ABB SCC-K Converter

ABB SCC-K Converter

Overview

The manual is aimed at on-site engineers and describes the installation, operation, and maintenance of the entire machine; The device is a 19 inch 3U rack unit that supports rack installation or optional bracket wall mounting.

Difference between two models:

NO ₂/NO catalytic converter: a carbon molybdenum catalyst that catalyzes the reduction of NO ₂ to NO, used for the measurement of total nitrogen oxides in flue gas; Equipped with bypass ball valve/solenoid valve components, catalyst consumables can be quickly replaced without tools.

Thermal converter: quartz glass reaction tube, high-temperature thermal cracking conversion of sulfur, chlorine, and organic components, no catalyst consumables; The unboxing of quartz tubes requires users to assemble them themselves.

General safety requirements

Personnel qualifications: Only certified personnel familiar with similar analytical instruments are allowed to carry out installation, wiring, and maintenance.

Electrical safety: Before wiring, it is necessary to first connect the protective grounding wire; Open cover maintenance must completely disconnect all power sources; After a power outage, there is still residual charge in the capacitor inside the machine. Only T3.15 AH250V slow melting fuses are allowed, and short circuiting of the fuse holder is prohibited.

High temperature risk: During operation, the temperature of the furnace chamber and catalyst shell can reach several hundred degrees Celsius. Before maintenance, it is necessary to cool them thoroughly and wear protective gloves to prevent burns.

Catalyst safety: Carbon molybdenum catalysts are irritating and flammable, and must be stored and disposed of using ABB original spare parts according to the material manual.

Failure determination: If the equipment casing is damaged, operates abnormally, is stored in harsh environments for a long time, or is subjected to severe impacts, it should be stopped from use and locked, and no further operation is allowed.

Installation and site selection requirements

Usage environment: Indoor only; The highest installation altitude is 5000   m; the working environment temperature is+10~+50   ℃; Annual average relative humidity ≤ 75%; Allow for brief slight condensation.

Installation key points

Try to get as close as possible to the analyzer, shorten the sample gas pipeline, and prevent re oxidation of NO and NO ₂ long pipelines, which may cause measurement deviation.

Ensure ventilation and heat dissipation around the perimeter; At least 1U of height space should be reserved above the equipment during cabinet installation; Stay away from heat sources, direct sunlight, dust, corrosive gases, and strong vibrations.

Open box inspection: Check for transportation damage and file a claim for damages with the freight forwarder within 7 days; Reserve the packaging box for subsequent transportation.

NO ₂/NO version: The catalyst box is pre installed at the factory.

Thermal converter: The quartz reaction tube is a loose component that can be assembled on-site by the user; Quartz glass is fragile and violent handling is strictly prohibited.

Installation steps for the quartz tube of the thermal converter: After power-off and cooling, open the cover; Remove the quartz tube, install the joint with a locking torque of 5 Nm, and install it into the furnace; Connect the inlet and outlet air ducts; Restore the cover plate; After assembly, an air tightness test must be conducted.

Gas and electrical wiring

1. Sample gas pipeline connection

Backboard air port thread standard: G ¼ internal thread, distinguish between inlet and outlet, and strictly prohibit reverse connection.

Use card sleeve connectors; The cut of the hose mouth must be flat to ensure sealing.

After assembly, conduct an air tightness check on the entire equipment.

Important application reminder: If the system needs to simultaneously measure NO ₓ and CO, the carbon molybdenum catalyst will generate CO interference readings; CO sampling requires a separate bypass gas path and cannot pass through the SCC-K catalytic unit. The manual provides the corresponding system gas path diagram.

2. Signal interface X2 (9-pin Sub-D female socket)

Passive relay contact for temperature alarm (pins 5-9): The alarm is triggered when the temperature deviates by ± 5 ℃ from the set value. The contact specification is 24V DC, 1A.

Version with solenoid valve bypass:

Internal control: pins 1-6 must be short circuited, use the device front panel knob to switch between bypass/catalyst channels; The panel LED indicates the current path.

External control: Remove the 1-6 short-circuit jumper and control the solenoid valve through passive contacts of the external PLC/control system. At this time, the front panel knob will fail.

The X2 plug must be inserted in place, otherwise the alarm and bypass functions will fail.

3. Power interface X1

Power supply: 120V AC/240V AC, the equipment body needs to match the grid voltage; Comes with a 2-meter power cord.

Main insurance: F1/F2 T3.15AH250V slow melting fuse, located under the power socket.

Engineering suggestion: Add independent circuit breakers to the power supply circuit to facilitate complete power-off isolation of the entire machine.

Initiate the operational process

5.1 NO ₂/NO catalytic converter start-up

Check the power supply voltage and connect the temperature alarm signal.

Switch the front panel to Bypass mode.

Confirm that the catalyst box is installed in place, and the O-ring can be slightly wetted. Do not apply lubricating grease as it will reduce the catalytic efficiency.

Set the target temperature of the thermostat based on the sample gas flow rate:

Sample gas flow rate set temperature

30   l/h, 60   l/h, 320   ℃

90 l/h 340 ℃

150 l/h 360 ℃

The preheating time is about 30 minutes, and the temperature controller LED1 lights up to indicate that the set temperature has been reached; If the cooling amplitude is greater than 10 ℃, the temperature control lock will be triggered, and a power outage and restart reset are required.

After reaching the temperature standard, switch to the catalyst pathway and introduce the sample gas.

