ABB SCK System Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Industrial Equipment
  5. SCK
  6. System manual
ABB SCK System Manual

ABB SCK System Manual

Sampling system for dry gas sampling at rotary cement kiln gas exit and calciner gas exit
Hide thumbs Also See for SCK:
Table of Contents

Advertisement

Quick Links

Download this manual
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

Advertisement

Table of Contents
loading

Related Manuals for ABB SCK

Summary of Contents for ABB SCK

  • Page 1 Sample conditioning for kiln Sampling system for dry gas sampling at rotary cement kiln gas exit and calciner gas exit System manual 42/23 81 EN Rev. 4...
  • Page 3 Sample conditioning for kiln 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: Table Of Contents

    Transport and unpacking ..................83     General transport information .................. 84   Transport the system in the company ..............87   Unpacking the system ..................... 89   Scope of delivery ..................... 90   System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 5 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   42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 6 Disposing of the system ..................231   Chapter 12 Appendix ......................233     Pneumatic/hydraulic interface plan................ 234   Electrical connection plan ..................236   Transformer connection plan ................. 238   Index   System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 7: Chapter 1 General

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

  • Page 8: About These Operating Instructions

    About these operating instructions Scope and purpose These operating instructions apply to the SCK gas sampling system, product num- ber: 23919. These operating instructions are intended to give all personnel handling the gas sampling system the information required to perform the following tasks correctly and safely: ...
  • Page 9 1, 2, 3, ... Identifies reference numbers in the figures. Further information Further information on ABB Analytical products and services is available on the Internet at "http://www.abb.com/analytical". 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 10: Safety Instructions In This Document

    Safety instructions Safety instructions with specific DANGER on a particular step instructions pertaining to one step WARNING only CAUTION System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 11 Warning of damage to Warnings of possible damage to property are marked by the word CAUTION in this property document if there is no danger of injury to persons. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 12: System Identification

    Serial number of the cooling module Year of manufacture of the system CE mark Environment-Friendly Use Period (EFUP) mark Warning triangle to DIN EN 61010: observe operating instructions Electric connections System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 13 Status signals as relay contacts Profibus Signals as relay contacts + Profibus Connection to ACX via Modbus Connection to ACX + signals as relay contact 12th digit Certificates CE design CSA design 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 14 Engraved nameplates present/not present Additional nameplates No. 1 / 2 / 3 / 4 / 5 (engraved) Orientation of probe S Sampling holes to the right / to the left System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 15: Service

     for ordering spare parts  for ordering maintenance work Service address 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 42/23-81 EN Rev. 4...

  • Page 17: Chapter 2 Description Of The Sampling System

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 18: Technical Data

    Width 634 mm, Height 953 mm (with base and transport lugs), Depth 400 mm Weight 140 kg 250-l compressed-air tank (optional): Dimensions Height 1785 mm, Diameter 530 mm Weight 140 kg System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 19: Intended Conditions Of Use

     at secondary firing at the gas outlet of the calcinator. 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...

  • Page 20: Structure And Function

    Structure and function Illustration The following diagram shows an overview of the SCK modules: Modules The individual modules of the gas sampling system have the following functions: Designation Function  mechanical movement of the probe Retractor  automatic removal of the probe when mal- functions occur Gas sampling probe ...

  • Page 21: Mode Of Functioning And Operating Modes

    Probe cleaning steps take place after set intervals (these can be defined using the control- ler). Manual mode Allows operation of the system in manual mode, required for maintenance, for example. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 22: Process Monitoring

     Locks follow-up func- tions  Ensures adequate  Triggers the retraction Pressure switch Emer- compressed-air reserve program if minimum gency tank full input pressure is not (optional) reached System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 23  Protects the plunger  Triggers the retraction Reed contact plunger against overheating program if end posi- retracted tion is not reached 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 24: Controls And Displays

    Description of the controller on page 37  See Protective installations on page 60 Warning buzzer  Puts the system into service mode Service switch  Cancels service mode System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 25 Designation and illus- Function tration  see Protective installations on page 60 EMERGENCY STOP switch on pneumatic box  see Protective installations on page 60 Warning lamps (2) on the terminal box 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 26: Probe Retractor

    Transports the sample gas from the probe to the downline sample gas analysis system. Heating function prevents condensation from build- ing up. Warning lamps Warn about insertion and retraction movements of the gas sampling probe. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 27 The shutter is moved either automatically by a pneumatic drive or manually. Supply lines The pneumatic/electric supply is connected at a central transition point. All required line connections are pre-installed in the probe retractor. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 28: Gas Sampling Probe H

