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42/23-81 EN Rev. 4

System Manual SCK Gas Sampling System

147

Chapter 9

Maintenance

Topic Page

Maintenance plan .......................................................................................... 148
Equipment layout plan ................................................................................... 152
Acquiring spare parts and wear parts ............................................................  155
Safety regulations for maintenance work ...................................................... 156
Operating the service switch ......................................................................... 159
Checking the condition of the system, cleaning the system ..........................  161
Evaluating trend displays ............................................................................... 164
Checking the residual current circuit breaker ................................................ 165
Checking protective installations ................................................................... 167
Checking for leaks ......................................................................................... 171
Gas sampling probe H: Removing incrustations ........................................... 174
Gas sampling probe H: Replacing the intake filter ........................................ 176
Gas sampling probe H: Replacing membrane pump membranes ................ 179
Gas sampling probe 60S: Removing incrustations ....................................... 182
Gas sampling probe 60S: Cleaning or replacing the outlet filter ................... 184
Gas sampling probe 60S: Replacing the seal set ......................................... 187
Probe retractor: Checking filter/pressure control combination ...................... 189
Probe retractor: Checking and replacing the filter muffler ............................. 191
Probe retractor: Checking and topping up the oiler .......................................  193
Probe retractor: Checking and tightening the drive chain ............................. 196
Probe retractor: Checking and, if necessary, adjusting the
position of the probe ...................................................................................... 198
Probe retractor: Checking and, if necessary, adjusting the
position indicator (probe end position) .......................................................... 202
Probe retractor: Checking the bellows .......................................................... 205
Cooling module: Vent the cooling-water circuit ............................................. 206
Cooling module: Checking and topping up cooling water ............................. 208
Pneumatic system: Replacing the compressed-air filter ................................ 211

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Summary of Contents for SCK

Page 1: ...Sample conditioning for kiln SCK Sampling system for dry gas sampling at rotary cement kiln gas exit and calciner gas exit System manual 42 23 81 EN Rev 4 ...

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Page 3: ...Sample conditioning for kiln SCK Sampling system for dry gas sampling at rotary cement kiln gas exit and calciner gas exit System manual Publication No 42 23 81 EN Revision 4 Edition November 2016 ...

Page 4: ...n of the control system 38 User interface Operation screen 40 User interface Trend screen 42 User interface Message screen 44 User interface Parameter screen 46 Error message display 48 Access permissions 49 Default operating parameter settings 50 Optimizing operating parameters 53 Chapter 4 Safety 55 Basic safety rules 56 Overview of dangers 58 Protective installations 60 Warning signs on the sys...

Page 5: ... Operation 135 Safety regulations for operation 136 Monitoring automatic mode 138 Checking general condition 140 Cleaning gas sampling probe H 142 Cleaning gas sampling probe 60S 144 Using the EMERGENCY STOP switch 146 Chapter 9 Maintenance 147 Maintenance plan 148 Equipment layout plan 152 Acquiring spare parts and wear parts 155 Safety regulations for maintenance work 156 Operating the service s...

Page 6: ...6 Cooling module Checking and topping up cooling water 208 Pneumatic system Replacing the compressed air filter 211 Chapter 10 Errors 213 Errors and irregularities 214 Touchscreen error displays 216 Handling error messages 221 Chapter 11 Shutting down storing putting back into operation disposal 223 Shutting down the system 224 Disassembling the system 227 Storing the system 229 Putting the system...

Page 7: ...42 23 81 EN Rev 4 System Manual SCK Gas Sampling System 7 Chapter 1 General Topic Page About these operating instructions 8 Safety instructions in this document 10 System identification 12 Service 15 ...

Page 8: ...actual layout of a gas sampling system as delivered Therefore the drawings in the supplied system documentation are always authoritative Failing to observe the information in this document can lead to a risk of damage to property injuries or even death In order to ensure safety all personnel handling the gas sampling system must have read and understood the following sections of this document befo...

Page 9: ...risks to the operator Identifies special information regarding handling of the gas sampling system as well as use of these operating instruc tions 1 2 3 Identifies reference numbers in the figures Further information on ABB Analytical products and services is available on the Internet at http www abb com analytical Symbols and typefaces Further information ...

Page 10: ...dangers and safety measures when handling the system They are intended to educate the operator about existing dangers and to instruct him in general safety behavior They are suitable for safety instruction of all personnel han dling the gas sampling system Indicated by the title of the section Safety regulations for specific sections Safety instructions pertaining to all tasks described in this se...

Page 11: ...instruction is not fol lowed And the consequence is DANGER an accident occurs serious bodily injury or death WARNING the accident may occur possibly serious bodily injury or death CAUTION the accident will definitely or may possibly occur major or minor bodily injury Warnings of possible damage to property are marked by the word CAUTION in this document if there is no danger of injury to persons D...

Page 12: ...late is laid out as follows The individual areas of the nameplate have the following meaning No Meaning 1 Product name 2 Product number 3 Customer order number 4 Production number 5 Manufacturer s address 6 Serial number of the retractor 7 Serial number of the cooling module 8 Year of manufacture of the system 9 CE mark 10 Environment Friendly Use Period EFUP mark 11 Warning triangle to DIN EN 610...

Page 13: ...tor Standard retractor 2 5 m 2 Standard retractor 3 5 m 3 Retractor with special length 8th digit 1 Sample gas line prepared for TBL01 C 2 prepared for heated sample gas line 3 prepared for unheated sample gas line 9th digit 0 n a 10th digit 1 Power supply 230 V 400 V 50 Hz 2 230 V 400 V 60 Hz 3 120 V 208 V 60 Hz incl transformer 4 230 V 400 V 50 Hz prep for UPS 5 230 V 400 V 60 Hz prep for UPS 6 ...

Page 14: ...ractor according to customer requirement Sturdy control unit present not present Wire labeling present not present Circuit breakers 2 pole present not present Residual current circuit breaker for entire system present not present Cable labeling present not present Engraved nameplates present not present Additional nameplates engraved No 1 2 3 4 5 Orientation of probe S Sampling holes to the right ...

Page 15: ...dling of the gas sampling system that are not dealt with in these operating instructions for ordering spare parts for ordering maintenance work Contact your local ABB Service representative For emergencies please contact ABB Service Telephone 49 0 180 5 222580 Telefax 49 0 621 38193129031 E Mail automation service de abb com Service Service address ...

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Page 17: ...age Technical data 18 Intended conditions of use 19 Structure and function 20 Mode of functioning and operating modes 21 Process monitoring 22 Controls and displays 24 Probe retractor 26 Gas sampling probe H 28 Gas sampling probe 60S 30 Cooling module 32 Transformer 34 Compressed air tank and pneumatic system 35 ...

Page 18: ...nsions Width 800 mm Height 600 mm Length 4500 5500 mm Weight 450 500 kg Probe H Weight 95 kg for 3 m special length Probe 60S Weight 45 kg for 3 m special length Control cabinet Dimensions Width 800 mm Height 1000 mm Depth 300 mm Weight 75 kg Cooling module Dimensions Width 1200 mm Height 1500 mm Depth 800 mm Weight 250 kg Transformer optional Dimensions Width 634 mm Height 953 mm with base and tr...

Page 19: ...tor Analysis of the sample gas is by means of a suitable analyzer system for example the ACX analysis system from ABB Automation GmbH The gas sampling system may not be used to measure mixtures of gas air or gas oxygen that are capable of ignition during normal service to measure flammable gas which may form an explosive mixture in combination with air or oxygen in a potentially explosive atmosphe...

Page 20: ... tank optional back up probe movement if the on site com pressed air supply fails The sampling system serves the purpose of continuous sampling of sample gas at the measuring point i e at the gas outlet of the rotary kiln or at the gas outlet of the calcinator The probe forms a unit with the pneumatic probe retractor It is integrat ed in a closed cooling water circuit with a heat exchanger cooling...

Page 21: ...sampling probe sucks the sample gas through the sample gas line and passes it on to the connected analysis system 5 The operator switches to automatic mode 6 The probe cleaning system cleans the probe after the set interval 7 The retractor moves the probe in and out after a set interval in order to prevent it from sticking The following modes are possible Mode Description Automatic mode Allows con...

Page 22: ...ment Cooling water flow temperature measure ment Protects gas sampling probe against conden sation build up inside Locks various follow up functions during start up Cooling water pressure measurement Protects the gas sam pling probe against overheating Triggers the retraction program if minimum cooling water pressure is not reached Cooling water circuit leak monitoring Cooling water flow measureme...

Page 23: ...robe if the sample gas line is not fully heated up Cable drag chain tem perature measurement Protects the cable drag chain against conden sation build up inside Prevents insertion of the gas sampling probe if the sample gas line is not fully heated up The following monitoring devices belong to the probe H only Monitoring device Purpose Function Reed contact plunger extended Protects the plunger ag...

Page 24: ...t operation is not possible This safe guard is only overridden by personnel safety measures The picture shows controls on the control cabinet side view left front operating panel right The controls and displays on the control cabinet have the following function No Designation Function 1 Main switch Switches power supply on and off 2 Uninterruptible power supply switch optional Switches uninterrupt...

Page 25: ...e are additional controls and displays on the retractor Designation and illus tration Function EMERGENCY STOP switch on pneumatic box see Protective installations on page 60 Warning lamps 2 on the terminal box see Protective installations on page 60 Other controls ...

Page 26: ...nt connection 5 Heated connection box ca ble drag chain Connection between the sample gas line of the gas sampling sys tem and the downline sample gas line of the gas analysis system 6 Shutter with automatic pneumatic or manual actuation Closes the kiln duct opening when the probe is retracted not illustrated Transport supports For safe transport storage of the retractor removed in operation 7 Gas...

Page 27: ...er pressure too low Circulation pump failure Power supply interrupted Compressed air failure To protect the process against ambient air from being drawn in and to protect operators the duct opening is closed by a shutter when the probe is retracted This does not apply however to regular retraction extension for cleaning the outside of the probe The shutter is moved either automatically by a pneuma...