After new catalysts or long-term storage, the T90 response time will significantly increase.

5.2 Thermal converter (quartz tube) start-up

Check the power supply and connect the alarm contacts.

Set the temperature according to the process conditions, preheat for about 60 minutes, and LED1 is ready to light up.

Typical operating parameters:

Application scenario analyzer temperature and flow rate

Pulp and paper TRS total reduced sulfur Uras26 650   ℃ 60   l/h

Chlorine plant H ₂ → HCl conversion Caldos25 450/500 ℃ 60-120 l/h

PVC、 Chlorinated hydrocarbon detection HCl Limas11 IR 650   ℃ 60   l/h

Similarly, if the set temperature drops by more than 10 ° C, the temperature control will lock and power off to restart and reset.

Maintain homework

Complete maintenance: Power off, cool down the equipment to room temperature, and wear protective gloves.

6.1 NO ₂/NO Converter: Catalyst Replacement

Switch to the bypass first to prevent sample gas leakage during catalyst disassembly.

Rotate the handle to unlock and remove the catalyst box; Replace the inner and outer O-ring seals.

Insert the brand new original catalyst box and push it to the bottom to ensure sealing; O-ring can be wetted, lubricating grease is prohibited; Lock the handle tightly.

Catalyst lifespan reference: Under conditions of 30 l/h, 320 ℃, 10 ppm NO ₂, and 5% O ₂, the lifespan should be greater than 6 months, and the conversion efficiency should be ≥ 95%; The efficiency is significantly lower than 95% and must be replaced.

NH3 can severely poison catalysts and reduce conversion efficiency.

6.2 Air tightness test (cooling the whole machine to room temperature)

Set the temperature controller to room temperature; Switching catalyst pathways; Closed sample gas outlet; Connect the U-shaped pressure gauge and pressurize it to approximately 50 hPa gauge pressure; Close the shut-off valve; Observe the pressure.

A significant decrease in pressure indicates the presence of a leak; Note maximum absolute pressure: NO ₂/NO version ≤ 2   bar; Thermal converter version ≤ 1.2 bar.

Troubleshooting Summary Table

Possible causes and solutions for fault phenomena

The LED of the whole machine is completely off, the valve does not operate, there is no power supply, the fuse is burnt out, and the Sub-D X2 is not plugged in tightly. Check the power cord; Replace T3.15A insurance; Confirm that the X2 plug is securely plugged in

Measure the terminal voltage of the heater when the device is not heating and the heater is damaged, the temperature controller is faulty, and the solid-state relay is faulty. Replace the damaged components in sequence

The bypass solenoid valve does not switch and the X2 plug jumper is missing; External control wiring error; Check the damage of the solenoid valve body and short-circuit 1-6; Check the external control circuit; Repair the solenoid valve

No sample gas flow valve malfunction, pipeline blockage/leakage gas path leak detection, unclog the pipeline

No conversion effect at all, heating failure; No sample gas flow rate; Catalyst failure investigation, heating and gas circuit; Replace catalyst box

The solenoid valve and LED are only available in the NO ₂/NO bypass version, and are not included in the thermal converter.

Shutdown, packaging and transportation, scrapping and disposal

Short shutdown (short standby): For the catalytic version, it is recommended to lower the temperature to about 100 ° C to reduce catalyst loss.

Long term shutdown: It is recommended to use inert gas or room temperature air to blow the equipment; The equipment environment should not freeze during shutdown.

Re packaging and transportation: The quartz tube of the thermal converter must be removed and secured inside the casing with proper protection; Use the original packaging box, add desiccants, and label "Fragile, vertically placed"; Transportation and storage temperature -25 to+65 ℃.

Scrap: The equipment belongs to WEEE EU electronic waste and is prohibited from being mixed with household waste. It should be handed over to professional electronic waste recycling; You can contact ABB service for paid recycling.

Principles, pneumatic circuits, and hardware parameters

1. NO ₂ → NO catalytic principle

Reaction: ( boldsymbol {2NO {2} leftightarrow2NO+O {2}} ); By relying on carbon molybdenum catalysts to reduce activation energy, achieve a conversion efficiency of ≥ 95% below 400 ℃; Ammonia can cause catalyst poisoning; The upstream of the sample gas must be equipped with filtration and drying pretreatment.

2. Hardware version and order number

NO ₂/NO converter

Ball valve versions: 23093-4-0801974 (240VAC), 23093-4-0801977 (120VAC)

Dual solenoid valve versions: 23093-4-0801975 (240VAC), 23093-4-0801978 (120VAC)

Electromagnetic valve version with heated sample gas inlet: 23093-4-0801976 (240VAC), 23093-4-0801979 (120VAC)

Quartz tube thermal converter:

240 VAC：3KXG801000U0100

120 VAC：3KXG801001U0100

3. Key technical parameters

Project NO ₂/NO catalytic thermal converter

Maximum sample gas flow rate of 150 l/h and 120 l/h (commonly 60 l/h)

Working temperature 320-360 ℃, maximum 680 ℃

Conversion efficiency ≥ 95% (new catalyst) ≥ 99%

Preheating time 30 minutes 60 minutes

T90 response time ≤ 10 seconds @ 60 l/h ≤ 10 seconds @ 60 l/h

Maximum absolute pressure 200   kPa 120   kPa

Power consumption 240V: 575   VA; 120V: 560   VA Same as left

Weight 8-9 kg 8-9 kg

Safety standard EN   61010-1 EN   61010-1