    Sucks in the sample gas in the rotary kiln. Differences Probe H is used when stubborn incrustations can be expected to build up on the probe due to the properties of the process and sampling conditions. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 29 Incrustations on the intake hole are removed by hole by means of plunger periodical pneumatically controlled movements of movements the plunger. Probe filter cleaning Filter in probe pipe is cleaned periodically with compressed air. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 30: Gas Sampling Probe 60S

    Passes the sample gas to the down- line sample gas analysis system. Heating sleeve Heats the filter unit to prevent con- densation build-up. Pipe sealing device Spring-mounted sealing of the tube System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 31 Material deposits and incrustations on the probe the probe are removed by regularly moving the probe in and out using the retractor. Probe filter cleaning Filter in filter unit is cleaned periodically with compressed air. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 32: Cooling Module

    The completely closed system monitors the following parameters:  Cooling water temperature  Cooling water flow rate  Cooling water pressure Structure The following illustrations show the cooling module: System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 33 The water flows through the heat exchanger and pressure-compensating vessel. Additional instruments for measuring pressure, flow rate and temperature and fitted in the water pipe. Monitoring is performed on the touchscreen on the control cabi- net. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 34: Transformer

    3 x 400 V (star) Degree of protection IP 54 Test voltage 4.0 kV Insulation category T 50/A separate Winding Protection class Frequency 60 Hz Switching YNd5 PRI-/SEC connection Terminals with screw connection System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 35: Compressed-Air Tank And Pneumatic System

    This tank is not required if the on-site compressed-air supply is of stable perfor- mance. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 37: Chapter 3 Description Of Control System

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 38: Structure And Function Of The Control System

    Navigation The user navigates the interface in the bottom right corner of the screen. The Menu button goes back to the main menu, the Back button jumps to the previous System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 39  User interface: operating screen on page 40  User interface: trend screen on page 42  User interface: message screen on page 44  User interface: parameter screen on page 46 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 40: User Interface: Operation Screen

    Menu path display Screen functions Displays screen functions and submenus Navigation area Allows the following functions:  jump to Message menu  jump to main menu  jump to previous menu System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 41 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 menu Display Message menu 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 42: User Interface: Trend Screen

     jump to main menu  jump to previous menu Save Saves trend data Diagram Allows you to zoom in/out in the line diagram navigation and move the window currently displayed System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 43 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: Colors Color Meaning Measured value blue Pre-alarm yellow Main alarm 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 44: User Interface: Message Screen

    Scroll up and down in the logbook Navigation area Allows the following functions:  jump to previous menu Screen functions Allows functions such as save history, reset mes- sage, etc. (see next page) System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 45 Click on crossed-out clock to display pending messages only Colors The following colors are used in the message screen display area: Color Meaning Status message in normal operation green Maintenance required yellow Error message 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 46: User Interface: Parameter Screen

    Allows navigation in the parameter list navigation Navigation area Allows the following functions:  jump to Message menu  jump to main menu  jump to previous menu Save Saves parameter settings System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 47 You can edit alarm limits in a set range to suit specific sys- tem conditions. Touch a parameter entry to select it. The program displays an input box for you to input the appropriate value. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 48: Error Message Display

    (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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 49: Access Permissions

    3 the system. Changes in these access areas may only be performed by experi- enced skilled personnel with ABB certification as level-2 service technician. Always be extremely careful to whom you disclose the password for this level. In the delivered state, the following passwords are stored in the system:...

  • Page 50: Default Operating Parameter Settings

    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 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 51 5 °C 1–100 °C Probe Heating Temp. MAX 190 °C 30–200°C Sample Gas Probe Pressure 600 mbar 250–900 mbar (indicated only when SCK is connected to the ACX analysis system) 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 52 Parameter Default Tolerance range Action / Cleaning Cycle Ratio C. Water Return Temp. Set Point 80 °C 15–140 °C Probe Heating Temp. Set Point 100 °C 1–190 °C System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 53: Optimizing Operating Parameters

    Path: Setup ► Basic Parameters Select parameter and enter appropriate value in the input box. Note: You can only edit basic values within the tolerance limits. Click the Save button to save the settings. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 55: Chapter 4 Safety

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 56: Basic Safety Rules

     that the safety regulations in force in your country are observed.  that the safety regulations pertaining to setting up and operating electrical equipment in force in your country are observed. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 57 Safety measures: transport and unpacking on page 68 Safety measures: installation on page 69 Safety measures: start-up on page 72 Safety measures: operation on page 75 Safety measures: maintenance and troubleshooting on page 78 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 58: Overview Of Dangers