Page 28: ...essed air cylinder Drives the plunger movement 6 Gas outlet Passes the sample gas to the down line sample gas analysis system 7 Bellows Flexible sealing component between the outer fixed part of the probe and the moving plunger part 8 Cooling water connections Cooling water supply for probe cool ing 9 Mounting flange For fastening the gas sampling probe to the retractor 10 Pipe sealing device Spri...

Page 29: ... H comprises the following procedures Cleaning procedure Mode of functioning Cleaning of the wall tube Compressed air blast from air cannon removes material deposits between the probe and the wall tube Cleaning of the outside of the probe Material deposits and incrustations on the probe are removed by regularly moving the probe in and out using the retractor Cleaning the probe intake hole by means...

Page 30: ...up material deposits between the probe and the wall tube 4 Wall tube Pipe stub on rotary kiln 5 Cooling water connections Cooling water supply for probe cool ing 6 Mounting flange For fastening the gas sampling probe to the retractor 7 Filter unit FE2 Initial filtering of the sample gas for dust removal 8 Ceramic filter 9 Compressed air connec tions Allows periodical cleaning of the filter with co...

Page 31: ...ocation of the filter element Inner filter element Outer filter element Sampling holes A front sampling hole Two side sampling holes The gas sampling probe 60S offers the following cleaning procedures Cleaning procedure Mode of functioning Cleaning of the wall tube Compressed air blast from air cannon removes material deposits between the probe and the wall tube Cleaning of the outside of the prob...

Page 32: ... provide and monitor the cooling water supply In addition to the speed controlled heat exchanger and cooling water transport unit this unit also houses all transducers for monitoring cooling water The completely closed system monitors the following parameters Cooling water temperature Cooling water flow rate Cooling water pressure The following illustrations show the cooling module Meaning Structu...

Page 33: ...ule D51 16 Winbloc CAN bridge D50 17 Terminal strip power supply for motor and pump X51 18 Terminal box W51 19 Cable glands and cable feed through 20 Flow controller B57 The closed cooling water circuit must be filled with approx 50 l potable water requirements see Preparing the cooling water circuit on page 114 The circulation pump transports at least 5 m3 h through the probe pipe The resistance ...

Page 34: ... with door and base wiring is by means of threaded connec tions The casing is dip impregnated to protect against moisture Power 6900 00 VA UL Primary voltage 3 x 208 V delta Secondary voltage 3 x 400 V star Degree of protection IP 54 Test voltage 4 0 kV Insulation category T 50 A Winding separate Protection class I Frequency 60 Hz Switching YNd5 PRI SEC connection Terminals with screw connection T...

Page 35: ...sure 6 bar 6000 hPa positive pressure Consumption approx 3 m3 h One probe travel 2 x 20 s requires approx 1 m3 Other requirements are The compressed air must be free of dirt and oil water droplets At ambient temperatures below 0 C make sure that the compressed air supply cannot freeze The sampling system can be fitted with a 250 l compressed air tank The com pressed air tank serves to back up prob...

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Page 37: ...age Structure and function of the control system 38 User interface Operation screen 40 User interface Trend screen 42 User interface Message screen 44 User interface Parameter screen 46 Error message display 48 Access permissions 49 Default operating parameter settings 50 Optimizing operating parameters 53 ...

Page 38: ... up maintenance etc Diagnosis Displays current measured values trend displays messages and system information etc Setup Setup for system optimization limits etc access permissions editing tolerance ranges network set tings etc Authentication is performed on the Login User screen that the operator accesses in the Start menu by pressing the Menu button and then Login Without user au thorization the ...

Page 39: ... e g to select a user name On off buttons e g to open and close the shutter Pop up input panel on screen keyboard alphanumeric e g to enter the user name Pop up input panel on screen keyboard numeric e g to enter the password The following list indicates the four basic screen types of the control system User interface operating screen on page 40 User interface trend screen on page 42 User interfac...

Page 40: ...Displays the mode AUTOMATIC MANUAL 2 System status lights Displays the current system status normal operation error maintenance requirement maintenance 3 Display area Current menu display area 4 Current menu Menu path display 5 Screen functions Displays screen functions and submenus 6 Navigation area Allows the following functions jump to Message menu jump to main menu jump to previous menu Illust...

Page 41: ...tion red error orange maintenance required blue maintenance Menu path display Display box white requirement not met process interrupted inactive green requirement met black follow up function process running active Progress bar time to next cleaning only enabled in cleaning menus Button to trigger a function associated with a control button grayed out if disabled Jump to previous menu Jump to main...

Page 42: ...ured value at the time defined by the reading rule 2 Current measured value Current measured value 3 Display area Displays measured values and alarm thresh olds in the form of a line diagram 4 Navigation area Allows the following functions jump to Message menu jump to main menu jump to previous menu 5 Save Saves trend data 6 Diagram navigation Allows you to zoom in out in the line diagram and move...

Page 43: ...ction Move the reading rule left right in the diagram Jump to previous menu Jump to main menu Display Message menu Save contents Save diagram data in xls format Move contents of window left right Zoom in out The following colors are used in the trend screen line diagram Color Meaning blue Measured value yellow Pre alarm red Main alarm Buttons and symbols Colors ...

Page 44: ... status lights Displays the current system status normal opera tion error maintenance requirement mainte nance 3 Display area Chronological list of messages with description of error and status 4 Current menu Menu path display 5 Scrollbar Scroll up and down in the logbook 6 Navigation area Allows the following functions jump to previous menu 7 Screen functions Allows functions such as save history...

Page 45: ...enu path display Scroll buttons scrolls logbook up down and jumps to begin ning end Jump to previous menu Display help texts Reset all messages Reset the select message Save contents Save messages in xls format Display all messages in chronological order Click on crossed out clock to display pending messages only The following colors are used in the message screen display area Color Meaning green ...

Page 46: ...ode AUTOMATIC MANUAL 2 System status lights Displays the current system status normal opera tion error maintenance requirement mainte nance 3 Display area List of parameters 4 Current menu Menu path display 5 Screen navigation Allows navigation in the parameter list 6 Navigation area Allows the following functions jump to Message menu jump to main menu jump to previous menu 7 Save Saves parameter ...

Page 47: ...intenance Menu path display Scroll up or down in the parameter list Jump to previous menu Jump to main menu Display Message menu Save contents save parameter settings The control system has factory settings that need to be modified to specific system conditions at start up You can edit alarm limits in a set range to suit specific sys tem conditions Touch a parameter entry to select it The program ...

Page 48: ...play Error messages are displayed on the touchscreen All error messages are stored in the logbook message screen Touch the Message button on the interface to display this logbook Refer to the section on Errors on page 213 for details on error messages and handling Error display ...

Page 49: ...up for system optimization limits etc Access permissions Edit tolerance ranges Network settings A higher access level always includes the permissions of the lower access levels In level 3 you can configure parameters that may result in functional impairment of the system Changes in these access areas may only be performed by experi enced skilled personnel with ABB certification as level 2 service ...

Page 50: ... system has the following factory settings that need to be modified to specific system conditions at start up Parameter Default Back Purging Interval 3 min Probe Retraction Check Time 90 s Time for Measured Value Release 100 s Automatic Retraction Interval Time 30 s Suction Unit Duration 60 s Time parameters ...

Page 51: ... C 40 135 C C Water Return Temp MAX2 95 C 90 100 C C Water Flow Rate MIN 12 l min 5 45 l min C Water Flow Rate MIN2 11 l min 1 35 l min C Water Pressure MIN 350 mbar 300 900 mbar C Water Pressure MIN2 150 mbar 50 600 mbar C Water Pressure MAX 2500 mbar 2250 2750 mbar C Water Flow Return Temp Diff 2 C 1 15 C Probe Heating Temp MIN 5 C 1 100 C Probe Heating Temp MAX 190 C 30 200 C Sample Gas Probe P...

Page 52: ...stem has the following factory settings that need to be modified to specific system conditions at start up Parameter Default Tolerance range Action Cleaning Cycle Ratio 3 C Water Return Temp Set Point 80 C 15 140 C Probe Heating Temp Set Point 100 C 1 190 C Basic parameters ...

Page 53: ...e Time Values parameter screen Path Setup Time Parameters 2 Select parameter and enter appropriate value in the input box Note You can only edit time values within the tolerance limits 3 Click the Save button to save the settings Proceed as follows to edit a limit parameter Step Procedure 1 Open the Alarm Values parameter screen Path Setup Limit Parameters 2 Select parameter and enter appropriate ...

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Page 55: ...rs 58 Protective installations 60 Warning signs on the system 63 Requirements to be met by personnel work places 65 Personal safety equipment 67 Safety measures Transport and unpacking 68 Safety measures Installation 69 Safety measures Start up 72 Safety measures Operation 75 Safety measures Maintenance and troubleshooting 78 ...

Page 56: ...ing parts or attaching non approved parts Specifically do not change or disable any protective installations Use only original spare parts when replacing defective components The gas sampling system may only be operated if maintenance work is per formed regularly and expertly The operator must ensure that personnel meets the requirements for their tasks that personnel is provided with the personal...

Page 57: ...position The probe is only retracted out of the rotary kiln after pressing the service switch Disconnect the system from the mains Turn off the main switch Evacuate the compressed air system Close the stop valve in the pneumatic box If it can be assumed that safe operation is no longer possible the gas sampling system must be taken out of operation and secured against being started up again It can...

Page 58: ...re all other connections If the protective earth conductor is interrupted inside or outside the gas sam pling system or the protective earth connector is disconnected If the set operating voltage and mains voltage do not match before switching on If work is performed on the open gas sampling system without disconnecting the gas sampling system from the power supply Due to charged capacitors in the...

