequate installation OR install suitable gas
b
monitoring equipment.
Channel sample gas off safely.
b
WARNING
Hazard through sample gas pressure
The stacks can have underpressure or overpressure.
Observe information from the plant operator.
b
WARNING
Risk of burns on hot surfaces
Filter housing, flanges and sample gas line can be hot.
Allow the surface of the device parts to cool down to body temperature or wear
b
suitable protective gloves.
WARNING
Danger to life by electric voltage
Only allow an authorized electrician to work on the electric system.
b
The assembly of the gas sampling unit contains the following work steps:
Step Work step Special features Side
1 Install the welding neck flange Has to be performed by the
operator beforehand
2 Connect the sample gas line page 17
3 Connect the hoses for valves page 18
4 Connect the electrical connec‐
tions
5 Install the gas sampling tube page 20
page 15
page 19
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