    Anti-freeze in the The cooling system contains cooling water with anti-freeze. This means: cooling water  Danger of injury to skin and eyes in the event of contact with anti-freeze. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 59  Danger of eye injuries if compressed air escapes, e.g. if compressed-air pipes system burst, when opening screw connections or inadvertently opening compressed- air pipes with no additional connector. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 60: Protective Installations

    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 protective installation (6). System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 61  Manual mode: immedi- ately after pressing the "Retract probe" button  Error: immediately be- fore probe retraction The buzzer stops buzzing when the probe has reached its end position. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 62 An EMERGENCY-STOP switch additionally installed by the operator has the same EMERGENCY-STOP function as the enclosed EMERGENCY-STOP switch described above. The addi- tional EMERGENCY-STOP switch must be installed if the above-described switch EMERGENCY-STOP switch is difficult to access. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 63: Warning Signs On The System

    A risk of hot surfaces can be expected during operation. Particular danger areas are: all cooling water pipes and the cooling water pump and the surface of the heat exchanger. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 64 Retractor movement can be expected during operation. Do not stand in the area of travel of the probe or probe carriage until the probe is completely inserted or retracted and the warning lamps go out. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 65: Requirements To Be Met By Personnel, Work Places

     Shutting down  correct storage  Trained unskilled worker Storage per- sonnel  packing of the system for transport  Trained disposal personnel Disposal Disposal of the gas sampling personnel system 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 66  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 protective installation. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 67: Personal Safety Equipment

    The following additional protective equipment is required when performing mainte- equipment 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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 68: Safety Measures: Transport And Unpacking

     Do not stand under sus- pended loads.  Follow the transport instruc- tions in these operating in- structions carefully. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 69: Safety Measures: Installation

     Disconnect the gas sam- pling system from the pow- er supply before opening the connection and terminal box.  Observe national regula- tions pertaining to electrical equipment. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 70  Observe instructions in the anti-freeze manufacturer's safety data sheet. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 71  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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 72: Safety Measures: Start-Up

     when actuating the after the warning lamps service switch light up or the warning buzzer buzzes.  when opening the protective installation securing the danger area around the re- tractor System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 73  If it is unavoidable to ap- proach the hot probe, wear a face mask against heat, heat-proof gloves and pro- tective welder's clothing. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 74  Always keep the floor Risk of slipping Around the gas sampling around the gas sampling system due to cooling system clean and dry. water or lubricating oil that escapes or is spilled. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 75: Safety Measures: Operation

     failure of the control system  when manually start- ing probe travel  when actuating the service switch  when opening the protective installation securing the danger area around the re- tractor 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 76  Wait until the entire cooling Risk due to hot In the event of hot cool- water has been evacuated cooling water ing water escaping if an before approaching. error occurs System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 77  Always keep the floor Risk of slipping Around the gas sampling around the gas sampling system due to cooling system clean and dry. water or lubricating oil that escapes or is spilled. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 78: Safety Measures: Maintenance And Troubleshooting

     Do not stand under sus- pended loads.  Follow the transport instruc- tions in these operating in- structions carefully. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 79  Disconnect the gas sam- pling system from the pow- er supply before working on other electric components.  Observe national regula- tions pertaining to electrical equipment. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 80  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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 81  Wear a dust mask. Danger due to harm- While cleaning the gas ful dust sampling system  Wash any dust off the skin immediately with water and soap. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 82  Always keep the floor Risk of slipping Around the gas sampling around the gas sampling system due to cooling system clean and dry. water or lubricating oil that escapes or is spilled. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 83: Chapter 5 Transport And Unpacking

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 84: General Transport Information

    The lifting ropes must be long enough to ensure an angle of at least 60° under strain. Otherwise the retractor cabinet can get twisted. If the cooling module is also transported by crane, observe the same points. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 85 -20 °C to +55 °C Air humidity: Year-round average max. 75 %, short-term max. 95 %, occasional slight condensation is permitted 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 86 -20 °C to +55 °C Air humidity: Year-round average max. 75 %, short-term max. 95 %, occasional slight condensation is permitted System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 87: Transport The System In The Company

    Control cabinet 75 kg  Lay the control cabinet on its back for transport.  Use a suitable transport pallet for transport.  Transport recommendation: For-lift truck or hand lift 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 88  Use a suitable transport pallet for transport. Transformer 140 kg  Lifting gear may only be attached at the designated attachment points (transport lugs).  Transport recommendation: For-lift truck, hand lift or crane System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 89: Unpacking The System