Page 59: ... of injury to skin and eyes in the event of contact with lubricating oil The pneumatic system contains compressed air This means Danger of eye injuries if compressed air escapes e g if compressed air pipes burst when opening screw connections or inadvertently opening compressed air pipes with no additional connector Lubricating oil in the pneumatic module Compressed air in the pneumatic system ...

Page 60: ...ng operation The protective installations must not be disabled and must be checked for proper functioning at regular intervals The illustrations show the location of the protective installations on the gas sam pling system Front view of the gas sampling system Top view of the rotary kiln with installed gas sampling probe and the danger zone around the probe retractor which is secured by a protecti...

Page 61: ...n from inserting hand into the system 3 Warning lamps Retractor termi nal box Warn about probe move ment The warning lamps flash in the following situations Automatic mode ap prox 20 seconds before probe movement Manual mode immedi ately after pressing the Retract probe button Error immediately be fore probe retraction 4 Warning buzzer Front of control cabinet Warns about probe move ment The buzze...

Page 62: ...en the protec tive installation is open When the protective instal lation is opened during operation the warning lamps flash the warning buzzer buzzes the probe moves out of the rotary kiln to parked position A warning horn additionally installed by the operator has the same function as the enclosed warning buzzer described above The additional warning horn must be installed if you cannot hear the...

Page 63: ...rrying parts There is a risk of electrocution by current carrying parts in the area of the terminal bar for normal mains supply and the terminal bar for the UPS This also applies when the main switch is turned off The warning signs on the cooling module 2 have the following meaning Warning sign Meaning Warns about hot surfaces A risk of hot surfaces can be expected during operation Particular dang...

Page 64: ...e connection box for the heated sample gas line on the probe retractor the heated sampling filter the entire gas sampling probe the metal structure of the probe retractor particularly in the area of the mounting flange the shutter on the duct opening Warns about probe movements Retractor movement can be expected during operation Do not stand in the area of travel of the probe or probe carriage unt...

Page 65: ...ssembly Electrical expert Start up per sonnel Initial start up Putting back into opera tion Technician familiar with the processes of cement production and specif ic works conditions Operator Operation Trained unskilled worker Mechanical maintenance personnel on mechanical parts Maintenance Troubleshooting Maintenance Shutting down Mechanical expert Electrical maintenance personnel on electric par...

Page 66: ...ies are located in the following places Activity Work places Installation Start up Maintenance Shutting down at the various modules of the gas sam pling system depending on the task Operation depending on the particular task at the control cabinet to operate the software around the gas sampling system to monitor operation but NOT in the dan ger area around the retractor that is protected by the pr...

Page 67: ...ety shoes Safety gloves suitable for mechanical work Safety glasses Protective helmet If necessary additional protective equipment if prescribed by the operator The following additional protective equipment is required when performing mainte nance work Dust mask Face mask against heat Heat proof gloves and protective welder s clothing Respiratory protection against toxic gases from the rotary kiln...

Page 68: ... oil During all work on the gas sampling system and in the vicinity of the gas sampling system Wear general personal protec tive equipment Closed overalls with long trousers and long sleeves Safety shoes Safety gloves suitable for mechanical work Safety glasses Protective helmet If necessary additional protective equipment if pre scribed by the operator Risk of crushing by heavy transport units Wh...

Page 69: ...rousers and long sleeves Safety shoes Safety gloves suitable for mechanical work Safety glasses Protective helmet If necessary additional protective equipment if pre scribed by the operator Risk of crushing by heavy transport units When lifting or lowering transport units Only appropriately trained personnel may transport the transport units and only with the aid of the recom mended transport equi...

Page 70: ...ful gases Due to gases escaping from the duct opening of the rotary kiln Only enter the danger area around the retractor when the shutter is closed Lock the shutter before commencing work Ensure adequate ventila tion of the work place If work is unavoidable in the area of the duct opening wear respiratory protection in addition to the general protective equipment Danger due to harm ful anti freeze...

Page 71: ... box on the pneumatic motor filter muffler inside the pneumatic motor Avoid contact with lubricat ing oil Wash any lubricating oil off the skin immediately with water and soap If any lubricating oil gets in the eyes despite protective glasses rinse them thor oughly under running water holding the eyelids open Observe instructions in the lubricating oil manufactur er s safety data sheet ...

Page 72: ...rushing due to moving gas sam pling probe In the travel area of the retractor when the probe moves in or out This is the case in the following situations at unforeseeable times during automat ic mode in the event of the following errors in au tomatic mode failure or interruption of the power supply failure of the com pressed air supply failure of the control system when manually start ing probe tr...

Page 73: ...ox for the heated sample gas line on the retrac tor the heated sampling filter the entire gas sam pling probe the metal structure of the retractor the shutter of the duct opening Do not touch these compo nents during and after op eration Do not touch these compo nents until they have cooled down to less than 50 C If it is unavoidable to touch hot components wear a face mask against heat heat proof...

Page 74: ...cooling system Avoid contact with the cooling water and the anti freeze Wash any cooling water or anti freeze off the skin im mediately with water and soap If cooling water or anti freeze gets in the eyes de spite protective glasses rinse them thoroughly un der running water holding the eyelids open Observe instructions in the anti freeze manufacturer s safety data sheet Danger due to harm ful lub...

Page 75: ...oes Safety gloves suitable for mechanical work Safety glasses Protective helmet If necessary additional protective equipment if pre scribed by the operator Risk of crushing due to moving gas sam pling probe In the travel area of the retractor when the probe moves in or out This is the case in the following situations at unforeseeable times during automat ic mode in the event of the following error...

Page 76: ... the danger area around the retractor during operation Do not touch these compo nents during and after op eration If it is unavoidable to touch hot components wear a face mask against heat heat proof gloves and pro tective welder s clothing Risk of burning due to falling or spalling material After the probe moves out of the rotary kiln hot material may fall or spall off the probe Never enter the d...

Page 77: ...g the eyelids open Observe instructions in the anti freeze manufacturer s safety data sheet Danger due to harm ful lubricating oil Lubricating oil escaping from the pneumatic module in the event of an error Avoid contact with lubricat ing oil Wash any lubricating oil off the skin immediately with water and soap If any lubricating oil gets in the eyes despite protective glasses rinse them thor ough...

Page 78: ...ling water anti freeze compressed air lubricating oil During all work on the gas sampling system and in the vicinity of the gas sampling system Wear general personal protec tive equipment Closed overalls with long trousers and long sleeves Safety shoes Safety gloves suitable for mechanical work Safety glasses Protective helmet If necessary additional protective equipment if pre scribed by the oper...

Page 79: ...ys tem Additionally press the EMERGENCY STOP switch before working on the retractor Do not enter the danger area around the retractor until it is at standstill and the warning lamps and buzzer are off Never stand in the danger area around the retractor when the protective instal lation is closed When the warning lamps light up or the earning buzzer buzzes leave the danger area around the probe ret...

Page 80: ...gainst heat heat proof gloves and pro tective welder s clothing Risk of burning due to falling or spalling material After the probe moves out of the rotary kiln hot material may fall or spall off the probe Never enter the danger area around the retractor during operation Do not approach the re tracted probe until it has cooled down If it is unavoidable to ap proach the hot probe wear a face mask a...

Page 81: ...ing water of the cooling system Avoid contact with the cooling water and the anti freeze Wash any cooling water and anti freeze off the skin immediately with water and soap If cooling water or anti freeze gets in the eyes de spite protective glasses rinse them thoroughly un der running water holding the eyelids open Observe instructions in the anti freeze manufacturer s safety data sheet Danger du...

Page 82: ...v 4 Danger Where in what situa tion does the danger arise Preventive action Risk of slipping Around the gas sampling system due to cooling water or lubricating oil that escapes or is spilled Always keep the floor around the gas sampling system clean and dry ...

Page 83: ...EN Rev 4 System Manual SCK Gas Sampling System 83 Chapter 5 Transport and unpacking Topic Page General transport information 84 Transport the system in the company 87 Unpacking the system 89 Scope of delivery 90 ...

Page 84: ...the transport packaging is not damaged or re moved Observe the below mentioned temperature and humidity limits during transport In the event of transport damage attributable to improper handling instigate dam age assessment by the carrier rail post office and forwarder within seven days Make sure that none of the enclosed accessories are lost during unpacking Store the screws in case the unit need...

Page 85: ...ort recommendation For lift truck or hand lift Transformer optional 140 kg Use a suitable transport pallet for transport transport recommenda tion fork lift truck or hand lift The casing is also fitted with transport lugs and can be lifted using a crane Compressed air tank optional 90 kg May only be transported on its side Ensure adequate protection of the attachments Only store after draining all...

Page 86: ...condensation is permitted Transformer optional Ambient temperature 25 C to 55 C Air humidity Year round average max 80 short term max 95 without condensation Compressed air tank optional Ambient temperature 5 C to 55 C after completely draining all water and drying parts in contact with cooling water or condensation 20 C to 55 C Air humidity Year round average max 75 short term max 95 occasional s...

Page 87: ...any Module Weight Transport conditions Retractor in cluding probe max 500 kg Probe tip must be adequately fixed to the retractor e g with a load strap in order to avoid bouncing that may damage the rollers and rails Use the two enclosed transport supports for transport in the company see illustration in Probe retractor on page 26 Lifting gear may only be attached at the designated attachment point...

Page 88: ...rt The compressed air tank may only be transported on its side Ensure adequate protection of the attachments Transport recommendation For lift truck or hand lift Transformer 140 kg Use a suitable transport pallet for transport Lifting gear may only be attached at the designated attachment points transport lugs Transport recommendation For lift truck hand lift or crane ...

Page 89: ...d transport equipment Do not stand under suspended loads Follow the transport instructions in these operating instructions carefully Perform the following steps to unpack the system Step Procedure 1 Remove outer packaging Transport crate Tensioning straps Cardboard films and wooden parts 2 Undo fasteners holding the system parts on the pallet 3 Lift system parts off the pallet with a crane fork li...