    Dispose of packaging material in accordance with the na- tional regulations. Transport system parts to the place of installation (see Transporting the system in the company on page 87). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 90: Scope Of Delivery

     Complete documentation DE/EN on CD-ROM  System manual The following optional components may be included in the scope of delivery: Optional  250-l compressed-air tank  Compressed-air piping (25 m)  Transformer IP44 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 91: Chapter 6 Installation

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 92: Overview: Installation

    Connect electric lines. Connecting internal electric cables on page 105 Connect external electric Connecting external electric cables. cables on page 107 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 93: Checking Site Conditions

    A suspension device for the Fastening elements and attachment probe retractor has been pre- points pared and holes drilled for instal- lation of the other modules. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 94 The danger area around the Creating the base area for the probe retractor is protected by a retractor protective installation. Creating the protective installation around the retractor System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 95: Installing The Probe Retractor

     6 fastening points are present to affix the probe retractor.  The probe retractor is unpacked. Instructions: How to install the probe retractor: Installing the probe retractor Step Procedure Set up probe retractor at the place of installation. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 96 During assembly it may be necessary to move the probe retractor without with Moving the probe compressed-air supply or control cabinet. However, this should be limited to abso- during assembly lutely necessary cases. Proceed as follows: System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 97 198. Make sure that the position indicator contact plates are firmly in place. Note: During operation, the energy chain will hang down when the probe is in inserted position. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 98: Installing The Control Cabinet

    How to install the control cabinet: Step Procedure Fasten control cabinet in suitable position (see Choosing the place of installation of the control cabinet) with 4 assembly screws or bolts. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 99: Installing The Compressed-Air Supply

    3 galvanized steel screws (or stainless material) or bolts M12 on the ground. Pneumatically connect compressed-air tank as per pneumatic/- hydraulic interface plan (see appendix) to the gas sampling system. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 100 Installing tubes  Pneumatic connections must be installed so as to rule out any damage caused by working in the proximity of the sampling system. ABB recommends installing 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.

  • Page 101: Installing The Cooling Module

     The site conforms to the designated site conditions (criteria see Choosing the place of installation of the peripheral modules).  Fastening points are present to affix the cooling module.  The cooling module is unpacked. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 102 4 as- sembly screws or bolts on the ground. Attach suitable drain pipe to safety valve outlet -J62 in order to prevent danger of cooling water escaping. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 103: Installing The Cooling Water Circuit

    Installing tubes  Install cooling-water hoses so as to rule out any damage caused by working in the proximity of the gas sampling system. ABB recommends installing tubes on trays or in tube conduits.  Minimum bending radius of the cooling-water hoses is 160 mm. If this is not possible for technical reasons, ABB recommends installing suitable pipe adapt- ers.

  • Page 104: Connecting The Sample Gas Line To The Retractor

     Install sample gas line separately from other lines.  When laying the sample gas line, avoid tight curves, bending or crossing other lines.  Refer to the manufacturer's installation instructions for further details. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 105: Connecting Internal Electric Cables

    All required lines are pre-installed in the probe retractor area. All downline connections are installed via the central connec- tion point to the electrical terminal box.  Electrical connection plan Required documents 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 106 Connecting the system bus cable to the frequency converter:  Loosen the short system bus cable with T-piece (2) from its transport fixing and connect it to the CAN adapter (1) at the fre- quency converter. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 107: Connecting External Electric Cables

     Check that the voltage setting of the analyzer system matches the mains volt- age.  Make sure the power supply leads have an adequately dimensioned protective device (circuit breaker). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 108 (see Integrating the air cannon into the control system). The control cabinet is fitted with an air cannon connector (-D32 64 in the electrical connection plan). System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 109 (see Detail "A" in pneumatic/hydraulic interface switch plan). To connect an additional EMERGENCY-STOP switch, remove the jumper and connect the connection wires to the EMERGENCY-STOP switch. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 111: Chapter 7 Start-Up

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 112: Overview: Start-Up

    131 delivery rate on the compressed- air oiler, and check direction of rotation of the heat exchanger. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 113: Installation Check

    Connection and laying of cooling-water lines checked. Heat exchanger connected with a shielded cable. Adherence to the bending radii of the installed lines and hoses checked. Stable fastening of the modules checked. Protective probe box fitted. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 114: Preparing The Cooling-Water Circuit

    The closed cooling-water circuit must be filled with approx. 50 l potable water (do requirements not use anti-corrosive). In ambient temperatures below 0 °C use approx. 20 l anti- freeze. ABB recommends Glykol as anti-freeze. Anti-freeze with anti-corrosive additive is not permitted. Ensuring anti-freeze If temperatures can be expected to fall below 0 °C, fill the cooling-water circuit with...
  • Page 115 (target cooling water pressure in cooled state: 1-1.5 bar (1000-1500 hPa)). Proceed as follows: Instructions: check for leaks Step Procedure Check cooling water circuit for leaks. Remedy any leaks before continuing with start-up. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 116: Preparing The Compressed-Air Supply

    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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 117 Remove any oil residue with a cloth. Open the compressed-air gate valve (1) again. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 118: Activation

     The system must not have any visible damage (see also Checking general condition on page 140).  The customer-side central compressed-air supply is switched on. Tools required  Control cabinet key to open the control cabinet System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 119 "Probe heating temperature MIN" "Cable Drag Chain Sample Gas Line Temp. Error" Path: Diagnosis ► Message Turn service switch to ON position. Note: This step resets various safety functions. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 120  Checking frequency converter settings on page 124  Checking/correcting operating parameters on page 127  Checks to perform when using probe H on page 128 Close the control cabinet. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 121: After Switching On: Working On The Cooling Module

     Control cabinet key to open the control cabinet Requirements 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). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 122 1-1.5 bar (1000-1500 hPa)). Close control cabinet again. Note: Severe fluctuations of the cooling-water flow rate indicate that the cooling- water circuit needs to be vented again. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 123: Checking The Pneumatic System

    (5 bar (5000 hPa) and 3 bar (3000 hPa); see Figure). Check mark in settings window and adjust with the setting screw on the head of the pressure switch if necessary. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 124: Starting Frequency Converter And Adapting Control Parameters

    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). System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 125 Note: Enter the KP value always negative using the +/– button. Adjust control parameter KI to further optimize the temperature run (TN, default: 10). If necessary, also adjust control parameter KD (TV, default: 0). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 126 Step Procedure Save control parameter settings using the button. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 127: Checking/Correcting Operating Parameters

    (Setup ► Time Parameters, Setup ► Limit Parameters, Setup ► Basic Parameters). Refer to Optimizing operating parameters on page 53 for details on editing operat- ing parameters. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 128: Checks To Perform When Using Probe H

    The following conditions must be met: Requirements 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). System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 129 There is a DIP switch under the white flap. Check the following settings here: 1 Undercurrent monitoring ON 2 NC contact operation 3 Storage off 4 (Default) Close the control cabinet. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 130 Check the following possibilities for adequate supply:  Lay larger cross-sections  Reduce lengths of supply lines System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 131: Inserting The Probe And Switching To Automatic Mode

    Leave danger area around the retractor, close protective installation and turn service switch to OFF position. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 132 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 133 In controller: wait for heating-up time. "C. Water Return Temp. MIN" Path: Diagnosis ► Message In controller: switch gas sampling probe to AUTOMATIC mode: Path: Operation ► Automatic on / off 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 134 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 135: Chapter 8 Operation

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 136: Safety Regulations For Operation

     the metal structure of the retractor,  the shutter of the duct opening.  If it is unavoidable to touch hot components, wear a face mask against heat, heat-proof gloves and protective welder's clothing. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 137 Risk of falling on slippery floor due to escaped or spilled cooling water and lubricating oil or dirt  Always keep the floor around the gas sampling system clean and dry. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 138: Monitoring Automatic Mode

    The probe (probe pipe and filter) may nevertheless get damaged, above all in the following situations:  if material falls on the probe  of too much material adheres to the probe pipe System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 139  if the sampling system is visibly seriously damaged,  if the sampling system is no longer operational,  after prolonged storage under adverse conditions,  after severe transport stress. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 140: Checking General Condition

    Note: Inserting the gas sampling probe when the duct opening is clogged can lead to damage to the probe. The same applies to re-inserting the gas sampling probe after prolonged standstill of the sampling system. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 141 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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 142: Cleaning Gas Sampling Probe H

    Gas sampling probe moves out and in to scrape off any adhering material. Plunger moves forward and backward to clean the sample gas inlet. Air blast to clean the probe filter. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 143 Cleaning in the event Note: The following function is available only when SCK is connected to the ACX of error message analysis system. When used with other analysis systems, a default sample gas probe pressure of "9999 hPa" is indicated in the "Diagnosis" menu.