Page 90: ...ding gas sampling probe H or 60S Control cabinet Cooling module Cooling water hose 30 m Bottle of compressed air lubricant 1 l Complete documentation DE EN on CD ROM System manual The following optional components may be included in the scope of delivery 250 l compressed air tank Compressed air piping 25 m Transformer IP44 Scope of delivery Optional ...

Page 91: ...te conditions 93 Installing the probe retractor 95 Installing the control cabinet 98 Installing the compressed air supply 99 Installing the cooling module 101 Installing the cooling water circuit 103 Connecting the sample gas line to the retractor 104 Connecting internal electric cables 105 Connecting external electric cables 107 ...

Page 92: ...ing during assembly of the probe retractor uncov ered duct opening Proceed as follows to install the complete system Step Procedure Instructions in 1 Check place of installation of the various modules of the gas sampling system Checking site conditions on page 93 2 Install the probe retractor such that personnel are not endangered and the system cannot be damaged Installing the probe retractor on ...

Page 93: ...n met The following conditions must be met Conditions Description in the Engineering Guideline in OK General rules regarding choice of installation site were ob served environmental conditions taken into account General rules regarding choosing the place of installation of the pe ripheral modules Environmental condition require ments Installation position of probe and probe retractor defined Posit...

Page 94: ...er and compressed air supply conforms to the require ments of the gas sampling sys tem Power and compressed air supply requirements Air cannon if present is inte grated into the gas sampling system control system only Integrating the air cannon into the control system The danger area around the probe retractor is protected by a protective installation Creating the base area for the retractor Creat...

Page 95: ...overed duct open ing when the rotary kiln is in operation Preferably install or remove the probe when the rotary kiln is out of operation If you install or remove the probe when the rotary kiln is in operation Wear a face mask against heat heat proof gloves and protective welder s clothing and respiratory protection against toxic gases Keep the time in which the duct opening is open as short as po...

Page 96: ... elements CAUTION The screw in transport lugs are for transporting the probe retractor only but not for permanent suspension For permanent suspension of the probe retractor only use the 6 designated fastening straps 6 Remove dummy flange on wall tube WARNING Risk of burning due to jet flames and hot gases at the uncovered duct opening when the rotary kiln is in operation Wear a face mask against h...

Page 97: ... completing work Release lock move probe carriage to original position and lock again 7 Fasten both ends of the tackle again avoid twisting the chain 8 Tighten tensioning device 9 Remove lock After completing all installation tasks and start up it may be necessary to change the position of the gas sampling probe so as to ensure precise extension into and retraction out of the rotary kiln Instructi...

Page 98: ...ly with the aid of the recommended transport equipment Do not stand under suspended loads Follow the transport instructions in these operating instructions carefully 4 galvanized steel screws or stainless material M10 or bolts M10 The following requirements must be met in order to install the control cabinet The site conforms to the designated site conditions criteria see Choosing the place of ins...

Page 99: ...he following assembly screws are required for installation of the compressed air tank 3 galvanized steel screws or stainless material or bolts M12 The following conditions must be met Compressed air conforms to the required quality of compressed air see Power and compressed air supply conditions When setting up the compressed air tank The site conforms to the designated site conditions criteria se...

Page 100: ...talling tubes on trays or in tube conduits Minimum bending radius of the compressed air tube is 100 mm If this is not possible for technical reasons ABB recommends installing suitable pipe adapt ers You can run the tubes for the necessary pneumatic connections central com pressed air supply compressed air tank flow compressed air tank return either via the central connection point of the probe ret...

Page 101: ...ing the transport unit Only appropriately trained personnel may transport the transport units and only with the aid of the recommended transport equipment Do not stand under suspended loads Follow the transport instructions in these operating instructions carefully 4 galvanized steel screws or stainless material M12x30 or bolts M12x30 The following requirements must be met in order to install the ...

Page 102: ...le Step Procedure 1 Fasten cooling module in suitable position see Choosing the place of installation of the cooling module with 4 as sembly screws or bolts on the ground 2 Attach suitable drain pipe to safety valve outlet J62 in order to prevent danger of cooling water escaping Instructions ...

Page 103: ... the cooling water hoses as follows Step Procedure 1 After assembling the probe retractor and cooling module determine the length of the cooling water hoses 2 Cut the cooling water hoses to length 3 Insert screw connectors into the ends of the hoses and secure with hose clamps Install the cooling water hoses as follows Step Procedure 1 Lay and fasten cooling water hoses along designated path 2 Con...

Page 104: ...edure 1 The connector from the sample gas line to the probe retrac tor cable drag chain can be found in the pneumatic hydraulic interface plan in the appendix If further information is re quired on installation and connection to the analyzer system consult the operating instructions of the analyzer system and analysis line Note These tasks apply only to connection of the sample gas line to the ana...

Page 105: ... shock when working on electric components Only specialized electrical personnel may work on the electrical system Disconnect the gas sampling system from the power supply before working on the electrical components Observe national regulations pertaining to electrical equipment The location of the electric connections on the various modules can be found in the electrical connection plan in the ap...

Page 106: ...tion 60S 230 VAC cable to probe retractor Signal cable to analyzer cabinet System bus cable control cabinet cooling module see step 3 System bus cable probe retractor cooling module see step 3 3 Connecting the system bus cable Install system bus cable from control cabinet to cooling module terminal box Connect to the 9 pin D Sub connector of the CAN bridge 1 Install system bus cable from the probe...

Page 107: ...ions pertaining to electrical equipment The control unit of the sampling system is equipped with an Ethernet interface This interface is intended solely for service purposes Any other use is not allowed When using the Ethernet interface external influences through the network con nection can disturb the time characteristics of the control program and thus of the complete sampling system The locati...

Page 108: ...ystem status signal cable Profibus cable to analyzer cabinet option Profibus DP Modbus cable to analyzer cabinet option ACX The gas sampling system is fitted with an electric signal input that allows you to integrate an external protective installation to secure the danger area around the retractor To do so connect the appropriate switching output of the movable protec tive installation to the sig...

Page 109: ... STOP switch the probe retractor is fitted with a connector for an additional EMERGENCY STOP switch As delivered both connectors are jumpered see Detail A in pneumatic hydraulic interface plan To connect an additional EMERGENCY STOP switch remove the jumper and connect the connection wires to the EMERGENCY STOP switch Connection option for additional warning horn Connection option for additional E...

Page 110: ......

Page 111: ...r circuit 114 Preparing the compressed air supply 116 Activation 118 After switching on working on the cooling module 121 Checking the pneumatic system 123 Starting frequency converter and adapting control parameters 124 Checking correcting operating parameters 127 Checks to perform when using probe H 128 Inserting the probe and switching to automatic mode 131 ...

Page 112: ... 121 6 Check pneumatic system with the aid of the compressed air switch in the pneumatic box Checking the pneumatic system on page 123 7 In the control cabinet check frequency converter settings and correct if necessary Checking frequency con verter settings on page 124 8 Check operating parameters of the gas sampling system and correct if necessary Checking correcting oper ating parameters on pag...

Page 113: ...ts is not met abort start up and do not continue until the appropriate conditions have been created How to check the installation Step Procedure 1 Based on the checklist below check whether the gas sampling system was installed correctly 2 Only continue to start up the gas sampling system once all condi tions have been met The following conditions must be met Conditions OK No visible damage to the...

Page 114: ... freeze Avoid contact with the cooling water and the anti freeze Wash any cooling water and anti freeze off the skin immediately with water and soap If cooling water or anti freeze gets in the eyes despite protective glasses rinse them thoroughly under running water holding the eyelids open Observe instructions in the anti freeze manufacturer s safety data sheet The closed cooling water circuit mu...

Page 115: ...exchanger Unscrew cap on drain valve and open vent cock red 3 Open drain valves 2 on gas sampling probe 4 Slowly open the shut off valve J63 on the cooling module and allow cooling water to flow in until cooling water appears at the drain valves of the heat exchanger and gas sampling probe 5 Close shut off valve J63 6 Close drain valves on heat exchanger and gas sampling probe 7 Check pressure of ...

Page 116: ... contact with lubricating oil Wash any lubricating oil off the skin immediately with water and soap If any lubricating oil gets in the eyes despite protective glasses rinse them thor oughly under running water holding the eyelids open Observe instructions in the lubricating oil manufacturer s safety data sheet Lubricating oil D DIN 51502 kinematic viscosity 30 mm2 s cST at 40 C ISO VG 32 DIN 51519...

Page 117: ...s have been permanently eliminated Fill the compressed air oiler before switching on the gas sampling system Step Procedure 1 Shut off the compressed air using the gate valve 1 in the pneumatic box of the probe retractor 2 Completely drain the compressed air tank if present 3 Unscrew the tank on the compressed air oiler J74 by turning it counter clockwise fill suitable oil to the top quarter in th...

Page 118: ...tions pertaining to electrical equipment Risk of crushing around the retractor due to gas sampling probe movements Do not stand in the danger area around the retractor Press the EMERGENCY STOP switch immediately if anyone is still in the danger area around the retractor after the warning lamps light up or the warning buzzer buzzes The connected analyzer system must be switched on Observe the warm ...

Page 119: ... cabinet 8 Wait for controller to boot 9 Start frequency converter 10 Adjust local time password for Advance Service required Path Setup System Time setting 11 Open the compressed air gate valve 1 again WARNING Depending on the current position the probe begins to move towards to the rear end position probe completely retracted Do not stand in the area of travel of the probe or probe car riage 12 ...

Page 120: ...re smooth operation of the gas sampling system before inserting the gas sampling probe for the first time After switching on Working on the cooling module on page 121 Checking the pneumatic system on page 123 Checking frequency converter settings on page 124 Checking correcting operating parameters on page 127 Checks to perform when using probe H on page 128 17 Close the control cabinet ...