  • Page 144: Cleaning Gas Sampling Probe 60S

    Air blast lasting 3 seconds to clean the probe pipe. Cleaning in the event Note: The following function is available only when SCK is connected to the ACX of error message analysis system. When used with other analysis systems, a default sample gas probe pressure of "9999 hPa"...
  • Page 145 (Default operating parameter settings on page 50). You can modify them in operation to suit local requirements and specific fuels (see Optimizing operating parameters on page 53). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 146: Using The Emergency-Stop Switch

    Result: The gas sampling probe is automatically retracted out of the kiln, the controller displays the Maintenance message. Turn service switch back to the initial position (OFF). System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 147: Chapter 9 Maintenance

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 148: Maintenance Plan

     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. Service switch...
  • Page 149  Replace intake filter Gas sampling probe H: Replacing the intake filter on page 176  Replace membrane pump Gas sampling probe H: Replacing mem- membranes brane pump membranes on page 179 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 150 198  Check position indicator on Probe retractor: Checking and, if neces- the retractor and, if neces- sary, adjusting the position indicator sary, re-align (probe end position) on page 202 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 151  Replace compressed-air filter Pneumatic system: Replacing the com- in pneumatic box pressed-air filter on page 211  Check compressed-air sys- Checking for leaks on page 171 tem for leaks 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 152: Equipment Layout Plan

    Pneumatic valve "shutter" -J79 Pneumatic motor -J81 Gate valve -J82 Air filter -J83 Probe movement warning lamp -P71 Probe movement warning lamp -P72 Position indicators -B71, -B72, -S72 not illustrated System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 153 Heat exchanger circuit breaker -F35 Cooling-water pump circuit breaker -F36 Cooling-water pump motor breaker -F37 Service switch -S31 Main switch for normal voltage -Q30 Main switch for UPS (optional) -Q40 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 154 The following table lists the above-mentioned equipment: Equipment Designation Shut-off valve cooling water -J63 Cooling water inlet Cooling water feed Safety relief valve outlet Heat exchanger -J60 Cooling water return System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 155: Acquiring Spare Parts And Wear Parts

    Acquiring spare parts and wear parts Service 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 42/23-81 EN Rev. 4...

  • Page 156: Safety Regulations For Maintenance Work

     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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 157  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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 158 Risk of falling on slippery floor due to escaped or spilled cooling water and lubricating oil or dirt  Always keep the floor around the gas sampling system clean and dry. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 159: Operating The Service Switch

    Explanation of safety measures: Safety regulations for maintenance work on page 156. The service switch is in the OFF position. Requirement 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 160 Re-insert the probe using the controller. 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 161: Checking The Condition Of The System, Cleaning The System

    Checking and cleaning the cooling module:  Do not perform work on the cooling water circuit until the gas sampling system has cooled down.  Avoid contact with the cooling water and the anti-freeze. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 162 Check condition of drive chain with regard to the following:  chain tension  chain link wear In pneumatic box: Check compressed-air oiler for the following:  damage  leaks  oil level System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 163 Clean motor casing with compressed air. Clean cooling fins with dry compressed air (accessible at the back of the heat exchanger). Check cooling module environment for any materials that can fly around easily. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 164: Evaluating Trend Displays

    The reading rule indicates the measured value at the specific time. A zoom function allows you to zoom in on details. For further details refer to section Description of control system on page 37. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 165: Checking The Residual Current Circuit Breaker

     Control cabinet key to open the control cabinet Requirements 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). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 166 Perform steps 1 through 3 with residual current circuit breaker for UPS -F40 (if present). Switch residual current circuit breaker -F30/-F40 back on. Lock the control cabinet. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 167: Checking Protective Installations

    156. Requirements The following conditions must be met:  System is in operation.  Gas sampling probe is inserted into the kiln.  Service switch is in the OFF position. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 168 WARNING! Gas sampling probe moves into the kiln. Do not stand in the area of travel of the gas sampling probe or probe car- riage until the probe is completely inserted into the kiln and the warning lamps go out. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 169 WARNING! Gas sampling probe moves into the kiln. Do not stand in the area of travel of the gas sampling probe or probe car- riage until the probe is completely inserted into the kiln and the warning lamps go out. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 170 WARNING! Gas sampling probe moves into the kiln. Do not stand in the area of travel of the gas sampling probe or probe car- riage until the probe is completely inserted into the kiln and the warning lamps go out. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 171: Checking For Leaks

     For checking the compressed-air system and cooling-water circuit for leaks: leak detection spray Instructions: How to check the sample gas paths up to the sample gas pump: checking sample gas paths 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 172 WARNING! Probe moves into the kiln. Do not stand in the area of travel of the probe or probe carriage until the probe is completely inserted into the kiln and the warning lamps go out. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 173 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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 174: Gas Sampling Probe H: Removing Incrustations

     Always keep the floor around the gas sampling system clean and dry. Explanation of safety measures: Safety regulations for maintenance work on page 156. Tools required  Chisel  Hammer System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 175 In controller: wait for heat-up time until the following error messag- es disappear: "C. Water Return Temp. MIN" Path: Diagnosis ► Message In controller: switch gas sampling probe to AUTOMATIC mode: Operation ► Automatic on / off 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 176: Gas Sampling Probe H: Replacing The Intake Filter

    For extensive work on the probe tip (e.g. when replacing the filter) it is advisable to swing the probe out to the right so that you can access the tip area more easily. Swing the probe tip back in after replacing the filter. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 177 Do not touch the probe until it has cooled down to be- low 50 °C. Unscrew the adjustment screws (1) on the probe carriage until you can swing the probe out. Swing the probe out to the right. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 178 In controller: wait for heat-up time until the following error messag- es disappear: "C. Water Return Temp. MIN" Path: Diagnosis ► Message In controller: switch gas sampling probe to AUTOMATIC mode: Path: Operation ► Automatic on / off System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 179: Gas Sampling Probe H: Replacing Membrane Pump Membranes

    Power off pump at the circuit breaker -F34. Clean outside of pump housing. Unscrew the four screws to open the pump housing. Detach the pump tubes, remove the pump -M71 and clean it exter- nally. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 180 Screw the new structure diaphragm with support bowl, adjusting washer(s) and cup spring onto the connecting rod and tighten to finger tightness. Reconnect pump hoses. Screw pump housing back on. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 181 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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 182: Gas Sampling Probe 60S: Removing Incrustations

     Always keep the floor around the gas sampling system clean and dry. Explanation of safety measures: Safety regulations for maintenance work on page 156. Tools required  Chisel  Hammer System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 183 In controller: wait for heat-up time until the following error messag- es disappear: "C. Water Return Temp. MIN" Path: Diagnosis ► Message In controller: switch gas sampling probe to AUTOMATIC mode: Path: Operation ► Automatic on / off 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 184: Gas Sampling Probe 60S: Cleaning Or Replacing The Outlet Filter

    Allow gas sampling 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 185 If the filter stone needs to be replaced: Unscrew locking screw (6) with open-end spanner. Screw the locking screw (6) out by hand. Unscrew the hex screw (7) below with an Allen key. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 186 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 187: Gas Sampling Probe 60S: Replacing The Seal Set

    Allow gas sampling 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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 188 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 189: Probe Retractor: Checking Filter/Pressure Control Combination

    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). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 190 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 191: Probe Retractor: Checking And Replacing The Filter Muffler

    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). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 192 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 193: Probe Retractor: Checking And Topping Up The Oiler

    The following conditions must be met: Requirements  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). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 194 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 195 If this is not ensured, the com- pressed-air motor may get damaged or this may lead to excessive soiling of the muffler. Move probe in/out to check oil quantity, modify again if necessary. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 196: Probe Retractor: Checking And Tightening The Drive Chain

     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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 197 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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 198: Probe Retractor: Checking And, If Necessary, Adjusting The Position Of The Probe

    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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 199 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. Unscrew counter nuts (1) on probe carriage. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 200 Press EMERGENCY STOP switch and allow gas sampling 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 below 50 °C. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 201 Follow the instructions in Probe horizontal position retractor: Checking and, if necessary, adjusting the position indicator (probe end position) on page 202. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 202: Probe Retractor: Checking And, If Necessary, Adjusting The Position Indicator (Probe End Position)

     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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 203 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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 204 WARNING! Probe moves into the kiln. Do not stand in the area of travel of the probe or probe carriage until the probe is complete- ly inserted into the kiln and the warning lamps go out. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 205: Probe Retractor: Checking The Bellows

    WARNING! Gas sampling probe moves into the kiln. Do not stand in the area of travel of the gas sampling probe or probe car- riage until the probe is completely inserted into the kiln and the warning lamps go out. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 206: Cooling Module: Vent The Cooling-Water Circuit

    Open the control cabinet. After retracting the probe wait until cooling-water temperature has dropped to 40 °C; you can monitor this on the controller: Path: Diagnosis ► Trends ► Cooling Water Return Temperature System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 207 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. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 208: Cooling Module: Checking And Topping Up Cooling Water