Page 121: ... equipment Danger of injury to skin and eyes in the event of contact with cooling water or anti freeze Avoid contact with the cooling water and the anti freeze Wash any cooling water and anti freeze off the skin immediately with water and soap If cooling water or anti freeze gets in the eyes despite protective glasses rinse them thoroughly under running water holding the eyelids open Observe instr...

Page 122: ...drain valve on the gas sampling probe 7 Close drain valve on gas sampling probe again as soon as only cooling water comes out of the drain valve 8 Switch cooling water pump M51 on again at motor breaker F37 1 or at circuit breaker F36 2 for approx 20 s 9 Wait 5 minutes vent again 10 Repeat step 8 through 9 if necessary until no more air comes out of the cooling water circuit 11 Check pressure of c...

Page 123: ...otective equipment if prescribed by the operator The service switch is in the ON position the gas sampling probe is retracted from the kiln see Operating the service switch on page 159 Proceed as follows to check compressed air settings before first insertion Step Procedure 1 Check the compressed air system with suitable equipment see Checking for leaks on page 171 2 Check the pressure switches in...

Page 124: ... connection or terminal boxes Only specialized electrical personnel may work on the electrical system Observe national regulations pertaining to electrical equipment The frequency converter ACS355 controls the heat exchanger motor In order to ensure constant cooling water temperature the factory set default control parame ters must be adapted to the conditions at the installation site Refer to the...

Page 125: ...ust be executed only during the first system start up and not after a system power failure 3 Close control cabinet 4 Turn service switch to OFF position 5 Insert probe 6 Monitor cooling water return temperature Path Diagnosis Trends Cooling water return Note If the set points are exceeded due to inadequate adaptation of the control parameters the program sequences for the protection of the probe a...

Page 126: ...126 System Manual SCK Gas Sampling System 42 23 81 EN Rev 4 Step Procedure 10 Save control parameter settings using the button ...

Page 127: ...nditions Limited configuration serves to protect the probe retractor against harmful or contradictory settings A list of operating parame ters can be found in Default operating parameter settings on page 50 You can display the operating parameters on the control cabinet touchscreen Setup Time Parameters Setup Limit Parameters Setup Basic Parameters Refer to Optimizing operating parameters on page ...

Page 128: ...he probe for the first time addi tional checks are required when using probe H These are Checking current monitoring relay settings Checking probe H heating power supply The following illustration shows the position of current monitoring relays K35 and K36 in the control cabinet Control cabinet key to open the control cabinet The following conditions must be met The service switch is in the ON pos...

Page 129: ...rrent monitoring relays K35 and K36 for correct settings Settings for K35 and K36 Hysteresis 5 Threshold 4 5 A Tripping delay 0 1 s Start up delay 5 s There is a DIP switch under the white flap Check the following settings here 1 Undercurrent monitoring ON 2 NC contact operation ON 3 Storage off OFF 4 Default OFF 3 Close the control cabinet Checking current monitoring relays ...

Page 130: ...eration Proceed as follows Step Procedure 1 Check voltage between Ground and the probe side terminal con nections 1 or 2 2 The following minimum values must be reached Probe length m 1 5 2 2 5 3 3 5 Minimum voltage V 24 26 26 28 30 If these values are not reached the system must not be put into operation in this set up as adequate heating of the integrated metal filter cannot be guaranteed and thi...

Page 131: ...re off Never stand in the danger area around the retractor when the protective installa tion is closed When the warning lamps light up or the earning buzzer buzzes leave the danger area around the probe retractor immediately as the probe is about to move at any moment Press the EMERGENCY STOP switch immediately if anyone is still in the danger area around the retractor after the warning lamps ligh...

Page 132: ...sampling probe to automatic mode using the touchscreen Path Operation Automatic on off Result The sampling system is thus in automatic mode and monitors itself After switching on the gas sampling system there may be differences in probe retractor travel speed depending on the capacity of the compressed air supply provided by the customer The travel time for one insertion retraction of the gas samp...

Page 133: ...G The probe moves out of the kiln Do not stand in the area of travel of the probe or probe carriage 2 Turn the setting screw in the inspection glass to modify the quantity of oil Meaning of the directions of rotation counter clockwise more oil clockwise less oil 3 Move probe in out to check oil quantity modify again if necessary 4 Turn service switch back to OFF position and insert probe again usi...

Page 134: ...to the greater flow speeds in this process after start up the gas sampling probe must be checked frequently for wear at the calcinator gas outlet measuring point If distinct signs of wear are visible after a short time check the installation position of the gas sampling probe Failing to observe this can lead to severe dam age or total loss of the gas sampling probe Instructions checking the direct...

Page 135: ...ng System 135 Chapter 8 Operation Topic Page Safety regulations for operation 136 Monitoring automatic mode 138 Checking general condition 140 Cleaning gas sampling probe H 142 Cleaning gas sampling probe 60S 144 Using the EMERGENCY STOP switch 146 ...

Page 136: ...t up or the warning buzzer buzzes Danger of electric shock when touching electric components Only specialized electrical personnel may work on the electrical system If you are not specialized electrical personnel Never open electric components Never touch damaged electric components cables or the inside of electric components danger of burning due to hot surfaces during and after operation of the ...

Page 137: ... cooling water and the anti freeze Wash any cooling water and anti freeze off the skin immediately with water and soap If cooling water or anti freeze gets in the eyes despite protective glasses rinse them thoroughly under running water holding the eyelids open Observe instructions in the anti freeze manufacturer s safety data sheet Danger due to skin and eye injuries in the event of contact with ...

Page 138: ...ure Sample Gas Pressure Cooling Water Flow Rate Cooling Water Flow Temp Cooling Water Return Temp Probe Heating Temp Observe the following rules in automatic mode In case of error signals read the message on the touchscreen immediately and take appropriate action Errors on page 213 Check general condition of the system Checking general condi tion on page 140 Failure of mains power leads to immedia...

Page 139: ...ecreases the SO2 concentration measured in the analyzer In the above mentioned cases the falsification of results will be all the more se vere the lower the concentration of SO2 Maximum reliability of SO2 measurement is given when the gas sampling hole s on the probe tips are completely open i e not clogged up with rust particles immediately after blow back Due to the propensity of rust particles ...

Page 140: ... damage missing or loose covers visible damage to electric cables hose and pipe leaks Control cabinet Check general condition of control cabinet with regard to the following general damage missing or loose covers visible damage to electric cables dripping water or other liquids Compressed air tank optional Check general condition of compressed air tank with regard to the following visible damage I...

Page 141: ...ampling probe must be checked frequently for wear at the calcinator gas outlet measuring point If distinct signs of wear are visible after a short time check the installation position of the gas sampling probe Failing to observe this can lead to severe dam age or total loss of the gas sampling probe Special case calcinator gas outlet ...

Page 142: ...ce to clean the sample gas inlet Start Manual Cleaning The system emits a blast of air lasting 5 sec onds to clean the probe filter the plunger is activated Note In MANUAL mode you can also remote control cleaning via a network con nection In AUTOMATIC mode the cleaning process is a time controlled automatic process that runs as follows Phase Description 1 Plunger moves forward and backward to cle...

Page 143: ...cleaning cycle is repeated up to three times If this does not remedy the error error message Error 3x Cleaning Not Successful Probe H is displayed and the gas sampling system switches to error mode The probe is retracted out of the kiln No more cleaning processes and movements take place See Errors on page 213 section for further details Cleaning parameters such as the time between cleaning cycles...

Page 144: ...g via a network con nection In AUTOMATIC mode the cleaning process is a time controlled automatic process that runs as follows Phase Description 1 Two air blasts lasting 1 second each to clean the probe filter 2 Two air blasts lasting 1 second each to clean the filter casing 3 One air blast lasting 3 seconds to clean the probe pipe The following processes runs after a number of cleaning cycles tha...

Page 145: ...p to three times If this does not remedy the error error message Error 3x Cleaning Not Successful Probe 60S is displayed and the gas sampling system switches to error mode The probe is retracted out of the kiln No more cleaning processes and movements take place See Errors on page 213 section for further details Cleaning parameters such as the time between cleaning cycles are delivered as default ...

Page 146: ...out of the rotary kiln after press ing the service switch What to do after pressing the EMERGENCY STOP switch Step Procedure 1 Remove danger 2 Make sure that the danger cannot occur again no one is standing in the area of probe retractor travel 3 Unlock the EMERGENCY STOP switch by turning the back ring in the direction of the arrow 4 Actuate service switch in control cabinet i e turn to ON positi...

Page 147: ... membranes 179 Gas sampling probe 60S Removing incrustations 182 Gas sampling probe 60S Cleaning or replacing the outlet filter 184 Gas sampling probe 60S Replacing the seal set 187 Probe retractor Checking filter pressure control combination 189 Probe retractor Checking and replacing the filter muffler 191 Probe retractor Checking and topping up the oiler 193 Probe retractor Checking and tighteni...

Page 148: ...ng system is visibly damaged if a check reveals problems if the gas sampling system no longer works after prolonged storage in adverse conditions after severe transport stress It is recommended to have the gas sampling system maintained by the ABB repre sentative responsible for you When performing maintenance work on the gas sampling system the service switch must be in the ON position with a few...

Page 149: ...X Functional test of residual current circuit breaker Checking the residual current circuit breaker on page 165 X Functional tests of EMERGENCY STOP switch Warning lamps Warning buzzer external warning horn op tional Checking protective installations on page 167 X Maintenance task See Inspection Maintenance intervall as required dayiy weekly twice yearly yearly every 2 years Gas sampling probe H M...

Page 150: ...g and replacing the filter muffler on page 191 X Check oil level in oiler in pneumatic box and changing the quantity of oil delivered Probe retractor Checking and topping up the oiler on page 193 X Check and if necessary tight en drive chain Probe retractor Checking and tightening the drive chain on page 196 X X Check and if necessary adjust the filter pressure con trol combination or replace fil ...

Page 151: ... 208 X Vent the cooling water circuit Cooling module Venting the cooling water circuit on page 206 X X Check cooling water system for leaks Checking for leaks on page 171 X Maintenance task See Inspection Maintenance intervall as required dayiy weekly twice yearly yearly every 2 years Pneumatic system Replace compressed air filter in pneumatic box Pneumatic system Replacing the com pressed air fil...

Page 152: ...ent Equipment ID Designation J53 Filter pressure control combination J54 Compressed air gate valve J74 Pneumatic motor oiler J75 EMERGENCY STOP switch for probe movement J77 Pneumatic valve Insert probe J78 Pneumatic valve Retract probe J79 Pneumatic valve shutter J81 Pneumatic motor J82 Gate valve J83 Air filter P71 Probe movement warning lamp P72 Probe movement warning lamp not illustrated Posit...

Page 153: ...cuit breaker for main switch optional F40 Residual current circuit breaker for UPS optional F31 Service socket circuit breaker F32 Power supply circuit breaker 24V F33 Probe heating circuit breaker F34 Sample gas line connection box 230 V valves heating circuit breaker F35 Heat exchanger circuit breaker F36 Cooling water pump circuit breaker F37 Cooling water pump motor breaker S31 Service switch ...

Page 154: ...tenance relevant equipment on cooling module The following table lists the above mentioned equipment No Designation 1 Shut off valve cooling water J63 2 Cooling water inlet 3 Cooling water feed 4 Safety relief valve outlet 5 Heat exchanger J60 6 Cooling water return Illustration Equipment ...

Page 155: ...pling System 155 Acquiring spare parts and wear parts To order spare parts or to order service please contact your local ABB service partner or ABB Service Phone 49 0 69 7930 4706 Fax 49 0 69 7930 4707 Email service analytical de abb com Service ...

Page 156: ...ommencing any work on the gas sampling system turn the service switch to ON and secure the service switch against unauthorized switching with a padlock Additionally press the EMERGENCY STOP switch before working on the retrac tor or probe Do not enter the danger area around the retractor until it is at standstill and the warning lamps and buzzer are off Never stand in the danger area around the re...

Page 157: ...r s clothing Danger due to harmful gases from the rotary kiln and jet flames in the area of the shutter particularly while the gas sampling probe is moving in and out Ensure adequate ventilation of the work place Only enter the danger area around the retractor when the shutter is closed If work is unavoidable in the area of the duct opening lock the shutter before commencing work and wear respirat...

Page 158: ...in the eyes despite protective glasses rinse them thor oughly under running water holding the eyelids open Observe instructions in the lubricating oil manufacturer s safety data sheet Danger due to harmful dusts when cleaning the gas sampling system Wear a dust mask when cleaning Wash any dust off the skin immediately with water and soap Risk of falling on slippery floor due to escaped or spilled ...

Page 159: ...CY STOP switch before working on the retrac tor or probe Do not enter the danger area around the retractor until it is at standstill and the warning lamps and buzzer are off Never stand in the danger area around the retractor when the protective installa tion is closed When the warning lamps light up or the earning buzzer buzzes leave the danger area around the probe retractor immediately as the p...

Page 160: ...out Result The gas sampling probe is automatically retracted out of the kiln the controller displays the Maintenance message 3 Secure the service switch against unauthorized actuation 4 When working on the retractor and gas sampling probe additionally actuate the EMERGENCY STOP switch for reasons of safety 5 Perform maintenance tasks 6 Leave danger area around the retractor and close the protectiv...

Page 161: ...til it has cooled down Always keep the floor around the gas sampling system clean and dry When performing any cleaning work Wear a dust mask when cleaning Wash any dust off the skin immediately with water and soap Ensure adequate ventilation of the work place Checking and cleaning the probe retractor If work is unavoidable in the area of the duct opening lock the shutter before commencing work and...

Page 162: ... to the follow ing general damage missing or loose covers visible damage to connection cables 2 Check control cabinet for dripping water or other liquids 3 In the event of excessive soiling of the surface of the control cabi net clean with a soft brush or compressed air 4 Clean touchscreen particularly edge areas with compressed air and or moist cloth if you use cleaning agents you can request a r...

Page 163: ...obe when the wall tube is clogged can lead to damage to the probe The same applies to re inserting the gas sampling probe after prolonged standstill of the gas sampling system Perform the following steps for the cooling module Step Procedure 1 Check general condition of cooling module with regard to the fol lowing general damage missing or loose covers visible damage to connection cables 2 Check h...

Page 164: ...assword Perform the following steps to evaluate trend displays Step Procedure 1 Open the Trends submenu Path Diagnosis Trends 2 Select one of the available parameters Sample Gas Pressure Cooling Water Pressure Cooling Water Flow Rate Cooling Water Flow Temp Cooling Water Return Temp 3 A typical trend screen is displayed The measured value is blue alarm thresholds are also highlighted with a specia...

Page 165: ...ions pertaining to electrical equipment The following diagram shows the location of the residual current circuit breaker in the control cabinet Integration of residual current circuit breakers is variable in the gas sampling system No residual current circuit breaker is integrated in the stand ard model the FI option F30 has a 4 pole residual circuit breaker for the normal grid the FI UPS option F...

Page 166: ...t breaker for normal grid 3 Result of function test If then the residual current circuit breaker trips the residual current circuit breaker is working as intended the residual current circuit breaker does not trip shut down the sampling system secure against start up and have it repaired by trained expert personnel 4 Perform steps 1 through 3 with residual current circuit breaker for UPS F40 if pr...

Page 167: ...ntrolled heat up of the probe tip if an error occurs at the same time Observe company regulations with regard to maintenance intervals Always take the following safety measures when performing this work Wear the general protective equipment Press the EMERGENCY STOP switch immediately if anyone is still in the dan ger area around the retractor after the warning lamps light up or the warning buzzer ...

Page 168: ...ce switch S31 on the control cabinet to the ON position WARNING Actuating the service switch moves the probe to its rear end position Do not stand in the area of travel of the probe or probe carriage until the probe has reached its end position Result The gas sampling probe is retracted to its rear end position the controller displays the Maintenance message 6 Turn service switch S31 back to the i...

Page 169: ...e or probe car riage until the probe is completely inserted into the kiln and the warning lamps go out Perform the following steps to check the warning buzzer H31 Step Procedure 1 Switch system to manual mode on the touchscreen if this has not already been done Path Operation Automatic on off 2 Retract gas sampling probe out of the kiln Path Operation Probe Probe Action Retract WARNING The probe i...

Page 170: ...rement The warning horn goes off 3 In the event of irregularities shut down the sampling system se cure against start up e g with a padlock and have it repaired by trained expert personnel If they are working as intended Turn service switch back to OFF position and insert gas sampling probe again using the controller WARNING Gas sampling probe moves into the kiln Do not stand in the area of travel...

Page 171: ...losed Do not perform the work until the gas sampling system has cooled down Avoid contact with the cooling water and the anti freeze Wash any cooling water and anti freeze off the skin immediately with water and soap If cooling water or anti freeze gets in the eyes despite protective glasses rinse them thoroughly under running water holding the eyelids open Observe instructions in the anti freeze ...

Page 172: ...ert gas sampling probe again using the controller WARNING Gas sampling probe moves into the kiln Do not stand in the area of travel of the gas sampling probe or probe carriage until the probe is completely inserted into the kiln and the warning lamps go out How to check the compressed air system for leaks Step Procedure 1 Switch service switch to ON position see Operating the service switch on pag...

Page 173: ...ce component and ensure adequate sealing no leak was found but pres sure continues to drop in operation follow steps 3 6 4 Drain the cooling water circuit 5 Fill cooling water circuit with compressed air max 3 bar 3000 hPa 6 Spray cooling water circuit with leak detection spray 7 If you locate a leak replace component and ensure adequate sealing 8 Fill up cooling water again and vent see Preparing...

Page 174: ...th a padlock Additionally press the EMERGENCY STOP switch Do not enter the danger area around the retractor until it is at standstill and the warning lamps and buzzer are off and the shutter is closed Do not perform the work until the gas sampling system has cooled down Lock the shutter when you start the work unlock the shutter after finishing the work Always keep the floor around the gas samplin...

Page 175: ...chemicals acids lyes etc for cleaning 4 Manually unlock the shutter 5 In controller insert the probe Path Operation Probe Probe Action Insert WARNING The probe moves into the kiln Do not stand in the area of travel of the probe or probe carriage 6 In controller launch compressed air cleaning Path Operation Probe Cleaning Manual Mechanical Cleaning 7 In controller retract the probe Path Operation P...

Page 176: ...e is closed Lock the shutter when working on the plunger unlock the shutter after replacing the filter Do not perform the work until the gas sampling system has cooled down Explanation of safety measures Safety regulations for maintenance work on page 156 Wrench SW32 The following conditions must be met The service switch is in the ON position the gas sampling probe is retracted from the kiln see ...

Page 177: ...ampling probe to cool down WARNING Risk of burning in the event of contact with the hot probe Do not touch the probe until it has cooled down to be low 50 C 2 Unscrew the adjustment screws 1 on the probe carriage until you can swing the probe out 3 Swing the probe out to the right Swinging the probe tip out ...

Page 178: ... Probe Plunger Action If you cleaned the probe tip while it was swung out proceed as follows before resuming measurements Step Procedure 1 Swing probe back in 2 Tighten adjustment screws 3 Check probe alignment in relation to the duct opening if necessary correct the position after unscrewing the adjustment screws again 4 Turn service switch back to OFF position 5 Inserting probe again Path Operat...

Page 179: ...ling system has cooled down Explanation of safety measures Safety regulations for maintenance work on page 156 Control cabinet key to open the control cabinet The following conditions must be met The service switch is in the ON position the gas sampling probe is retracted from the kiln see Operating the service switch on page 159 The EMERGENCY STOP switch is pressed Perform the following steps to ...