    In ambient temperatures below 0 °C admix approx. 20 l anti-freeze. Anti-freeze If ambient temperatures below 0 °C can be expected, you must admix anti-freeze. ABB recommends Glykol as anti-freeze. Anti-freeze with anti-corrosive additive is requirements not permitted. Maintenance interval Check cooling water pressure and cooling water flow rate on a daily basis.
  • Page 209 Also, make sure (e.g. by rinsing beforehand) that no dirt is deposited in the filling pipe. Unscrew cap and slowly open vent cock (red) so that air can es- cape. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 210 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 211: Pneumatic System: Replacing The Compressed-Air Filter

    Explanation of safety measures: Safety regulations for maintenance work on page 156. Requirements 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). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 212 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. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 213: Chapter 10 Errors

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

  • Page 214: Errors And Irregularities

     Loose parts  Have trained experts find Unusual probe out the cause movements (probe  Severe soiling of rails rocks up and down, sways to the sides, jerky travel) System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 215  Do not begin repair work until it has cooled down  Mechanical damage  Press EMERGENCY Probe movement STOP switch before work- blocked  Incrustation ing on the probe  Remove blockage 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 216: Touchscreen Error Displays

    Compressed Central compressed- supply disrupted supply Air Not OK air supply input pres- sure too low  Pressure switch 577 error  Check functioning and setting of pressure switch 577 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 217  Both plunger movement limit  Check function and position of Error Posi- Plunger movement switches triggered simulta- limit switches tion Switch limit switch error neously Plunger Action 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 218  Rear limit switch error  Check and, if necessary, clean gas sampling probe entry zone  Check gas sampling probe travel time, modify speed set- ting if necessary System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 219  Can bus connection error to  Check CAN bus cable for CAN Error Can bus error to slave slave 1 -D31 damage Slave 1  Contact ABB Service if neces- sary 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 220  Can bus connection error to  Check CAN bus cable for CAN Error Can bus error to slave slave 9 -D74 damage Slave 9  Contact ABB Service if neces- sary System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 221: Handling Error Messages

    WARNING! The probe moves into the kiln. Do not stand in the area of travel of the probe or probe carriage. In controller: switch gas sampling system to Automatic mode. Path: Operation ► Automatic on / off 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 223: Chapter 11 Shutting Down, Storing, Putting Back Into Operation, Disposal

    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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 224: Shutting Down The System

     Observe instructions in the anti-freeze manufacturer's safety data sheet. Requirements The following conditions must be met:  The system is switched off at the main switch. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 225 Detach cooling-water tubes from screw connectors on the cooling module and allow cooling water to drain. Empty any remaining water in the cooling-water tubes. If anti-freeze (Glykol) was ad- mixed, observe disposal regulations in accordance with national legislation. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 226 Further procedure Refer to Disassembling the system on page 227 for details on further procedure. System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 227: Disassembling The System

     System must have been properly shut down (see Shutting down the system on page 224).  Cooling water must be drained (see Shutting down the system on page 224).  Probe retractor powered off and unpressurized (by trained personnel). 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 228 Note: The retractor must not be transported by fork-lift truck without suitable additional transport pack- aging. is to be put back into opera- Start-up on page 111. tion System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 229: Storing The System

    -20 °C to +55 °C Air humidity: Year-round average max. 75 %, short-term max. 95 %, occasional slight condensation is permitted 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 230: Putting The System Back Into Operation

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

  • Page 231: Disposing Of The System

     All other components of the gas sampling system must be disposed of expertly and in accordance with national legislation. 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 233: Chapter 12 Appendix

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

  • Page 234: Pneumatic/Hydraulic Interface Plan

    Pneumatic/hydraulic interface plan System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 235 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 236: Electrical Connection Plan

    Electrical connection plan System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 237 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...

  • Page 238: Transformer Connection Plan

    Transformer connection plan System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...

  • Page 239: Index

    Checking and topping up cooling water • 208 Inserting the probe and switching to automatic Vent the cooling-water circuit • 206 mode • 131 Installation • 91 Installation check • 113 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 240 Structure and function of the control system • 38 Pneumatic system System identification • 12 Replacing the compressed-air filter • 211 Pneumatic/hydraulic interface plan • 234 Preparing the compressed-air supply • 116 Preparing the cooling-water circuit • 114 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4...
  • Page 241 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 42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System...
  • Page 244 ABB has Sales & Customer Support expertise The Company’s policy is one of continuous product in over 100 countries worldwide. improvement and the right is reserved to modify the information contained herein without notice. www.abb.com Printed in the Fed. Rep. of Germany (11.16) ...

Table of Contents