Page 180: ...ting washer s 8 do not fall off the threaded bolt of the struc tural diaphragm into the housing 10 Remove the cup spring 7 adjusting washer s 8 and support bowl 9 from the threaded bolt of the structural diaphragm and store them 11 Check all the parts for dirt and if necessary clean them with a dry cloth or compressed air 12 Push the support bowl 9 the adjusting washer s 8 and the cup spring 7 ont...

Page 181: ... control cabinet again 19 Unlock EMERGENCY STOP switch turn service switch back to OFF position and insert probe again using the controller WARNING Probe moves into the kiln Do not stand in the area of travel of the probe or probe carriage until the probe is com pletely inserted into the kiln and the warning lamps go out ...

Page 182: ...h a padlock Additionally press the EMERGENCY STOP switch Do not enter the danger area around the retractor until it is at standstill and the warning lamps and buzzer are off and the flap valve is closed Do not perform the work until the gas sampling system has cooled down Lock the shutter when you start the work unlock the shutter after finishing the work Always keep the floor around the gas sampl...

Page 183: ...shutter 5 In controller insert the probe Path Operation Probe Probe Action Insert WARNING The probe moves into the kiln Do not stand in the area of travel of the probe or probe carriage 6 In controller launch compressed air cleaning Path Operation Probe Cleaning Manual Cleaning 7 In controller retract the probe Path Operation Probe Probe Action Retract WARNING The probe moves out of the kiln Do no...

Page 184: ...ger area around the retractor until it is at standstill and the warning lamps and buzzer are off and the flap valve is closed Do not perform the work until the gas sampling system has cooled down Explanation of safety measures Safety regulations for maintenance work on page 156 Wrench SW 22 Socket head screwdriver New filter stone The following conditions must be met The service switch is in the O...

Page 185: ...idge and detaching disk out 5 Turn detaching disk until it can be pulled off from the hexagon screws 4 over the elongated holes 6 Mechanically clean the filter stone WARNING The filter insert may be soiled with toxic and corrosive substances depending on the substances with which it comes into contact in operation Wear appropriate protective clothing when cleaning 7 If the filter stone needs to be...

Page 186: ... cleaning 11 Replace filter stone 12 If necessary replace seals see Gas sampling probe 60S Replac ing the seal set on page 187 13 Reassemble filter insert and push back into casing tighten T handle 14 Unlock EMERGENCY STOP switch turn service switch back to OFF position and insert probe again using the controller WARNING Probe moves into the kiln Do not stand in the area of travel of the probe or ...

Page 187: ...e is closed Do not perform the work until the gas sampling system has cooled down Explanation of safety measures Safety regulations for maintenance work on page 156 Wrench SW 22 Socket head screwdriver O rings The following conditions must be met The service switch is in the ON position the gas sampling probe is completely retracted from the kiln see Operating the service switch on page 159 The EM...

Page 188: ...cessary mechanically clean the filter stone WARNING The filter insert may be soiled with toxic and corrosive substances depending on the substances with which it comes into contact in operation Wear appropriate protective clothing when cleaning 7 Replace O rings 6 Note The O rings do not need to be re greased 8 Reassemble filter insert and push back into casing tighten T handle 9 Unlock EMERGENCY ...

Page 189: ...robe retractor immediately as the probe is about to move at any moment Press the EMERGENCY STOP switch immediately if anyone is still in the dan ger area around the retractor after the warning lamps light up or the warning buzzer buzzes Avoid contact with lubricating oil Wash any lubricating oil off the skin immediately with water and soap If any lubricating oil gets in the eyes despite protective...

Page 190: ...ter casing by turning it counter clockwise remove impurities and clean the inside of the filter casing with a cloth 5 Screw filter casing back on Note During this procedure also check central compressed air supply for soiling The system must not be switched on again until all impurities have been completely removed 6 Open the compressed air inlet again at the shut off valve J54 4 7 Turn service sw...

Page 191: ...tractor immediately as the probe is about to move at any moment Press the EMERGENCY STOP switch immediately if anyone is still in the dan ger area around the retractor after the warning lamps light up or the warning buzzer buzzes Avoid contact with lubricating oil Wash any lubricating oil off the skin immediately with water and soap If any lubricating oil gets in the eyes despite protective glasse...

Page 192: ...r element 3 Inspect and if necessary replace filter element 4 Screw filter element back on 5 Put the drip cup back on 6 Unlock EMERGENCY STOP switch turn service switch back to OFF position and insert probe again using the controller WARNING Probe moves into the kiln Do not stand in the area of travel of the probe or probe carriage until the probe is com pletely inserted into the kiln and the warn...

Page 193: ...immediately as the probe is about to move at any moment Press the EMERGENCY STOP switch immediately if anyone is still in the dan ger area around the retractor after the warning lamps light up or the warning buzzer buzzes Avoid contact with lubricating oil Wash any lubricating oil off the skin immediately with water and soap If any lubricating oil gets in the eyes despite protective glasses rinse ...

Page 194: ...tractor 3 Completely drain the compressed air tank if present 4 Unscrew the tank on the compressed air oiler J74 by turning it counter clockwise 5 Fill oil up to the top quarter of the top inspection window and screw tank back on 6 Remove any oil residue with a cloth 7 Open the compressed air gate valve J54 1 again 8 Turn service switch back to OFF position and insert probe again using the control...

Page 195: ...dify the quantity of oil Meaning of the directions of rotation counter clockwise more oil clockwise less oil Note The compressed air oiler J74 must deliver approx 2 drops of oil per insertion retraction cycle If this is not ensured the com pressed air motor may get damaged or this may lead to excessive soiling of the muffler 2 Move probe in out to check oil quantity modify again if necessary Instr...

Page 196: ...a padlock Additionally press the EMERGENCY STOP switch Do not enter the danger area around the retractor until it is at standstill and the warning lamps and buzzer are off and the flap valve is closed Do not perform the work until the gas sampling system has cooled down Explanation of safety measures Safety regulations for maintenance work on page 156 The following conditions must be met The servi...

Page 197: ...he probe car riage using the adjustment nuts 1 such that the upper part of the chain does not droop onto the lower part of the chain Note Ensure that the drive chain is not twisted Also ensure ade quate tightening of the adjustment nuts 3 Unlock EMERGENCY STOP switch turn service switch back to OFF position and insert probe again using the controller WARNING Probe moves into the kiln Do not stand ...

Page 198: ...r are off and the flap valve is closed Do not perform the adjustment work until the gas sampling system has cooled down Explanation of safety measures Safety regulations for maintenance work on page 156 How to check probe position Step Procedure 1 With the probe inserted check the distance between the flange and the pipe sealing device Target requirement The flange must be touching 2 If this targe...

Page 199: ...or probe carriage until the probe is com pletely inserted into the kiln and the warning lamps go out Proceed as follows to change the vertical alignment of the gas sampling probe Step Procedure 1 Turn service switch to ON position WARNING Gas sampling probe moves out of the kiln Do not stand in the area of travel of the gas sampling probe or probe carriage until the probe is completely retracted a...

Page 200: ...robe is com pletely inserted into the kiln and the warning lamps go out If you have changed the position of the probe as described you must then check and if necessary adjust the end position sensor Follow the instructions in Probe retractor Checking and if necessary adjusting the position indicator probe end position on page 202 Proceed as follows to change the horizontal alignment of the gas sam...

Page 201: ...heck the position of the entire sampling pipe in relation to the mounting flange adjust if necessary WARNING Probe moves into the kiln Do not stand in the area of travel of the probe or probe carriage until the probe is com pletely inserted into the kiln and the warning lamps go out If you have changed the position of the probe as described you must then check and if necessary adjust the end posit...

Page 202: ...e following positions No Limit switch Signal position 1 Inductive position indicator B71 The probe is completely inserted into the kiln 2 Inductive position indicator B72 The probe is completely retracted 3 Mechanical position indi cator S72 The probe is retracted so far that it has reached the mechanical limit of the pneumatic motor Always take the following safety measures when performing this w...

Page 203: ... and the warning lamps go out 2 Press EMERGENCY STOP switch 3 Unscrew lock screws on the contact plate 1 with an Allen key and push contact plate for inductive indicator B72 until the controller displays the appropriate signal Proceed in the same way for mechanical position indicator S72 Note If inductive indicator B72 does not trigger despite the contact plate above it check the height adjustment...

Page 204: ...he marked position 6 Unlock EMERGENCY STOP switch 7 Turn service switch to OFF position then turn back to ON 8 Press the Insert button to move the probe to the desired position until the controller displays the appropriate signal e g Probe Inserted display box in the Probe Action dialog changes from white to black Note If inductive indicator B71 does not trigger despite the contact plate above it ...

Page 205: ...in the dan ger area around the retractor after the warning lamps light up or the warning buzzer buzzes Explanation of safety measures Safety regulations for maintenance work on page 156 The following conditions must be met The service switch is in the ON position the gas sampling probe is retracted from the kiln see Operating the service switch on page 159 The EMERGENCY STOP switch is pressed Proc...

Page 206: ... freeze gets in the eyes despite protective glasses rinse them thoroughly under running water holding the eyelids open Observe instructions in the anti freeze manufacturer s safety data sheet Always keep the floor around the gas sampling system clean and dry Explanation of safety measures Safety regulations for maintenance work on page 156 Control cabinet key to open the control cabinet The servic...

Page 207: ...it breaker F36 2 for approx 20 s 8 Wait 5 minutes and vent again 9 Repeat steps 7 and 8 until no more air comes out of the cooling water circuit 10 Check pressure of cooling water in the controller and top up if necessary target cooling water pressure in cooled state 1 1 5 bar 1000 1500 hPa 11 Switch cooling water pump M51 on again at motor breaker F37 1 or at circuit breaker F36 2 for approx 20 s...

Page 208: ...tem Do not perform work on the cooling water circuit until the cooling water has cooled down Avoid contact with the cooling water and the anti freeze Wash any cooling water and anti freeze off the skin immediately with water and soap If cooling water or anti freeze gets in the eyes despite protective glasses rinse them thoroughly under running water holding the eyelids open Observe instructions in...

Page 209: ...oller Path Diagnosis Trends Cooling Water Return Temp 3 Open the control cabinet 4 Switch off the cooling water pump M51 at the motor breaker F37 1 Note You can also switch off the cooling water pump at circuit breaker F36 2 5 Connect filling pipe to the cooling water supply of the cooling mod ule If possible the filling pipe should be filled with water before connecting it to the cooling module i...

Page 210: ...ling water pressure display on the touchscreen Fill cooling water to a pres sure of 1 1 5 bar 1000 1500 hPa Note It is advisable for two people to do this job 11 Switch the cooling water pump M51 on again at motor breaker F37 or circuit breaker F36 12 Close control cabinet again 13 Turn service switch back to OFF position and insert probe again using the controller WARNING Probe moves into the kil...

Page 211: ...tely as the probe is about to move at any moment Press the EMERGENCY STOP switch immediately if anyone is still in the dan ger area around the retractor after the warning lamps light up or the warning buzzer buzzes Avoid contact with lubricating oil Wash any lubricating oil off the skin immediately with water and soap If any lubricating oil gets in the eyes despite protective glasses rinse them th...

Page 212: ... on filter pressure control combination J53 3 Screw in new filter element hand tight 4 Perform steps 2 and 3 in the same way for pneumatic valves J77 J78 and J79 5 Open the compressed air gate valve J54 1 again 6 Turn service switch back to OFF position and insert probe again using the controller WARNING Probe moves into the kiln Do not stand in the area of travel of the probe or probe carriage un...

Page 213: ...42 23 81 EN Rev 4 System Manual SCK Gas Sampling System 213 Chapter 10 Errors Topic Page Errors and irregularities 214 Touchscreen error displays 216 Handling error messages 221 ...

Page 214: ... defec tive Compressed air motor defective Inform internal mainte nance department or ABB Service Whistling noise from compressed air system Compressed air sys tem leak See Checking for leaks on page 171 Probe travel is jerky Probe carriage rails dirty Wrong inclination of probe carriage Clean rails Readjust probe carriage inclination using the ad justment screws see Probe retractor Checking and i...

Page 215: ...rsts or cracks Mechanical damage to the pipe from outside Wait until all cooling water has run out before ap proaching Shut down gas sampling system and secure against start up until the cause has been fixed Do not begin repair work until it has cooled down Probe or heat exchanger cracks Mechanical damage and thermal stress Wait until all cooling water has run out before ap proaching Shut down gas...

Page 216: ... or several pending error messages Rectify single error message Faulty Entry ___ Value input error The value input is great er less than the limits de fined by the system Observe tolerance ranges when entering values see De fault operating parameter set tings on page 50 Emergency Stop Active EMERGENCY STOP activated The EMERGENCY STOP switch was pressed Find reason for activating the EMERGENCY STO...

Page 217: ...temper ature too high Probe heating overheating Check PT100 sensor Probe Heat ing Temp MIN Probe heating temper ature too low At start up probe heating not switched on long enough Probe heating defective Defect in temperature con troller Heating connection cable damaged Heating sleeve defective Wait for heating up time ap prox 20 min Check probe heating for prop er functioning Cable Drag Chain Sam...

Page 218: ...f necessary clean gas sampling probe entry zone Check gas sampling probe travel time modify speed set ting if necessary Error Probe H Blocked During Insertion Probe movement blocked during inser tion Incrustation on probe tip Duct opening clogged up Retractor drive defect Shutter drive defect Front limit switch error Check shutter functioning Check drive and limit switch of shutter Check gas sampl...

Page 219: ...re too low Bent cooling water tube Vent the cooling water circuit Check cooling water level and if necessary top up If necessary replace pump C Water Flow Rate MIN2 Cooling water flow rate main alarm low not reached Insufficient capacity of cool ing water pump Cooling water temperature too low Bent cooling water tube Vent the cooling water circuit Check cooling water level and if necessary top up ...

Page 220: ...e if neces sary CAN Error Slave 5 Can bus error to slave 5 Can bus connection error to slave 5 D71 Check CAN bus cable for damage Contact ABB Service if neces sary CAN Error Slave 6 Can bus error to slave 6 Can bus connection error to slave 6 D72 Check CAN bus cable for damage Contact ABB Service if neces sary CAN Error Slave 7 Can bus error to slave 7 Can bus connection error to slave 7 D73 Check...

Page 221: ...es Explanation of safety measures Safety regulations for maintenance work on page 156 In the event of an error the probe is automatically retracted out of the kiln until the probe reaches its end position To make sure that it really has reached its end position and that no unexpected probe movement can be expected wait for the warning lamps on the retractor terminal box to go out before fixing the...

Page 222: ......

Page 223: ...ing System 223 Chapter 11 Shutting down storing putting back into operation disposal Topic Page Shutting down the system 224 Disassembling the system 227 Storing the system 229 Putting the system back into operation 230 Disposing of the system 231 ...

Page 224: ...after operation Do not touch the gas sampling system until it has cooled down to 50 C Specifi cally do not touch the cooling module the heated sample gas line the connection box for the heated sample gas line on the retractor the heated sampling filter the entire gas sampling probe the metal structure of the retractor the shutter of the duct opening If it is unavoidable to touch hot components wea...

Page 225: ...ree and oil free instrument air flow rate approx 100 l h for about 15 minutes 4 Clean any residue and incrustations off the filter unit and probe pipe Note Only clean mechanically Do not use chemicals particularly acids and lyes for cleaning Proceed as follows to drain the cooling water Step Procedure 1 Unscrew cap and slowly open vent cock 1 so that air can escape 2 Open drain valves 2 on probe p...

Page 226: ...226 System Manual SCK Gas Sampling System 42 23 81 EN Rev 4 Refer to Disassembling the system on page 227 for details on further procedure Further procedure ...

Page 227: ... is in operation Preferably install or remove the probe when the rotary kiln is out of operation If you install or remove the probe when the rotary kiln is in operation Wear a face mask against heat heat proof gloves and protective welder s clothing and respiratory protection against toxic gases Keep the time in which the duct opening is open as short as possible Danger due to harmful dusts when c...

Page 228: ...rew and remove fastening screws on mounting flange and attachment points 8 Using lifting gear lower probe retractor until you can screw on the enclosed transport supports 9 Place probe retractor on ground and secure from falling over The following table shows further procedure If the system follow the following instructions is to be stored for a pro longed period Storing the system on page 229 is ...

Page 229: ...ons for storage Retractor including probe Ambient temperature 5 C to 55 C after completely draining all water and drying parts in contact with cooling water or condensation 20 C to 55 C Air humidity Year round average max 75 short term max 95 occasional slight condensation is permitted Cooling module Ambient temperature 5 C to 55 C after completely draining all water and drying parts in contact wi...

Page 230: ...30 System Manual SCK Gas Sampling System 42 23 81 EN Rev 4 Putting the system back into operation Follow the instructions given in Start up on page 111 to put the system back into operation Instructions ...

Page 231: ...ctive glasses rinse them thor oughly under running water holding the eyelids open Observe instructions in the lubricating oil manufacturer s safety data sheet The following conditions must be met System was properly shut down and disassembled see Shutting down the system on page 224 Disassembling the system on page 227 Drain oil from compressed air oiler and dispose of it in accordance with nation...

Page 232: ......

Page 233: ...42 23 81 EN Rev 4 System Manual SCK Gas Sampling System 233 Chapter 12 Appendix Topic Page Pneumatic hydraulic interface plan 234 Electrical connection plan 236 Transformer connection plan 238 ...

Page 234: ...234 System Manual SCK Gas Sampling System 42 23 81 EN Rev 4 Pneumatic hydraulic interface plan ...

Page 235: ...42 23 81 EN Rev 4 System Manual SCK Gas Sampling System 235 ...

Page 236: ...236 System Manual SCK Gas Sampling System 42 23 81 EN Rev 4 Electrical connection plan ...

Page 237: ...42 23 81 EN Rev 4 System Manual SCK Gas Sampling System 237 ...

Page 238: ...238 System Manual SCK Gas Sampling System 42 23 81 EN Rev 4 Transformer connection plan ...

Page 239: ...lectric cables 107 Connecting internal electric cables 105 Connecting the sample gas line to the retractor 104 Controls and displays 24 Cooling module 32 Checking and topping up cooling water 208 Vent the cooling water circuit 206 D Default operating parameter settings 50 Description of control system 37 Description of the sampling system 17 Dimensions and weights 18 Disassembling the system 227 D...

Page 240: ...t 114 Probe retractor 26 Checking and replacing the filter muffler 191 Checking and tightening the drive chain 196 Checking and topping up the oiler 193 Checking and if necessary adjusting the position indicator probe end position 202 Checking and if necessary adjusting the position of the probe 198 Checking filter pressure control combination 189 Checking the bellows 205 Process monitoring 22 Pro...

Page 241: ...r displays 216 Transformer 34 Transformer connection plan 238 Transport and unpacking 83 Transport supports 26 87 Transport the system in the company 87 U Unpacking the system 89 User interface Message screen 44 Operation screen 40 Parameter screen 46 Trend screen 42 Using the EMERGENCY STOP switch 146 W Warning signs on the system 63 Work places 65 ...

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Page 244: ... of continuous product improvement and the right is reserved to modify the information contained herein without notice Printed in the Fed Rep of Germany 11 16 ABB 2016 42 23 81 EN Rev 4 ABB Automation GmbH Analytical Stierstaedter Strasse 5 60488 Frankfurt am Main Germany Fax 49 69 7930 4566 E mail cga de abb com ...

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